Maintenance Manual

Truck Edition
V-500/V-600 Series

Revision A

February 2019 TK 61377-18-MM-EN

Introduction
This manual is published for informational purposes only. Thermo King® makes no representations warranties express
or implied, with respect to the information recommendations and descriptions contained herein. Information provided
should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King
Corporation Service Department should be consulted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired
or altered as, in the manufacturer’s judgment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any
other direct, indirect, special, or consequential damages whatsoever, arising out of the use of this manual or
any information, recommendations or descriptions contained herein. The procedures described herein should
only be undertaken by suitably qualified personnel. Failure to implement these procedures correctly may cause
damage to the Thermo King unit or other property or personal injury.

Revision History
Revision A (02/19) Original release

©2019 Trane Technologies TK 61377-18-MM-EN

 Introduction

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.
When working on transport temperature control systems, a recovery process that prevents or minimizes refrigerant
loss to the atmosphere is required by law. In addition, service personnel must be aware of the appropriate European
Union, National, Federal, State, and/or Local regulations governing the use of refrigerants and certification of
technicians. For additional information on regulations and technician programs, contact your local THERMO KING
dealer.
S e r v i c e T o o l s - Use the proper service tools. Gauge manifold sets should include appropriate shutoff valves or
disconnects near the end of each service line.
R e c o v e r y E q u i p m e n t - Recovery equipment must be used. Proper recovering, storing and recycling of refrigerants is
an important part of all service work.
S e r v i c e P r o c e d u r e s - Recommended procedures must be used to minimize refrigerant loss.
C o m p o n e n t s m a y b e i s o l a t e d by closing service valves and performing system pump-downs.
C o m p o n e n t s u n a b l e t o b e i s o l a t e d for service must be repaired only after refrigerant is properly recovered.

R-134a/R-404A/R-452A
R-134aR-404AR452A

NOTICE
Equipment Damage!
Use only Polyolester-based refrigeration compressor oil in R-134a/R-404A/R-452A systems. See Thermo King
Parts Manual for part number.

NOTICE
System Contamination!
Do not mix Polyolester and standard synthetic compressor oils. Keep Polyolester compressor oil in tightly
sealed containers. If Polyolester oil becomes contaminated with moisture or standard oils, dispose of
properly–DO NOT USE.

NOTICE
System Contamination!
When servicing Thermo King R-134a, R-23, R-404A, R-452A or R-513A units, use only those service tools
certified for and dedicated to R-134a/R-23/R-404A/R-452A/R-513A refrigerant and Polyolester compressor oils.
Residual non-HFC refrigerants or oils will contaminate R-134a/R-23/R-404A/R-452A/R-513A systems.Please
check serial# plate for type and volume of Refrigerant charged. Please do not blend with other refrigerants
than the original charged refrigerant

TK 61377-18-MM-EN 3
Introduction

About This Manual

Purpose
The purpose of this manual is to provide general maintenance information necessary to maintain the climate control
unit at peak operating standards. This includes safety information, unit information such as bills of material and kit
numbers, general unit information, maintenance procedures and related information (such as wiring and schematic
diagrams), and some diagnostic and troubleshooting information.
N o t e : This manual may cover more than one unit. Therefore, it may contain information not applicable to your unit.

Contents
This manual is organized into the following chapters:

Chapter Purpose

Safety Precautions Provides detailed safety information. You should be familiar with the safety
precautions before working on any unit.

Model Systems (Systems Designations) Table This table lists the bills of material and kit options that make up your unit.
Use them for the following purposes:
1. To determine if you have the right manual for your unit: the bill of
material (B/M) number on your unit serial plate should match one of
the bill of material numbers listed in this section. If you cannot find
your unit in the matrix, call TK Service for more information.
2. To communicate with TK Service Department: If you need to call TK
Service, you must know your model number(s) in order for the service
representative to help you.

Specifications Lists unit specifications.

Unit Description Gives an overview description of your unit including standard and optional
features, illustrations, and general a/c theory.

Operating Instructions Provides unit operating instructions.

Maintenance Inspection Schedule Table of routine maintenance procedures.

Maintenance Chapters Provide detailed maintenance procedures required for your unit. (Electrical,
Refrigeration, Compressor, Clutch, Structural)

Diagnosis Chapters Provides troubleshooting information for diagnosing problems.

Diagrams Wiring, Schematic and Refrigeration diagrams applicable to the unit.

Before you Call Thermo King Service!

Who to call: Your Thermo King Service Representative.
Before you call Thermo King Service, have the following information on hand:
• Bill of Material (usually located on the unit serial plate)
• Model Number - found on side of the unit

Blank Pages
This manual may contain blank pages at the end of chapters. This is normal. There is no information missing from the
manual.

Roadside/Curbside Terminology
Roadside/Curbside terminology: These terms can be confusing because of differences between North America and
Europe. Please note:

4 TK 61377-18-MM-EN
 Introduction

Curbside: The side of the truck to the driver’s right when the driver is in his seat and facing forward.

Roadside: The side of the truck to the driver’s left when the driver is in his seat and facing forward.

Using the Model Systems Tables in “Model Systems (System Designations)”

The Model Systems Tables in this section list important unit information that you will need to communicate with the
Thermo King Service Department.

Customer Satisfaction Survey

Let your voice be heard!
Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a
web browser.
Scan the Quick Response (QR) code or click or type the web address https://tranetechnologies.iad1.qualtrics.com/jfe/
form/SV_2octfSHoUJxsk6x?Q_CHL=qr&Q_JFE=qdg to complete the survey.

TK 61377-18-MM-EN 5
Introduction

General Information
The maintenance information in this manual covers unit models:

V–500 10 (702677/702678) V–500 SPECTRUM 30 (702840/702841) V–600 MAX 10 (703677/703678)

V–500 20 (702679/702680) V–500 SPECTRUM 50 (702842/702843) V–600 MAX 20 (703684/703685)

V–500 MAX 10 (702669/702670) V–600 MAX 30 (703686/703687)

V–500 MAX 20 (702671/702672) V–600 MAX 50 (703688/703689)

V–500 MAX 30 (702673/702674)

V–500 MAX 50 (702675/702676)

For further information, refer to:

V-Series Vehicle Powered Truck Units Operator’s Manual TK 61651

V-500 & V-500 MAX Series Parts Manual TK 61615

V-600 MAX Series Parts Manual TK 61558

Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096

V-Series Installation Manual TK 61484

Vehicle Powered Truck Installation Standards and Procedures TK 61588

Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984

Tool Catalog TK 5955

Evacuation Station Operation and Field Application TK 40612

The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance
of Thermo King units.

6 TK 61377-18-MM-EN
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auto Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Microprocessor Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electric Standby Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional Electric Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DSR Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Evaporator Drain Line Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Standard Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

TK 61377-18-MM-EN 7
Table of Contents

P.C. Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electronic Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Solenoids and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hot Gas Solenoid (HGS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Liquid Injection Solenoid (LIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Discharge Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Condenser Inlet Solenoid (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Suction Pressure Regulator Valve (SPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CPR Bypass Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Compressor Pressure Regulator Valve (CPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Liquid Line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CPR Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Liquid Line Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Switches and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Unit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cool Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Null Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Purge Mode – Model 30 and Model 50 Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Heat Mode – Model 30 and Model 50 Units Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Defrost Termination Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Defrost Termination Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Condenser Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Condenser Fan Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Evaporator Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Evaporator Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drain Line Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drain Line Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Controller Fuses: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control Box Fuses: Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Harness Fuses: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
AC Components Model 20 and Model 50 Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electrical Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Compressor Motor Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Motor Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Electric Heat Contactor – HC (Model 20 Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Electric Heat Contactor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Motor Overload Relay – OL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Motor Overload Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Transformer – T1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Transformer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Transformer Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Bridge Rectifier – BR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Capacitor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Start Relay – SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Start Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Start Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Testing 115/1/60 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Testing 208-230/1/60 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Testing 208-230/3/60 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Compressor Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electric Standby Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Evacuating and Charging the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Testing the Refrigerant Charge with an Empty Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Testing the Refrigerant Charge with a Loaded Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Suction (Low Side) Bump Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking Compressor Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Refrigeration System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Cleanup Procedure for Small Truck Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Clean-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Putting the Unit Back Into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Putting the Unit Back Into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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Engine Driven Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Electric Standby Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Discharge Pressure Transducer (DPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Hot Gas Solenoid (HGS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Liquid Injection Solenoid (LIS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Condenser Inlet Solenoid (CIS) Test (Model 30 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
CPR Bypass Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Solenoid Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Splice Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Discharge Check Valve (Model 20 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Testing the Discharge Check Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Discharge Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Checking Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Expansion Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Low Pressure Cutout Switch (LPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Low Pressure Cutout Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Low Pressure Cutout Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Suction Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Suction Pressure Regulator Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Suction Pressure Regulator Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

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Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Accumulator (Model 30 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Liquid Line Check Valve (Model 30 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Liquid Line Check Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Liquid Line Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Replacing Refrigerant Hoses (Speedy Clip System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Compressor Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Compressor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Belt Tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Engine Driven Compressor Belt and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Electric Standby Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Micro-Channel Coil Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Cleaning Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Unit Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Over-the-Road Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Electric Standby Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Refrigeration Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

TK 61377-18-MM-EN 11
Safety Precautions
Danger, Warning, Caution, and Notice
Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general
safety practices.
Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit
depend upon the strict observance of these precautions. The four types of advisories are defined as follows:

DANGER
Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury!

WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury!

CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury and unsafe practices!

NOTICE
Indicates a situation that could result in equipment or property-damage only
accidents!

Auto Start/Stop
CAUTION
Risk of Injury!
The unit can start and run automatically any time the unit is turned on. Turn the unit On/Off switch Off before
doing inspections or working on any part of the unit. Please note that only Qualified and Certified personnel
should attempt to service your Thermo King unit.

CAUTION
Risk of Injury!
The vehicle's engine may be equipped with Auto Start/Stop. The vehicle must be turned off before servicing
the unit.

Battery Installation and Cable Routing

WARNING
Hazard of Explosion!
An improperly installed battery could result in a fire, explosion, or injury. A Thermo King approved battery
must be installed and properly secured to the battery tray.

12 TK 61377-18-MM-EN
 Safety Precautions

WARNING
Hazard of Explosion!
Improperly installed battery cables could result in a fire, explosion, or injury. Battery cables must be installed,
routed, and secured properly to prevent them from rubbing, chaffing, or making contact with hot, sharp, or
rotating components.

WARNING
Fire Hazard!
Do not attach fuel lines to battery cables or electrical harnesses. This has the potential to cause a fire and
could cause serious injury or death.

WARNING
Personal Protective Equipment (PPE) Required!
A battery can be dangerous. A battery contains a flammable gas that can ignite or explode. A battery stores
enough electricity to burn you if it discharges quickly. A battery contains battery acid that can burn you.
Always wear goggles or safety glasses and personal protective equipment when working with a battery. If you
get battery acid on you, immediately flush it with water and get medical attention.

WARNING
Hazard of Explosion!
Always cover battery terminals to prevent them from making contact with metal components during battery
installation. Battery terminals grounding against metal could cause the battery to explode.

CAUTION
Hazardous Service Procedures!
Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent
unit from starting unexpectedly and causing personal injury.

NOTICE
Equipment Damage!
Do not connect other manufacturer’s equipment or accessories to the unit or to the TK Batteries unless
approved by Thermo King. Failure to do so can result in severe damage to equipment and void the warranty.

Refrigerant Hazards
DANGER
Hazardous Pressures!
Always store refrigerant in proper containers, out of direct sunlight and away from intense heat. Heat
increases pressure inside storage containers, which can cause them to burst and could result in severe
personal injury.

DANGER
Combustible Hazard!
Do not use oxygen (O2 ) or compressed air for leak testing. Oxygen mixed with refrigerant is combustible.

WARNING
Hazardous Gases!
Do not use a Halide torch. When a flame comes in contact with refrigerant, toxic gases are produced. These
gases can cause suffocation, even death.

TK 61377-18-MM-EN 13
Safety Precautions

WARNING
Personal Protective Equipment (PPE) Required!
Refrigerant in a liquid state evaporates rapidly when exposed to the atmosphere, freezing anything it contacts.
Wear butyl lined gloves and other clothing and eye wear when handling refrigerant to help prevent frostbite.
When working with or around hazardous chemicals, ALWAYS refer to appropriate Material Data Safety Sheets
(MSDS) and OSHA/GHS (Global Harmonized System of Classification and Labelling of Chemicals) guidelines
for information on allowable personal exposure levels, proper respiratory protection, and handling
instructions.

NOTICE
Equipment Damage!
When being transferred, refrigerant must be in liquid state to avoid possible equipment damage.

Refrigerant Oil Hazards

WARNING
Personal Protective Equipment (PPE) Required!
Protect your eyes from contact with refrigerant oil. The oil can cause serious eye injuries. Protect skin and
clothing from prolonged or repeated contact with refrigerant oil. To prevent irritation, wash your hands and
clothing thoroughly after handling the oil. Rubber gloves are recommended. When working with or around
hazardous chemicals, ALWAYS refer to appropriate Material Data Safety Sheets (MSDS) and OSHA/GHS
(Global Harmonized System of Classification and Labelling of Chemicals) guidelines for information on
allowable personal exposure levels, proper respiratory protection, and handling instructions.

NOTICE
Equipment Damage!
Use the correct oil in Thermo King systems to avoid damaging equipment and nullifying its warranty.

NOTICE
Equipment Damage!
Do not mix refrigerant oils. Mixing incompatible oils will damage the system.

NOTICE
Equipment Damage!
Use dedicated refrigeration equipment to prevent contaminating refrigeration systems with the wrong type of
oil or refrigerant.

NOTICE
System Contamination!
Do not expose the refrigerant oil to the air any longer than necessary. Store refrigerant oil in an approved
sealed container to avoid moisture contamination. The oil will absorb moisture, which results in much longer
evacuation times and possible system contamination.

NOTICE
Material Damage!
Wipe up spills immediately. Refrigerant oil can damage paints and rubber materials.

14 TK 61377-18-MM-EN
 Safety Precautions

Electrical Hazards
High Voltage
I m p o r t a n t : Do not move the vehicle if the power cable or the electric standby icon is illuminated.

DANGER
Hazardous Voltage!
Lethal amounts of voltage are present in some electrical circuits. Use extreme care when working on an
operating refrigeration unit. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put
on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc
flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR
VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL
METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

WARNING
Hazardous Voltage!
Treat all wires and connections as if they were high voltage until a meter and wiring diagram indicate
otherwise. Only use tools with insulated handles. Never hold uninsulated metal tools near exposed, energized
conductors. If there is a risk of energized electrical contact, arc, or flash, technicians MUST put on all PPE in
accordance with OSHA, NFPA 70E, or other local, state, or country-specific requirements for arc flash
protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING, DISCONNECTING, OR VOLTAGE
TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND
EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

WARNING
Hazardous Voltage!
Never work alone on high voltage circuits in the refrigeration unit. Another person should be nearby to shut
off the unit and provide aid in the event of an accident. If there is a risk of energized electrical contact, arc, or
flash, technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-
specific requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,
DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING
CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

WARNING
Personal Protective Equipment (PPE) Required!
In the event of an electrical accident, all required PPE should be near the work area in accordance with OSHA,
NFPE 70E, or other local, state, or country-specific requirements for a Category 2 risk.

WARNING
Risk of Injury!
Do not make rapid moves when working on high voltage circuits in refrigeration units. Do not grab for falling
tools because you might accidentally touch a high voltage source.

WARNING
Hazardous Voltage w/Capacitors!
Be careful when working with electrical circuits that contain capacitors. Some capacitors hold a significant
electrical charge that might cause burns or shocks if accidentally discharged. Capacitors must be discharged
before working on electrical circuits. If there is a risk of energized electrical contact, arc, or flash, technicians
MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific
requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,
DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING
CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

TK 61377-18-MM-EN 15
Safety Precautions

Low Voltage
WARNING
Live Electrical Components!
Control circuits used in refrigeration units are low voltage (12 to 48 Vdc). However, the large amount of
amperage available can cause severe burns if accidentally shorted to ground with metal objects, such as tools.
Do not wear jewelry, watches, or rings because they increase the risk of shorting out electrical circuits and
damaging equipment or causing severe burns. If there is a risk of energized electrical contact, arc, or flash,
technicians MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific
requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,
DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING
CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

Microprocessor Service Precautions

Take precautions to prevent electrostatic discharge when servicing the microprocessor and its related components.
Even tiny amounts of current can severely damage or destroy electronic components.
Observe the following precautions when servicing a microprocessor control system to avoid damaging electronic
components. Refer to the appropriate microprocessor diagnosis manual for more information.
• If the microprocessor has a power switch, turn it OFF before connecting or disconnecting the battery.
• Disconnect power to the unit.
• Avoid wearing clothing that generates static electricity (wool, nylon, polyester, etc.).
• Wear a wrist strap (P/N 204-622 or equivalent) with the lead end connected to the microprocessor’s ground terminal.
These straps are available from most electronic equipment distributors. DO NOT wear these straps with power
applied to the unit.
• Avoid unnecessary contact with the electronic components.
• Store and ship electronic components in antistatic bags and protective packaging.
• Leave electronic components in their antistatic packing materials until you’re ready to use them.
• After servicing any electronic components, check the wiring for possible errors before restoring power to the unit.
• Never use a battery and a light bulb to test circuits on any microprocessor-based equipment.

Welding Precautions
Take precautions before electrically welding any portion of the unit or the vehicle to which it is attached. Verify that
welding currents are not allowed to flow through the unit’s electronic circuits.
Observe the following precautions when welding to avoid damaging electronic components.
• If the microprocessor has a power switch, turn it OFF before connecting or disconnecting the battery.
• Disconnect power to the unit.
• Disconnect all wire harnesses from the microprocessor. Disconnect the ECU and the battery charger if so equipped.
• If there are any electrical circuit breakers in the control box, switch them OFF.
• Close the control box.
• Components that could be damaged by welding sparks should be removed from the unit.
• Use normal welding procedures, but keep the ground return electrode as close to the area being welded as
practical. This will reduce the likelihood of stray welding currents passing through any electronic circuits.

First Aid
REFRIGERANT
• E y e s : For contact with liquid, immediately flush eyes with large amounts of water and get prompt medical
attention.

16 TK 61377-18-MM-EN
 Safety Precautions

• S k i n : Flush area with large amounts of warm water. Do not apply heat. Remove contaminated clothing and shoes.
Wrap burns with dry, sterile, bulky dressing to protect from infection. Get prompt medical attention. Wash
contaminated clothing before reuse.
• I n h a l a t i o n : Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth
resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
• F r o s t B i t e : In the event of frost bite , the objectives of First Aid are to protect the frozen area from further injury,
warm the affected area rapidly, and to maintain respiration.
REFRIGERANT OIL
• E y e s : Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.
• S k i n : Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation
persists.
• I n h a l a t i o n : Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth
resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
• I n g e s t i o n : Do not induce vomiting. Immediately contact local poison control center or physician.
ENGINE COOLANT
• E y e s : Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.
• S k i n : Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation
persists.
• I n g e s t i o n : Do not induce vomiting. Immediately contact local poison control center or physician.
BATTERY ACID
• E y e s : Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention. Wash
skin with soap and water.
• I N H A L A T I O N : Provide fresh air. Rinse mouth and nose with water. Seek immediate medical assistance.
• S K I N C O N T A C T : Immediately remove contaminated clothing. Wash skin with large volumes of water, for at least
15 minutes. Wash skin with soap and water. Do not apply fatty compounds. Seek immediate medical assistance.
• I N G E S T I O N : If the injured person is fully conscious: make the person drink extensive amounts of milk. Do not
induce vomiting. Take the injured person immediately to a hospital.
ELECTRICAL SHOCK
Take IMMEDIATE action after a person has received an electrical shock. Get quick medical assistance, if possible.
The source of the shock must be quickly stopped, by either shutting off the power or removing the victim. If the power
cannot be shut off, the wire should be cut with an non-conductive tool, such as a wood-handle axe or thickly insulated
cable cutters. Rescuers should wear insulated gloves and safety glasses, and avoid looking at wires being cut. The
ensuing flash can cause burns and blindness.
If the victim must be removed from a live circuit, pull the victim away with a non-conductive material. Use wood, rope,
a belt or coat to pull or push the victim away from the current. DO NOT TOUCH the victim. You will receive a shock from
current flowing through the victim’s body. After separating the victim from power source, immediately check for signs
of a pulse and respiration. If no pulse is present, start Cardio Pulmonary Resuscitation (CPR). If a pulse is present,
respiration might be restored by using mouth-to-mouth resuscitation. Call for emergency medical assistance.
ASPHYXIATION
Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore
breathing, if necessary. Stay with victim until emergency personnel arrive.

TK 61377-18-MM-EN 17
Specifications
Electrical System
12 Vdc 24 Vdc

Fuses

Common Fuses

Fuse 3: Evaporator Fan Motor (EFM1) 15 amps 10 amps

Fuse 4: Evaporator Fan Motor (EFM2) 15 amps 10 amps

Fuse 5: Roadside (Engine) Compressor Clutch (CCL1), Liquid Injection Switch 20 amps 10 amps
(LIS), Liquid Injection Valve (LIV), EVAP1 Defrost Hot Gas Solenoid Valve (PS1),
Compressor Motor Contactor (CMC), Heat Pilot Solenoid (PS5)

Fuse 14: Vehicle Ignition Switch 5 amps 5 amps

Fuse 30: Condenser Fan Motor (CFM) (located in CF1 wire near terminal strip in 16 amps 10 amps
condenser section)

V-500/V-600 and Spectrum

Fuse 6: Condenser Fan 1/2 10 amps 7.5 amps

Fuse 8: (Spectrum Only) EVAP2 Liquid Solenoid Valve (PS2), EVAP1 Liquid 20 amps 10 amps
Solenoid Valve (PS3), EVAP2 Defrost Hot Gas Solenoid Valve (PS4), Drain Heaters
3 and 4 (HT3, HT4)

Fuse 9: (Spectrum Only) Evaporator Fan 3 15 amps 10 amps

Fuse 10: (Spectrum Only) Evaporator Fan 4 15 amps 10 amps

Fuse 11: Drain Heaters (H1 and H2) 2 amps 2 amps

Fuse 17: Drain Heaters (H3 and H4) 2 amps 2 amps

Fuse 20: Transformer AC Power Supply (located at compressor motor contactor in 4 amps 4 amps
condenser section)

Fuse 21: Battery Power Supply (located in 2 wire near battery) 50 amps (Single Temp) 60 amps (Multi-Temp)

Fuse 31: Condenser Fan Motor 2 (CFM2) (located in CF2 wire near terminal strip in 16 amps 10 amps
condenser section)

Condenser Fan Motor

Voltage 13 Vdc 26 Vdc

Full Load Current 10 Amps 4.7 Amps

Power Rating 130 W 122 W

RPM with Full Load 2,800 2,800

Evaporator Fan Motors (Each)

Voltage 13 Vdc 26 Vdc

Full Load Current 7.5 Amps 4 Amps

Power Rating 97.5 W 104 W

RPM with Full Load 2,800 2,800

Coil for Hot Gas Solenoid (PS1, PS2, PS3, PS4)

18 TK 61377-18-MM-EN
 Specifications

Voltage 12 Vdc 24 Vdc

Current 2.3 amps 1.3 amps

Resistance 5.2 ohms 20 ohms

Coil for Liquid Injection Solenoid (LIS) – MAX Only

Voltage 12 Vdc

Current 1.2 amps

Resistance 10.0 ohms

Coil for Heat Pilot Solenoid (PS5) - Truck Engine Coolant Heat Option Only

Voltage 12 Vdc

Current 1.5 amps

Resistance 8.0 ohms

Drain Line Heaters (Each) - MAX Only

Voltage 12 Vdc

Current 0.9 amps ± 5% at 68 F (20 C)

Resistance 13.8 ohms ± 5% at 68 F (20 C)

Battery Relay (BATR)

Type Single Pole Single Throw

(SPST)

Contacts Terminals 30 to 87 Normally Open (NO)

Coil Resistance Terminals 85 to 86 90 ohms

Electric Standby Power Relay (STDR)

Type Single Pole Single Throw

(SPST)

Contacts Terminals 30 to 87 Normally Open (NO)

Coil Resistance Terminals 85 to 86 90 ohms

Start Key Relay (C1R)

Type Single Pole Double Throw

(SPDT)

Contacts Terminals 30 to 87 Normally Open (NO)

Terminals 30 to 87A Normally Closwe (NC)

Coil Resistance Terminals 85 to 86 90 ohms

Capacitors

Starting Capacitor (CS) – all voltages 250–300 μF

Running Capacitor (CR) 40 μF

TK 61377-18-MM-EN 19
Specifications

Compressor Motor Contactor (CMC)

Contacts Normally Open

Coil Voltage 12 Vdc

Coil Current 0.25 amps

Coil Resistance 48 ohms

Transformer

Power 500 VA

Frequency 50/60 Hz

Primary Inputs 115-208-230 Vac

Secondary Nominal Voltage 11.7 Vac (21.4 Amps)

AC Electric Compressor Motors and Overload Relays

Voltage/Phase/ Horsepower Kilowatts RPM Full Load (amps) Overload Relay

Frequency Setting (amps)

V-500/V-600

115/1/60 1.5 1.1 1710 14 14

208/1/60 2.0 1.5 1740 9.5 9.5

230/1/60 2.0 1.5 1750 9 9

208/3/60 2.4 1.8 1730 7.2 7.2

230/3/60 2.4 1.8 1750 6.9 7

Electric Standby Power Supply Requirements

Power Cord Length
Power Cord Size (AWG)

Voltage Phase Hz Power Supply Circuit Breaker 25 ft 50 ft 75 ft

230 Vac 1 50/60 30 amp 10 8 8

230 Vac 3 50/60 30 amp 10 8 8

Optional Electric Heaters

Voltage Power Rating Watts Current Resistance

230 Vac 1500 6.5 amps 35.4 ohms

Refrigeration System
N o t e : Units from January 2016 are available with R-404A, R-452A or R-134A Refrigerants. All of which comply with F-
Gas legislation revision 2014 (Regulation (EC) No 517/2014)

Refrigerant GWP

R-404A 3922

R-452A 2140

R-134A 1430

20 TK 61377-18-MM-EN
 Specifications

CAUTION
Service Procedure!
Fluorinated Refrigerant gases should not be ventilated to atmosphere. Take note of the refrigerant type (label
on outside of unit) and do not cross-contaminate.
Refer to the Vehicle Powered Truck Installation Standards and Procedures TK 61588 (Section 10 – System Evacuation
Procedures) and Section 12 – System Charging Procedures) for service information about evacuating and charging the
refrigeration system.
N o t e : *Final refrigerant charge will vary based on each unique installation
Table 1. R-134a Refrigeration System V-Series

Refrigerant Charge:

V-500 10 4.85 lb (2.2 kg) R-134a

V-500 20 4.85 lb (2.2 kg) R-134a

Defrost Method Hot Gas

Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C)

Closes 36.0 ± 5.0 F (2.2 ± 2.8 C)

Low Pressure Cutout Switch (LPCO): Opens 5 to 11 in. Hg vacuum (-17 to -37 kPa)
Closes 4 to 7 psig (28 to 48 kPa)

Over Temperature Switch - Electric Heater Opens 105 ± 5 F (41 ± 3 C)

Option Only: Closes 90 ± 5 F (32 ± 3 C)

High Pressure Cutout Switch (HPCO) Opens 2,068 ± 69 kPa (300 ± 10 psi)
Closes 1,379 ± 69 kPa (200 ± 10 psi)

CFPS (condenser fan pressure switch) Opens 896 ± 69 kPa (130 ± 10 psi)
Closes 1,241 ± 69 kPa (180 ± 10 psi)

CFSC (condenser fan speed control) switch Opens 1517 ± 48 kPa (220 ± 7 psi)
Closes 1,241 ± 48 kPa (180 ± 7 psi)

CSPS (condenser pressure control switch) Opens 1,724 + 138 kPa/-0 kPa (250 + 20 psi/-0 kPa)
Closes 1,379 ± 138 kPa (200 ± 20 psi)

Table 2. R-404A/R-452A Refrigeration System V-Series MAX

V-500 MAX 10 4.63 lb (2.1 kg) R-452A
V-500 MAX 20/30 4.85 lb ( 2.2 kg) R-452A
V-500 MAX 50 5.07 lb (2.3 kg) R-452A
V-500 MAX Spectrum 10 5.07 lb (2.3 kg) R-452A
V-500 MAX Spectrum 20/30 5.29 lb (2.4 kg) R-452A
V-500 MAX Spectrum 50 5.51 lb (2.5 kg) R-452A
V-600 MAX 10 4.85 lb (2.2 kg) R-452A
V-600 MAX 20/30 5.07 lb (2.3 kg) R-452A
V-600 MAX 50 5.29 lb (2.4 kg) R-452A

Defrost Method* Hot Gas

Defrost Termination Switch: Opens 48.0 ± 5.0 F (8.9 ± 2.8 C)

Closes 36.0 ± 5.0 F (2.2 ± 2.8 C)

Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)

Closes 230 ± 5 F (110 ± 3 C)

Low Pressure Cutout Switch (LPCO): Opens 5 to 11 in. Hg vacuum (-17 to -37 kPa)
Closes 4 to 7 psig (28 to 48 kPa)

Over Temperature Switch - Electric Heater Opens 105 ± 5 F (41 ± 3 C)

Option Only: Closes 90 ± 5 F (32 ± 3 C)

High Pressure Cutout Switch (HPCO) Opens 3,100 ± 69 kPa (450 ± 10 psi)
Closes 2,585 ± 69 kPa (375 ± 10 psi)

CFPS (condenser fan pressure switch) Opens 896 ± 69 kPa (130 ± 10 psi)
Closes 1,241 ± 69 kPa (180 ± 10 psi)

TK 61377-18-MM-EN 21
Specifications

Table 2. R-404A/R-452A Refrigeration System V-Series MAX (continued)

CFSC (condenser fan speed control) switch Opens 2,068 + 138 kPa/-0 kPa (300 + 20 psi/-0 kPa)
Closes 1,379 ± 138 kPa (200 ± 20 psi)

CSPS (condenser pressure control switch) Opens 2,068 + 138 kPa/-0 kPa (300 + 20 psi/-0 kPa)
Closes 1,586 + 138 kPa/-0 kPa (230 + 20 psi/-0 kPa)

CPR (Compressor Pressure Regulator) Valve Setting - Model 30 and 50 Only 24 ± 2 psig (165 ± 14 kPa)

SPR (Electric Standby Suction Pressure Regulator) Valve Setting - Model 20 MAX Only 24 ± 2 psig (165 ± 14 kPa)

Compressors
NOTICE
Equipment Damage!
Use the correct oil in Thermo King systems to avoid damaging equipment and nullifying its warranty.

N o t e : Once the oil has been extracted from the compressor, note the oil level in order to be able to maintain the same
level in the replacement compressor. Polyol Ester (POE) or Polyvinyl Ether (PVE) compressor oil must be used in
conventional Thermo King units. Mineral oils or PAG oils must not be added to systems.

Standard Engine Driven Compressor: V-500/V-600 TK-16, 9.9 cu. in. (163 cc), Swash Plate, 6 Cylinder

Optional Engine Driven Compressor TK-312R, 11.4 cu. in. (187 cc), Reciprocating, 3 Cylinder

Electric Standby Compressor - Model 20 and 50 Only TK-13, 8 cu. in. (131 cc), Electric Motor Driven, Swash Plate, 6
Cylinder

System Oil Capacity - Swash Plate Model 10/20/30 6.1 oz (180 cc)
Compressors: Model 50 42.2 oz (1200 cc)

System Oil Capacity - Reciprocating Model 10/20/30 12.3 oz (350 cc)

Compressor: Model 50 42.2 oz (1200 cc)

Compressor Oil Type: POE 120 2030515 33.8 oz. (1 Liter)

Compressor Clutch Coil - Swash Plate: Voltage 12 Vdc

Resistance 3.2 ohms at 77 F (25 C)

Compressor Clutch Coil - Reciprocating: Voltage 12 Vdc

Resistance 3-4 ohms

Defrost Method Hot Gas

Defrost Timer Initiation Interval Adjustable, 1 minute to 8 hours, default is 4 hours

Defrost Termination Interval Defrost is terminated by Klixon switch, or by Defrost

Termination Timer [dtt] adjustable, 5 to 50 minutes, default is
30 minutes.

22 TK 61377-18-MM-EN
 Specifications

Belt Tension
Belt Field Reset

Engine Driven Compressor Belt Check vehicle manufacturer specifications

Solder Applications
Refrigeration Components

For general refrigeration tubing connections: Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
copper to copper or copper to brass
Use: Solder Type 15% Silver TK No. 203-364 Use: Flux Type TK
No. 203-365

For refrigeration tubing connections of dissimilar metals: Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
copper to stainless steel or brass to stainless steel
Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK
No. 203-365

Hot Water Component

For hot water tubing connections: Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
copper to copper or copper to brass
Use: Solder Type 95% Tin and 5% antimony TK No. 204-167 Use:
Flux Type TK No. 204-417

For hot water tubing connections of dissimilar metals: Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
copper to stainless steel or brass to stainless steel
Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK
No. 203-365

NOTE: Some units may be equipped with compressor pressure regulator (CPR) valve and/or suction pressure regulator (SPR)
valve. To reduce the chance of overheating the CPR/SPR/DPR valve, 95-5 solder or equivalent may be used.

Use 95-5 TK No. 204-167

Use Flux TK No. 204-417

Thermostatic expansion valve (TXV) Use tin welding

TK 61377-18-MM-EN 23
Unit Description
Introduction
The Thermo King Vehicle Powered Single Temperature and Multi-Temperature (Spectrum) truck refrigeration systems
are designed for transporting cold, frozen and deep frozen products on medium-sized trucks with one or more
compartments. There are four basic units:
• Model 10: Cool and defrost on truck engine driven compressor operation.
• Model 20: Cool and defrost on both truck engine driven compressor operation and electric standby compressor
operation.
• Model 30: Cool, heat, and defrost on truck engine driven compressor operation. Only available on MAX units.
• Model 50: Cool, heat, and defrost on both vehicle engine driven compressor operation and electric standby
compressor operation. Only available on MAX units.
The system consists of at least three separate assemblies: the condenser, the evaporator, and the compressor(s). The
condenser is installed on the front section or under the truck chassis, with the evaporator(s) (1 for Single–Temperature,
2 or 3 for Spectrum applications) on the roof. The road compressor is activated by the vehicle engine, using a belt. The
unit is connected to the compressor through refrigeration hoses and refrigeration tubes. On models with electric
standby operation, the second processor is activated using an electric motor.

Condenser
The condenser is mounted on the front of the truck box.

Evaporator
The evaporator is mounted on the ceiling inside the truck box. SPECTRUM units have two evaporators, one in each
compartment.

Compressor
The compressor is mounted to the trucks engine and driven by the engine by a belt-drive system. Model 20 and 50 units
also have an additional compressor driven by an electric motor in the condenser section for electric standby operation.
The evaporator, condenser and engine driven compressor are connected with refrigeration hoses that are assembled
during the installation process.
The engine driven compressor and the standby compressor are connected in parallel to the same refrigeration system
circuit. The compressors share refrigerant, but check valves isolate one compressor from the other during operation.

Control Circuits
The control circuits operate on 12 Vdc or 24 Vdc supplied by the vehicle batteries for engine operation. On standby
operation, the power is rectified from an AC transformer

DSR Control System

The DSR Control System is composed of an Electronic Control Module (ECM) located in the control box, and the In-Cab
Control Box. This In-Cab Control Box, also called the HMI, allows the truck driver to operate the Thermo King
refrigeration unit.
Refer to the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096 for complete service
information about the DSR Control System and the related components.
Refer to the Vehicle Powered Truck Units Operator’s Manual TK 61651 for information about basic unit operation.

Oil Separator
An oil separator is a standard feature. The oil separator separates compressor oil from refrigerant vapor and returns the
oil to the compressor through the suction line. The oil separator helps provide positive oil return at high compressor
speeds and low operating temperatures. This feature enhances compressor lubrication and extends compressor life.

24 TK 61377-18-MM-EN
 Unit Description

Refrigerant
• V-Series units use R-134a refrigerant.
• V-Series MAX units use R-452A or R-404A refrigerant.

Liquid Injection System

MAX units use R-404A or R-452A. These units have a liquid injection system to limit discharge temperature of the
engine driven compressor. Liquid injection is activated when the temperature switch is closed or when the unit is
running in heat mode on Model 30 and Model 50 units. 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 in the evaporator to the metering
orifice. The metering orifice is attached to the suction tube assembly in the condenser. As the refrigerant passes
through the metering orifice it expands and evaporates, cooling the suction gas entering the compressor. This cooling
effect is transferred to the discharge gas leaving the compressor from the adjacent cavity in the compressor head.
When the discharge gas is cooled to 200 ± 5 F (93 ± 3 C), the liquid injection switch opens, the liquid injection solenoid
closes and refrigerant no longer flows through the liquid injection system.

Evaporator Drain Line Heaters

Evaporator drain line heaters are used in these units to avoid drain line blockage because of ice accumulation inside the
evaporator. Two harnesses are located inside the drain lines. These resistive wires melt the ice when energized/while in
defrost mode. These drain line heaters are standard on all MAX units, but can be an option with R-134A units. Please
contact your Thermo King Dealer for more information.

Electric Standby Operation

When the unit is connected to an electric power source, the battery relay is de-energized, and the standby relay is
energized to provide rectified power from the transformer to the electronic control system.
During electric standby operation, the electronic control system controls the operation of the unit by energizing and de-
energizing the compressor contactor and standby compressor clutch (if applicable) and places the unit in cool, heat, or
defrost mode by energizing the compressor contactor and standby compressor clutch (if applicable).
The electronic control system places the unit in null by de-energizing the compressor contactor and standby
compressor clutch.

Unit Features
Standard Features
• In-Cab Controls with Digital LCD Thermometer
• Hot Gas Defrost
• Defrost Termination Switch
• Oil Separator
• Evaporator Drain Line Heaters (MAX Units Only, Optional on R-134a Units)
• Liquid Injection (MAX Units Only)
• Electric Standby Compressor (Model 20 and 50 Units Only)
• Hot Gas Heat (Model 30 and 50 units only)

Optional Features
• Door Switch Kit
• Discharge Muffler Kit
• Heat, Truck Engine Coolant (Only available for Model 10 and 20 Units)
• Heat, Truck Engine Coolant and Electric Standby Heater Strip (Only available for Model 20 Units)
• Snow Covers
• Electric Standby Plug (115Vac, 230Vac 1 phase, 230Vac 3 phase)

TK 61377-18-MM-EN 25
Unit Description

Door Switch Kit

A door switch is typically installed to stop unit operation when the cargo compartment door is opened to improve
temperature control.
Discharge M uffler Kit
A discharge muffler is used to reduce the noise from the engine driven compressor. It is mounted in the compressor
discharge line and is adjustable to reduce noise as much as possible.
Heat, Truck Engine Coolant
This option is added to Model 10 and 20 units to allow the unit to use engine coolant to heat the cargo compartment as
require during truck engine operation. The main components are the heater assembly, coolant pump assembly (coolant
pump and coolant valve), and connecting hoses. The heater assembly is mounted on the bottom of the evaporator. The
coolant pump assembly is typically mounted in the truck engine compartment. The connecting hoses connect the
engine cooling system to the coolant pump assembly and the heater assembly.
Heat, Truck Engine Coolant and Electric Standby Heater Strip
This option is added to Model 20 units. It allows the unit to use engine coolant to heat the cargo compartment as
require during truck engine operation, and to use an electric heater strip during electric standby operation. In addition
to the engine coolant heat components (see above), the main components are the electric heater strip, the heater
contactor, and the electric heating harness. The electric heater strip is mounted in the heater assembly, the heater
contactor is mounted in the contactor box in the heater assembly, and the heater harness connects the heater assembly
to the unit control box.
Snow Covers
A snow cover is available to keep snow from collecting on the condenser fan and keep it from operating properly.
Electric Standby Plug
Electric plugs that mate with the unit power receptacles are available for installation on power supply cords.

Protection Features
• Discharge (High) Pressure Transducer - The discharge pressure transducer is a pressure sensitive device. It is
located in the condenser section discharge line near the oil separator.
If the discharge pressure rises above a certain pressure, the ECM opens the circuit to the compressor clutch to
stop unit operation.
For units with R-134a, the ECM opens the compressor clutch circuit at 300 psig (2068 kPa) and shuts down the
unit. The ECM closes the compressor clutch circuit when the pressure drops to 200 psig (1379 kPa).
For units with R-404A or R-452A, the ECM opens the compressor clutch circuit at 450 psig (3103 kPa) and shuts
down the unit. The ECM closes the compressor clutch circuit when the pressure drops to 375 psig (2586 kPa).
• Low Pressure Cutout Switch - The Low Pressure Cutout Switch is a pressure sensitive switch located on the suction
line assembly in the evaporator. If the suction pressure falls below 5 to 11 in. Hg vacuum (-17 to -34 kPa), the switch
opens the LPCO/CH circuit. This signals the ECM to open the circuit to the compressor clutch to stop unit operation.
The ECM closes the compressor clutch circuit when the pressure rises to 4 to 7 psig (28 to 48 kPa).

Control Box
P.C. Boards
All Printed Circuit Boards within this unit, supplied by Thermo King can be easily identified by the Part Number
stamped on them.

Electronic Control Module (ECM)

The ECM, located inside the unit’s control box, contains the system’s microprocessor(s), I/O connectors, output relays,
fuses, and discrete electronic components mounted on two or three printed circuit boards (platforms). The
microprocessor(s) receives output signals from the load compartment return air sensor and electronic thermostat.
Based on setpoint temperature and other parameters, the microprocessor determines when to adjust the temperature-
control state in the main and/or remote load compartment to Cool, Heat, or Null mode, or to initiate a Defrost cycle.
Refer to your units Diagnostic Manual for complete service information about the Electronic Control Module.

26 TK 61377-18-MM-EN
 Unit Description

Refrigeration System Components

Solenoids and Valves
Hot Gas Solenoid (HGS)
This valve is energized (open) in the defrost mode, and in the heat mode on Model 30 and Model 50 units. It allows hot
gas to enter the evaporator coil. This is a normally closed valve. SPECTRUM units have one in each evaporator.

Liquid Injection Solenoid (LIS)

This valve helps control the temperature of the compressor. It is energized (open) when the liquid injection switch is
closed or when the unit is running in heat mode on 30 and 50 model units. This valve is normally closed.

Discharge Check Valve

This valve is only used on Model 20 and Model 50 units. It isolates the engine driven compressor from the electric
standby compressor, ensuring the compressor oil and refrigerant do not migrate between compressors.

Condenser Inlet Solenoid (CIS)

Only used on Model 30 and Model 50 units. This valve stops the flow of refrigerant to the condenser. It is energized
(closed) when the unit is operating in the heat and defrost modes. This valve is normally open.

Suction Pressure Regulator Valve (SPR)

This valve is only used on Model 20 and Model 50 MAX units. It limits the suction pressure (load) on the electric
standby compressor.

CPR Bypass Solenoid

This valve is only used on Model 30 and Model 50 units. When it is closed It forces the refrigerant to flow through the
CPR. It is energized (closed) when the unit is operating in the heat and defrost modes, and when Model 50 units are in
electric standby. This valve is normally open.

Compressor Pressure Regulator Valve (CPR)

This valve is only used on Model 30 and Model 50 Single Temp units, and on all SPECTRUM units. On Model 30 and
Model 50 Single Temp units it limits the suction pressure (load) on the engine driven compressor. On SPECTRUM units
it limits the suction pressure from the Zone 2 (Fresh) evaporator to ensure Zone 1 (Frozen) will pull down faster when
both evaporators are in cool.

Liquid Line Check Valve

This valve is only used on Model 30 and Model 50 units. It prevents refrigerant from moving into the condenser during
heat and defrost modes.

CPR Check Valve

This valve is only used on SPECTRUM units. It prevents refrigerant from moving into the Zone 2 (Remote) evaporator
when the suction pressure in the Zone 2 (Remote) evaporator is lower that the suction pressure in the Zone 1 (Main/
Host) evaporator.

Liquid Line Solenoid

These valves are only used on SPECTRUM units. They are normally closed valve and there is on in each evaporator. An
LLS is energized (open) when its evaporator is in cool. It allows liquid refrigerant to enter the evaporator coil through
the expansion valve.

Switches and Transducers

L o w P r e s s u r e C u t - o u t ( L P C O ) S w i t c h - opens when the refrigerant suction line pressure falls below a determined
pressure and stops unit operation.
L o w p r e s s u r e a d j u s t a b l e p r e s s u r e s w i t c h L P S ( s o m e S P E C T R U M u n i t s ) - opens when the pressure in the
refrigerant suction tube falls below a specific pressure and activates the solenoid valve which controls the refrigerated
capacity of the compressor.
H i g h P r e s s u r e T r a n s d u c e r - used to control the high-pressure circuit of the unit.

TK 61377-18-MM-EN 27
Unit Description

L i q u i d I n j e c t i o n S w i t c h L I S ( M A X u n i t s ) - closes when the temperature of the refrigerant gas leaving the compressor
exceeds a determined temperature and activates the liquid injection valve (LIV) if the road clutch (CLU1) is also
activated. The LIV allows liquid refrigerant to flow from the liquid line to the metering orifice that is attached to the
suction line fitting on the compressor. As the refrigerant passes through the metering orifice, it expands and
evaporates, and cools the suction gas entering the compressor. This cooling effect is transferred to the discharge gas
leaving the compressor. When the discharge gas is cooled to a determined value, the LIS opens and refrigerant no
longer flows through the liquid injection system.
D e f r o s t T e r m i n a t i o n S w i t c h ( D K 1 , D K 2 ) - normally closed, DK1 or DK2 opens to stop the defrost operation in the
load compartment (DK1 for the main load compartment, DK2 for a remote load compartment, also used for condenser
defrost in reverse cycle units).
D o o r S w i t c h e s ( D S W 1 , D S W 2 ) - used to stop unit operation except in defrost mode, when the load compartment
doors are opened.
O v e r l o a d S w i t c h ( O L ) - used to protect the motor from an electrical overload. When this normally open switch closes,
the unit shuts down.
T h e r m a l p r o t e c t i o n s w i t c h ( H T T 1 , H T T 2 ) - opens when engine temperature exceeds a determined value. This
information is used by the microprocessor to energise the tEP alarm.
P o w e r s u p p l y t h e r m a l p r o t e c t i o n s w i t c h ( T H M R 1 / 2 ) - Alarm tP4 appears when the power supply temperature
exceeds the preset value.

Unit Operation
Standard Model 10 and 20 units (without heat options) operate in Cool mode or Null mode, as required, to maintain the
load compartment temperature at the setpoint temperature.
Model 30 and 50 units, and 10 and 20 units with heat options (coolant or electric heat), operate in Cool, Null, or Heat as
required, to maintain the load compartment temperature at the setpoint temperature.
Defrost cycles occur manually or automatically, as required.
If power is shut off, the unit comes back in Null mode when the unit is restarted. There is a momentary delay at auto
start-up for circuit protection.
N o t e : The compressor will “bump start” five times while coming out of Null or when the unit is first started. In a “bump
start” the compressor is turned on for about one second and then goes off for about four seconds.
Figure 1. Thermostat Algorithm

Options:
• Coolant Heat - This option provides auxiliary heating by circulating hot engine coolant through the evaporator.
• Electric Heat - Provides auxiliary heat through resistive heat strips in the evaporator when connected to electric
standby.

28 TK 61377-18-MM-EN
 Unit Description

Operation
The vehicle engine must be running and the unit must be turned on. On units with Electric Standby, connect the
external power cord and the unit switches to Electric mode operation. Unit operation can be tailored, as required, using
programmable settings as shown in the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK
61096.

Cool Mode
When cooling is required (when there is a requirement to lower the evaporator return air temperature in the load
compartment), the controller energizes the compressor clutch (and compressor motor contactor in model 20/50 units)
and evaporator fans. The controller monitors the discharge pressure through the discharge pressure transducer (DPT).
The condenser fan is energized if necessary and turn on and off as determined by the controller.
The unit operates in Cool mode until the setpoint temperature is reached. The unit then enters Null mode. When the
temperature rises to a pre-determined number of degrees (programmable setting), the unit restarts in Cool mode.
Cool Mode Model 10
Notes:
• The following shows the Model 10 MAX unit. The standard Model 10 is similar but does not have the liquid
injection system (liquid injection solenoid (LIS), connecting lines, and liquid injection switch).
High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and
returned to the splice fitting in the suction line. The refrigerant flows through the condenser where the refrigerant
releases heat and condenses into high pressure liquid. The liquid refrigerant flows through the drier, liquid indicator,
and the expansion valve into the evaporator. There, liquid refrigerant absorbs heat as it evaporates into low pressure
vapor. The refrigerant returns to the compressor through the suction line.
If the compressor discharge temperature rises enough to close the liquid injection switch, the liquid injection valve
opens and liquid refrigerant flows through the liquid injection line, liquid injection orifice and splice fitting in the suction
line to cool the compressor. When the compressor discharge temperature falls enough to open the liquid injection
switch, liquid injection valve closes to stop liquid injection.
• Hot Gas Solenoid (HGS) – Closed/De-energized
• Liquid Injection Solenoid (LIS) – Closed/De-energized, but will open (energize) when the liquid injection switch is
closed to control the engine driven compressor temperature.

TK 61377-18-MM-EN 29
Unit Description

Figure 2. Cool Mode Model 10

1. Low Pressure Cutout switch (LPCO) 9. Drier 17. Defrost Line (Hose #6)

2. Pressure Transducer 10. Service Valve 18. Suction Line (hose #12)

3. Oil Return Line 11. Liquid Indicator 19. Liquid Line (Hose #6)

4. Oil Separator 12. Liquid Injection Valve (LIS) 20. PS1 (Defrost Valve)

5. Injection Line 13. Discharge Line (hose #8) 21. Evaporator Coil

6. Condenser Coil 14. Suction Line (Hose # 16) 22. Expansion Valve

7 Service Valve 15. Liquid Injection Switch

8. Receiver 16. Truck Engine Compressor

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

30 TK 61377-18-MM-EN
 Unit Description

Cool Mode Model 20 Engine Operation

N o t e : The following shows the Model 20 MAX unit. The standard Model 20 is similar but does not have the liquid
injection system (liquid injection solenoid (LIS), connecting lines, and liquid injection switch).
High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and
the oil separator where oil is separated and returned to a suction line. The refrigerant flows through the condenser
where the refrigerant releases heat and condenses into high pressure liquid. The liquid refrigerant flows through the
drier, liquid indicator, and the expansion valve into the evaporator. There, liquid refrigerant absorbs heat as it
evaporates into low pressure vapor. The refrigerant returns to the compressor through the suction line.
If the compressor discharge temperature rises enough to close the liquid injection switch, the liquid injection valve
opens and liquid refrigerant flows through the liquid injection line, liquid injection orifice and splice fitting in the suction
line to cool the compressor. When the compressor discharge temperature falls enough to open the liquid injection
switch, liquid injection valve closes to stop liquid injection.
• Discharge Check Valve – Open to engine driven compressor, closed to electric standby compressor
• Hot Gas Solenoid (HGS) – Closed/De-energized
• Liquid Injection Solenoid (LIS) – Closed/De-energized, but will open (energize) when the liquid injection switch is
closed to control the engine driven compressor temperature.

TK 61377-18-MM-EN 31
Unit Description

Figure 3. Cool Mode Model 20 Engine Operation

1. Low Pressure Cutout switch (LPCO) 10. Service Valve 19. Liquid Line (Hose #6)

2. Pressure Transducer 11. Liquid Indicator 20. PS1 (Defrost Valve)

3. Oil Return Line 12. Liquid Injection Valve (LIS) 21. Evaporator Coil

4. Oil Separator 13. Discharge Line (hose #8) 22. Expansion Valve

5. Injection Line 14. Suction Line (Hose # 16) 23. Discharge check valve

6. Condenser Coil 15. Liquid Injection Switch 24. Oil Balance Line

7 Service Valve 16. Truck Engine Compressor 25. Standby Compressor (CMC)

8. Receiver 17. Defrost Line (Hose #6)

9. Drier 18. Suction Line (hose #12)

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

Cool Mode Model 20 Electric Standby Operation

N o t e : The following shows the Model 20 MAX unit. The standard Model 20 is similar but does not have the liquid
injection system (liquid injection solenoid (LIS), connecting lines, and liquid injection switch).

32 TK 61377-18-MM-EN
 Unit Description

High pressure refrigerant vapor leaves the electric standby compressor and flows through the discharge check valve
and the oil separator where oil is separated and returned to a suction line. The refrigerant flows through the condenser
where the refrigerant releases heat and condenses into high pressure liquid. The liquid refrigerant flows through the
drier, liquid indicator, and the expansion valve into the evaporator. There, liquid refrigerant absorbs heat as it
evaporates into low pressure vapor. The refrigerant returns to the compressor through the suction pressure regulator.
• Discharge Check Valve – Closed to engine driven compressor, open to electric standby compressor
• Hot Gas Solenoid (HGS) – Closed/De-energized
• Liquid Injection Solenoid (LIS) – Closed/De-energized

TK 61377-18-MM-EN 33
Unit Description

Figure 4. Cool Mode Model 20 Electric Standby Operation

1. Low Pressure Cutout switch (LPCO) 10. Service Valve 19. Liquid Line (Hose #6)

2. Pressure Transducer 11. Liquid Indicator 20. PS1 (Defrost Valve)

3. Oil Return Line 12. Liquid Injection Valve (LIS) 21. Evaporator Coil

4. Oil Separator 13. Discharge Line (hose #8) 22. Expansion Valve

5. Injection Line 14. Suction Line (Hose # 16) 23. Discharge check valve

6. Condenser Coil 15. Liquid Injection Switch 24. Oil Balance Line

7 Service Valve 16. Truck Engine Compressor 25. Standby Compressor (CMC)

8. Receiver 17. Defrost Line (Hose #6) 26. Suction Pressure Regulator

9. Drier 18. Suction Line (hose #12)

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

34 TK 61377-18-MM-EN
 Unit Description

Cool Mode Model 30

High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and
returned to the splice fitting in the suction line. The refrigerant flows through the open condenser inlet solenoid to the
condenser where the refrigerant releases heat and condenses into high pressure liquid. The liquid refrigerant flows
through the drier, liquid indicator, liquid line check valve, and the expansion valve into the evaporator. There, liquid
refrigerant absorbs heat as it evaporates into low pressure vapor. The refrigerant returns to the compressor through the
accumulator and open CPR bypass solenoid.
If the compressor discharge temperature rises enough to close the liquid injection switch, the liquid injection valve
opens and liquid refrigerant flows through the liquid injection line, liquid injection orifice and splice fitting in the suction
line to cool the compressor. When the compressor discharge temperature falls enough to open the liquid injection
switch, liquid injection valve closes to stop liquid injection.
• Condenser Inlet Solenoid (CIS) – Open/De-energized
• Hot Gas Solenoid (HGS) – Closed/De-energized
• Liquid Line Check Valve – Open
• Liquid Injection Solenoid (LIS) – Closed/De-energized, but will open (energize) when the liquid injection switch is
closed to control the engine driven compressor temperature.
• CPR Bypass Solenoid – Open/De-energized

TK 61377-18-MM-EN 35
Unit Description

Figure 5. Cool Mode Model 30

1. Low Pressure Cutout switch (LPCO) 10. Service Valve 19. Liquid Line (Hose #6)

2. Pressure Transducer 11. Liquid Indicator 20. PS1 (Hot Gas Solenoid Valve)

3. Oil Return Line 12. Liquid Injection Valve (LIS) 21. Evaporator Coil

4. Oil Separator 13. Discharge Line (hose #8) 22. Expansion Valve

5. Injection Line 14. Suction Line (Hose # 16) 23. Service Port

6. Condenser Coil 15. Liquid Injection Switch 24. Suction Pressure Regulator

7 Service Valve 16. Truck Engine Compressor 25. Accumulator (Suction Receiver)

8. Receiver 17. Defrost Line (Hose #6) 26. PS5 (Condenser Solenoid Valve)

9. Drier 18. Suction Line (hose #12)

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

36 TK 61377-18-MM-EN
 Unit Description

Figure 6. Cool Mode Model 30 SPECTRUM

1. Low Pressure Cutout switch (LPCO) 10. Service Valve 19. Liquid Line (Hose #6)

2. Pressure Transducer 11. Liquid Indicator 20. PS1 (Hot Gas Solenoid Valve)

3. Oil Return Line 12. Liquid Injection Valve (LIS) 21. Evaporator Coil

4. Oil Separator 13. Discharge Line (hose #8) 22. Expansion Valve

5. Injection Line 14. Suction Line (Hose # 16) 23. Service Port

6. Condenser Coil 15. Liquid Injection Switch 24. Pressure Switch

7 Service Valve 16. Truck Engine Compressor 25. Accumulator (Suction Receiver)

8. Receiver 17. Defrost Line (Hose #6) 26. PS5 (Condenser Solenoid Valve)

9. Drier 18. Suction Line (hose #10) 27. By-Pass Solenoid Valve

28. Solenoid Valve

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

TK 61377-18-MM-EN 37
Unit Description

Cool Mode Model 50 Engine Operation

High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and
the oil separator where oil is separated and returned to a suction line. The refrigerant flows through the open condenser
inlet solenoid to the condenser where the refrigerant releases heat and condenses into high pressure liquid. The liquid
refrigerant flows through the drier, liquid indicator, liquid line check valve, and the expansion valve into the evaporator.
There, liquid refrigerant absorbs heat as it evaporates into low pressure vapor. The refrigerant returns to the
compressor through the accumulator and open CPR bypass solenoid.
If the compressor discharge temperature rises enough to close the liquid injection switch, the liquid injection valve
opens and liquid refrigerant flows through the liquid injection line, liquid injection orifice and splice fitting in the suction
line to cool the compressor. When the compressor discharge temperature falls enough to open the liquid injection
switch, liquid injection valve closes to stop liquid injection.
• Discharge Check Valve – Open to engine driven compressor, closed to electric standby compressor
• Condenser Inlet Solenoid (CIS) – Open/De-energized
• Hot Gas Solenoid (HGS) – Closed/De-energized
• Liquid Line Check Valve – Open
• Liquid Injection Solenoid (LIS) – Closed/De-energized, but will open (energize) when the liquid injection switch is
closed to control the engine driven compressor temperature.
• CPR Bypass Solenoid – Open/De-energized

38 TK 61377-18-MM-EN
 Unit Description

Figure 7. Cool Mode Model 50 Engine Operation

1. Low Pressure Cutout switch (LPCO) 11. Liquid Indicator 21. Evaporator Coil

2. Pressure Transducer 12. Liquid Injection Valve (LIS) 22. Expansion Valve

3. Oil Return Line 13. Discharge Line (hose #8) 23. Oil Balance Line

4. Oil Separator 14. Suction Line (Hose # 16) 24. Suction Pressure Regulator

5. Injection Line 15. Liquid Injection Switch 25. Accumulator (Suction Receiver)

6. Condenser Coil 16. Truck Engine Compressor 26. PS5 (Condenser Solenoid Valve)

7 Service Valve 17. Defrost Line (Hose #6) 27. Standby Compressor (CMC)

8. Receiver 18. Suction Line (hose #12) 28. Discharge Check Valve

9. Drier 19. Liquid Line (Hose #6) 29. Check Valve

10. Service Valve 20. PS1 (Hot Gas Solenoid Valve) 30. Heat Exchanger

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

TK 61377-18-MM-EN 39
Unit Description

Figure 8. Cool Mode Spectrum Model 50 Engine Operation

1. Low Pressure Cutout switch (LPCO) 12. Liquid Injection Valve (LIS) 23. Service Port

2. Pressure Transducer 13. Discharge Line (hose #10) 24. Pressure Switch

3. Oil Return Line 14. Suction Line (Hose # 16) 25. Accumulator (Suction Receiver)

4. Oil Separator 15. Liquid Injection Switch 26. PS5 (Condenser Solenoid Valve)

5. Injection Line 16. Truck Engine Compressor 27. By-Pass Solenoid Valve

6. Condenser Coil 17. Defrost Line (Hose #6) 28. PS2/PS3 (Solenoid Valve)

7 Service Valve 18. Suction Line (hose #12) 29. Check Valve

8. Receiver 19. Liquid Line (Hose #6) 30. Oil Balance Line

9. Drier 20. PS1/PS4 (Hot Gas Solenoid Valve) 31. Compressor

10. Relief Valve 21. Evaporator Coil 32. Discharge Check Valve

11. Liquid Indicator 22. Expansion Valve

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

40 TK 61377-18-MM-EN
 Unit Description

Cool Mode Model 50 Electric Standby Operation

High pressure refrigerant vapor leaves the electric standby compressor and flows through the discharge check valve
and the oil separator where oil is separated and returned to a suction line. The refrigerant flows through the open
condenser inlet solenoid to the condenser where the refrigerant releases heat and condenses into high pressure liquid.
The liquid refrigerant flows through the drier, liquid indicator, liquid line check valve, and the expansion valve into the
evaporator. There, liquid refrigerant absorbs heat as it evaporates into low pressure vapor. The refrigerant returns to
the compressor through the accumulator and the compressor pressure regulator because the CPR bypass solenoid is
closed.
• Discharge Check Valve – Closed to engine driven compressor, open to electric standby compressor
• Condenser Inlet Solenoid (CIS) – Open/De-energized
• Hot Gas Solenoid (HGS) – Closed/De-energized
• Liquid Line Check Valve – Open
• Liquid Injection Solenoid (LIS) – Closed/De-energized
• CPR Bypass Solenoid – Closed/Energized
Figure 9. Cool Mode Model 50 Electric Standby Operation

1. Low Pressure Cutout switch (LPCO) 11. Liquid Indicator 21. Evaporator Coil

2. Pressure Transducer 12. Liquid Injection Valve (LIS) 22. Expansion Valve

3. Oil Return Line 13. Discharge Line (hose #8) 23. Oil Balance Line

4. Oil Separator 14. Suction Line (Hose # 16) 24. Suction Pressure Regulator

5. Injection Line 15. Liquid Injection Switch 25. Suction Receiver

TK 61377-18-MM-EN 41
Unit Description

6. Condenser Coil 16. Truck Engine Compressor 26. PS5 (Condenser Solenoid Valve)

7 Service Valve 17. Defrost Line (Hose #6) 27. Standby Compressor (CMC)

8. Receiver 18. Suction Line (hose #12) 28. Discharge Check Valve

9. Drier 19. Liquid Line (Hose #6) 29. Check Valve

10. Service Valve 20. PS1 (Hot Gas Solenoid Valve)

Legend

On Road Cool Mode Copper Tubing Flexible Hose

Standby Cool Mode Heating and Defrost Mode Wire Names

42 TK 61377-18-MM-EN
 Unit Description

Null Mode
The unit operates in Null mode when the setpoint temperature is reached and cooling (or heating) is not required. All
outputs are de-energized. If the temperature rises a pre-determined number of degrees (programmable setting), the
unit restarts in Cool mode. If the temperature falls a pre-determined number of degrees, and a heat option is present,
the unit restarts in Heat mode.
In addition, the evaporator fans might operate during Null mode if evaporator fan constant blow feature is enabled. See
the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096.

Purge Mode – Model 30 and Model 50 Units Only

When the temperature falls a pre-determined number of degrees below the setpoint temperature, the controller
prepares the unit for the Heat mode by placing the unit in the Null mode for 10 seconds, and then placing the unit in the
Purge mode for 45 seconds before shifting to the Heat mode. In the Purge mode the compressor clutch is energized but
the evaporator fans are not. This moves the refrigerant from the condenser to the low side to increase the heating
capacity. The refrigerant flow is the same as shown previously in the Cool mode.

Heat Mode – Model 30 and Model 50 Units Only

If a Heat option is present, the unit enters Heat mode when the temperature falls a pre-determined number of degrees
below the setpoint temperature. When heat is required, the outputs of the microprocessor energize the compressor
clutch, the evaporator fans, the hot gas solenoid and the condenser inlet solenoid. (For units with Electric Standby, the
compressor motor contactor and compressor clutch are energized.)
The unit operates in Heat mode until the setpoint temperature is reached. The unit then enters Null mode.
• If the temperature falls a pre-determined number of degrees, the unit restarts in Heat mode.
• If the temperature rises a pre-determined number of degrees, the unit restarts in Cool mode.

TK 61377-18-MM-EN 43
Unit Description

Heat Mode Model 30

High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and
returned to the splice fitting in the suction line. The condenser inlet solenoid is closed and the hot gas solenoid is open
so the refrigerant flows through the hot gas line and the drain pan heater to the evaporator. There, the refrigerant heats
the evaporator. The refrigerant returns to the compressor through the accumulator and the compressor pressure
regulator because the CPR bypass solenoid is closed.
• Condenser Inlet Solenoid (CIS) – Closed/Energized. To control the discharge pressure the controller will open the
CIS briefly if the discharge pressure rises to a certain level and will then close it when the discharge pressure drops
to a lower level.
• Hot Gas Solenoid (HGS) – Open/Energized
• Liquid Line Check Valve – Closed
• Liquid Injection Solenoid (LIS) – Open/Energized
• CPR Bypass Solenoid – Closed/Energized
Heat Mode Model 50 Engine Operation
High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and
the oil separator where oil is separated and returned to a suction line. The condenser inlet solenoid is closed and the
hot gas solenoid is open so the refrigerant flows through the hot gas line and the drain pan heater to the evaporator.
There, the refrigerant heats the evaporator. The refrigerant returns to the compressor through the accumulator and the
compressor pressure regulator because the CPR bypass solenoid is closed.
• Discharge Check Valve – Open to engine driven compressor, closed to electric standby compressor
• Condenser Inlet Solenoid (CIS) – Closed/Energized. To control the discharge pressure the controller will open the
CIS briefly if the discharge pressure rises to a certain level and will then close it when the discharge pressure drops
to a lower level.
• Hot Gas Solenoid (HGS) – Open/Energized
• Liquid Line Check Valve – Closed
• Liquid Injection Solenoid (LIS) – Open/Energized
• CPR Bypass Solenoid – Closed/Energized
Heat Mode Model 50 Electric Standby Operation
High pressure refrigerant vapor leaves the electric standby compressor and flows through the discharge check valve
and the oil separator where oil is separated and returned to a suction line. The condenser inlet solenoid is closed and
the hot gas solenoid is open so the refrigerant flows through the hot gas line and the drain pan heater to the
evaporator. There, the refrigerant heats the evaporator. The refrigerant returns to the compressor through the
accumulator and the compressor pressure regulator because the CPR bypass solenoid is closed.
• Discharge Check Valve – Closed to engine driven compressor, open to electric standby compressor
• Condenser Inlet Solenoid (CIS) – Closed/Energized. To control the discharge pressure the controller will open the
CIS briefly if the discharge pressure rises to a certain level and will then close it when the discharge pressure drops
to a lower level.
• Hot Gas Solenoid (HGS) – Open/Energized
• Liquid Line Check Valve – Closed
• Liquid Injection Solenoid (LIS) – Open/Energized
• CPR Bypass Solenoid – Closed/Energized

44 TK 61377-18-MM-EN
 Unit Description

Defrost Mode
Defrost can be initiated any time the evaporator coil temperature is below 36 F (2.2 C), causing the defrost termination
switch to close. Defrost is initiated automatically by the defrost timer, or manually using the In-Cab Control Box.
Defrost will continue until the evaporator coil temperature rises to 48 F (8.9 C) causing the defrost termination switch to
open or the defrost termination timer has expired (whichever occurs first), ending the defrost cycle. Defrost cycle can be
also terminated by pressing the On/Off Key to turn the unit off, and then pressing it again to turn the unit back on.
The drain hose heaters are also energized during defrost (if so equipped).

Defrost Mode Model 10

High pressure refrigerant vapor leaves the compressor and flows through the oil separator where oil is separated and
returned to the splice fitting in the suction line. The hot gas solenoid is open so the refrigerant flows through the hot
gas line and the drain pan heater to the evaporator. There, the refrigerant heats the evaporator. The refrigerant returns
to the compressor through the suction line.
• Hot Gas Solenoid (HGS) – Open/Energized
• Liquid Injection Solenoid (LIS) – Closed/De-energized, but will open (energize) if the liquid injection switch closes.
Defrost Mode Model 20 Engine Operation
High pressure refrigerant vapor leaves the engine driven compressor and flows through the discharge check valve and
the oil separator where oil is separated and returned to a suction line. The the hot gas solenoid is open so the
refrigerant flows through the hot gas line and the drain pan heater to the evaporator. There, the refrigerant heats the
evaporator. The refrigerant returns to the compressor through the suction line.
• Discharge Check Valve – Open to engine driven compressor, closed to electric standby compressor
• Hot Gas Solenoid (HGS) – Open/Energized
• Liquid Injection Solenoid (LIS) – Closed/De-energized, but will open (energize) if the liquid injection switch closes.
Defrost Mode Model 20 Electric Standby Operation
High pressure refrigerant vapor leaves the electric standby compressor and flows through the discharge check valve
and the oil separator where oil is separated and returned to a suction line. The hot gas solenoid is open so the
refrigerant flows through the hot gas line and the drain pan heater to the evaporator. There, the refrigerant heats the
evaporator. The refrigerant returns to the compressor through the suction pressure regulator.
• Discharge Check Valve – Closed to engine driven compressor, open to electric standby compressor
• Hot Gas Solenoid (HGS) – Open/Energized
• Liquid Injection Solenoid (LIS) – Closed/De-energized
Defrost Mode Model 30 and 50 Units
Defrost in Model 30 and 50 units is basically the same as Heat mode in Model 30 and 50 Units except the evaporator
fans are not energized. The refrigerant flow is the same as shown previously in the Heat mode.

TK 61377-18-MM-EN 45
Unit Description

Serial Number Locations

C O N D E N S E R : Nameplate located on the back inside wall of condenser frame.
E N G I N E D R I V E N C O M P R E S S O R : Nameplate located on compressor body. The engine driven compressor is located in
the truck engine compartment.
S T A N D B Y C O M P R E S S O R : Nameplate located on compressor body. The Standby compressor is located inside the
Condenser assembly.
1. C O N D E N S E R : Nameplate located on the front inside edge of condenser frame (Cover needs to be removed).
2. S T A N D B Y C O M P R E S S O R : 20 and 50 Models only. Nameplate located on standby compressor body. Standby
compressor is located inside the Condenser.
3. E N G I N E D R I V E N C O M P R E S S O R : Nameplate located on compressor body. Engine driven compressor is located in
the vehicle’s engine compartment.
Figure 10. Condenser and Standby Compressor Serial Number Locations

46 TK 61377-18-MM-EN
 Unit Description

Unit Components
Figure 11. V-500/V-600 MAX 10/20/30/50 Condenser

1 Liquid Reservoir 11 Transformer (20/50)

2 Filter-Drier 12 Rectifier Heat Sink (20/50)

3 Liquid Sight Glass 13 Standby Compressor (20/50)

4 Liquid Injection Solenoid (LIS) 14 Electric Box Cover

5 Hot Gas Solenoid 15 AC Compressor Electric Box (20/50)

6 Receiver Tank (30/50 units) 16 Condenser Coil

7 Oil Separator 17 Discharge Check Valve (20/50 units)

8 Suction Pressure Regulator Valve (SPR) (20/30/50) 18 Low Pressure Switch

9 Compressor Pressure Regulator Valve (CPR) 19 Liquid Line Check Valve (30/50 units)

10 Condenser Fans

TK 61377-18-MM-EN 47
Unit Description

Figure 12. V-500 MAX SPECTRUM 10/20/30/50 condenser

1 Liquid reservoir 11 Suction pressure regulator valve (SPR) (Evaporator 2)

2 Dryer filter 12 Electric transformer (20/50)

3 Liquid sight glass 13 Rectifier heat sink (20/50)

4 Liquid injection valve (LIS) 14 Electric compressor (20/50)

5 Hot Gas Solenoid (30/50) 15 Electric control box cap

6 Receiver tank (30/50) 16 AC power compressor electric control box (20/50)

7 Oil separator 17 Condenser coil

8 Condenser fans 18 Discharge Check valve (20/50)

9 Compressor Pressure Regulator Valve (CPR) 19 Low pressure switch

10 Suction pressure regulator valve (SPR) (Evaporator 1) 20 Liquid Line Check Valve (30/50 units)

48 TK 61377-18-MM-EN
 Unit Description

Figure 13. Condenser electric box

1. BATR battery relay 6. OLR overload relay (20/50 units)

2. Terminal strip 7. Contactor (20/50 units)
3. ECM Electronic Control Module 8. Thermistor (20/50 units)
4. C1R switching relay 9. EMC filter (20/50 units)
5. F20 fuse (2) (20/50 units) 10. STDR electrical power relay (20/50 units)

Figure 14. ES600 MAX Evaporator

TK 61377-18-MM-EN 49
Unit Description

1. Expansion valve 5. Defrost valve

2. Liquid solenoid valve 6. Defrost thermostat (Klixon)
3. Evaporator fans 7. Evaporator coil
4. Temperature sensor

Figure 15. ES400 MAX Evaporator

1. Temperature sensor 5. Evaporator coil

2. Expansion valve 6. Liquid solenoid valve
3. Defrost valve 7. Evaporator fans
4. Defrost thermostat (Klixon)

50 TK 61377-18-MM-EN
 Unit Description

Figure 16. ES150 MAX Evaporator

1. Liquid solenoid valve 5. Evaporator fan

2. Expansion valve 6. Temperature sensor
3. Defrost thermostat (Klixon) 7. Evaporator coil
4. Defrost valve

TK 61377-18-MM-EN 51
Maintenance Inspection Schedule
N o t e : Please refer to your V-Series Operator Manual TK 61651-1-OP for Operator Weekly Checks

N o t e : Please refer to the latest EDAC labour Standards Guide on EMEA infocentral for Service Inspection Schedules for
your unit.

The following should be checked a part of the F i r s t M o n t h D e a l e r I n s p e c t i o n a n d M a i n t e n a n c e (5000km):

1. Check belt tension.
2. Check unit mounting bolts.
3. Check for chafing of wiring harnesses and all hoses.

52 TK 61377-18-MM-EN
Electrical Maintenance
Electronic Control System
Refer to the Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096 for complete service
information about Electronic Control System and the related components.

Defrost System
Defrost is initiated automatically by the programmable defrost timer, or manually by means of the In-Cab Control Box.
If demand defrost is enabled, a demand defrost cycle occurs, based on the Defrost Initiation Timer (DIT) and the Defrost
Termination Switch being closed. The evaporator coil temperature must be below 36 F (2.2 C) to allow defrost.
When defrost is required, the microprocessor output energizes the hot gas solenoid to supply hot refrigerant to the
evaporator coil and de-energizes the evaporator fans. The Defrost Initiation Timer (DIT) has counted-down its required
time-setting, and the Defrost Termination Switch is closed.
The unit remains in Defrost mode until the Defrost Termination Switch setpoint is reached (that is, when the evaporator
coil temperature rises to 48.0 F (8.9 C), or until the Defrost Termination Timer (DTT) count is completed). If the
evaporator coil temperature does not rise above 48.0 F (8.9 C) within the defrost duration time limit, the microprocessor
terminates the defrost operation.
The startup of the evaporator fans is delayed for several seconds after Defrost mode ends to prevent water from the
melting ice from being sprayed on the load.
Defrost initiation and termination settings are accessed through the Guarded Access Menu. Refer to the for instructions
on the use of Guarded Access Menu features.
The Defrost Initiation Timer offers programming choices of 0 to 480 minutes, in increments of 30 minutes. The factory
setting is 240 minutes. This parameter allows maintenance personnel to set the Defrost Initiation Timer. When it times-
out, it switches the unit from Cool mode to Defrost mode. The timer counts all the time that the unit is in Cool mode.
The count resets when Defrost mode starts. If the timer is set at 0 (zero), this is a test position. Defrost mode starts in 15
seconds.
The Defrost Termination Timer offers programming choices of 5 to 50 minutes, in increments of 5 minutes. The factory
setting is 30 minutes. This parameter allows maintenance personnel to set the Defrost Termination Timer, which begins
counting from the initiation of a Defrost mode. When the timer times-out, the unit is switched from Defrost mode to
Null mode. The timer resets at the end of a Defrost mode, or after the Defrost Termination Timer has timed-out. If the
timer is set at 0 (zero), this is a test position. Defrost mode stops in 15 seconds.

Defrost Termination Switch

The switch is mounted in the evaporator coil and controls the defrost cycle in response to the evaporator coil
temperature. The switch is closed when the evaporator coil temperature is below 36 F (2.2 C), which allows the unit to
enter the defrost cycle.
When the unit does shift into a defrost cycle, the evaporator fan stops, and heat from the hot refrigerant gas melts the
frost from the evaporator coil. The switch opens and terminates the defrost cycle when the evaporator coil temperature
rises above 48 F (8.9 C).

Defrost Termination Switch Replacement

Removal
1. Remove the evaporator cover, and disconnect the evaporator fan motor wires as needed.
2. Disconnect the wires from the switch.
3. Remove the mounting hardware and remove the switch.

Installation
1. Place the switch in position and install the mounting hardware.
2. Connect the wires to the switch.
3. Connect the evaporator fan motor wires if needed and install the evaporator cover.

TK 61377-18-MM-EN 53
Electrical Maintenance

Liquid Injection System

MAX units use R-404A or R-452A. These units have a liquid injection system to limit discharge temperature of the
engine driven compressor. Liquid injection is activated when the temperature switch is closed or when the unit is
running in heat mode on Model 30 and Model 50 units. 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 in the evaporator to the metering
orifice. The metering orifice is attached to the suction tube assembly in the condenser. As the refrigerant passes
through the metering orifice it expands and evaporates, cooling the suction gas entering the compressor. This cooling
effect is transferred to the discharge gas leaving the compressor from the adjacent cavity in the compressor head.
When the discharge gas is cooled to 200 ± 5 F (93 ± 3 C), the liquid injection switch opens, the liquid injection solenoid
closes and refrigerant no longer flows through the liquid injection system.

Condenser Fan Motor

N o t e : Non-repairable fan motor assemblies are used. If a motor malfunctions, it must be replaced.

WARNING
Risk of Injury!
Take precautions to verify the unit will not accidentally start while servicing the system. Always turn off the
unit On/Off Switch when inspecting or servicing any components.

The condenser fan motors are maintenance free. If erratic or intermittent operation is observed, the current draw of the
motor should be measured while proper voltage is applied. The current draw for a condenser fan motor is
approximately 10.0 to 10.8 amps at 13 volts.
If the condenser fan motor does not run at all, check the fuses in the condenser fan motor circuit and the output to the
condenser fan when it should be energized.

Condenser Fan Motor Removal and Installation

Removal
1. Turn the unit off.
2. Remove the fan guard / motor mounting screws (4).
3. Lift the fan motor and disconnect the motor power plug.
4. Remove the fan motor from the condenser.

Installation
1. Connect the fan motor power plug.
2. Place the fan motor in . Install and tighten the fan motor mounting screws (4).
3. Install the fan shroud and condenser cover.
4. Start the unit and verify correct fan motor operation.

Evaporator Fan Motors

N o t e : Non-repairable fan motor assemblies are used. If a motor malfunctions, it must be replaced.

WARNING
Risk of Injury!
Take precautions to verify the unit will not accidentally start while servicing the system. Always turn off the
unit On/Off Switch when inspecting or servicing any components.

The evaporator fan motors are maintenance free. If erratic or intermittent operation is observed, the current draw of the
motor should be measured while proper voltage is applied. The current draw for a evaporator motor is approximately
5.7 to 6.2amps at 13 volts.
If any of the evaporator fan motors do not run at all, check the fuses in the evaporator fan motor circuits and the outputs
to the evaporator fans when they should be energized.

54 TK 61377-18-MM-EN
 Electrical Maintenance

Evaporator Fan Motor Removal and Installation

Removal
1. Turn the unit off.
2. Remove the evaporator cover. On multi-temp units also disconnect the motor power plugs.
3. Remove the fan motor screws (4).
4. On single temp units disconnect the motor power plug.
5. Remove the fan motor.

Installation
1. Attach the fan motor to the evaporator or evaporator cover and tighten the fan motor mounting screws (4).
2. Connect the fan motor power plug(s).
3. Ensure the wires do not contact the fan blades inside the evaporator.
4. Install the evaporator cover.
5. Start the unit and verify correct fan motor operation.

Drain Line Heaters

Drain line heaters are used on MAX units to prevent ice build-up in the evaporator drain pan and drain hoses. They are
activated when the defrost termination switch is closed.
Check the operation of a drain line heater as follows:
1. Set the thermostat on the lowest setting.
2. Start and run the unit in Cool on the engine driven compressor until the return air temperature is below 32 F (0 C).
3. Disconnect the 2-pin wire connector from the drain line heater and check for 12 Vdc between the 27/27A and wires.
• If voltage is present, check the resistance of the drain line heater. It should be approximately 14.0 ohms.
• If voltage is not present, Check the continuity of the 27/27A circuit back to the ECM, Fuse , and the continuity of
the circuit to ground.

Drain Line Heater Replacement

Removal
1. Remove the evaporator cover and disconnect the evaporator fan motor wires.
2. Disconnect the drain line heater wires from the wire harness.
3. Remove the heater wires from the drain hose.

Installation
1. Insert the heater wires into the drain hose drain hose as far as they will go. Note the following:
• Heater wires must extended into drain pan and be inserted into each drain hose as far as they will go.
• NEVER CUT HEATER RESISTANCE WIRES!
• DO NOT install more than one heater wire into each drain tube.
• DO NOT use band wraps to hold heater wires.
• DO NOT cover or wrap heater wires.
• DO NOT pinch the end of the heater wires tight.

TK 61377-18-MM-EN 55
Electrical Maintenance

Figure 17. Drain Line Heater Installation

2. Connect the drain line heater wires to the wire harness.

3. Connect the evaporator fan motor wires and install the evaporator cover.

Fuses
N o t e : Please refer to “Specifications Chapter of this manual ,” p. 18 for more information pertaining to your particular
unit.

Controller Fuses:
These fuses are located on the controller.
N o t e : Platform II ECM shown here as an example.
Figure 18. Controller Fuses

F3. Fuse 10 - 15 amps F6. Fuse 2 amps F10. Fuse 10 - 15 amps

F4. Fuse 10 - 15 amps F8. Fuse 10 - 20 amps F11. Fuse 2 amps

F5. Fuse 10 - 20 amps F9. Fuse 10 - 15 amps

56 TK 61377-18-MM-EN
 Electrical Maintenance

Control Box Fuses: Printed Circuit Boards

These fuses are located inside the control box and are not on the controller.
N o t e : Platform I ECM shown here as an example
Figure 19. Control Box Fuses

1. Fuse F20 - 5 amps (Model 20 and Model 50 only) 3. Fuse 26 - 15 amps (Electric Heat Option only)

2. Fuse F30 - 20 amps 4. Fuse F16 - 5 amps (Model 20 and Model 50 only)

Harness Fuses:
These fuses are located in wiring harnesses outside of the control box.

TK 61377-18-MM-EN 57
Electrical Maintenance

Figure 20. Harness Fuses

F1. Fuse F22 - 10 amps

F2. Fuse F21 - 40 amps (60 amps for Spectrum units)

Relays
One or more relays are used in these units.
• Battery Power Relay (all units) Single Pole Single Throw (SPST)
• Electric Standby Power Relay (Model 20 and Model 50 units only) Single Pole Single Throw (SPST)
• Battery Relay (Model 20 and Model 50 units only) Single Pole Double Throw (SPDT)
Figure 21. Single Pole Single Throw (SPST) Relay

58 TK 61377-18-MM-EN
 Electrical Maintenance

Figure 22. Single Pole Double Throw (SPDT) Relay

Relay Testing
A relay is energized when 12 Vdc or 24 Vdc power is applied to the relay coil across pins 85 and 86. When energized the
normally open (NO) contacts close and the normally closed (NC) contacts open.
1. Remove covers as needed to access the relays.
2. To check the battery power relay, turn the truck ignition switch on. To check the electric standby power relay and the
battery disconnect relay, connect the unit to an appropriate electric standby power supply.
3. Remove the relay from its socket and check for 12 Vdc or 24 Vdc between pins 85 and 86 in the relay socket. If
voltage is not present, check the circuits that supply power and ground to the relay coil.
4. Check the resistance between pins 85 and 86 on the relay. It should be approximately 90 ohms. If not, replace the
relay.
5. On a SPDT relay, check the NC contacts by checking for continuity between pins 30 and 87A. If the continuity is not
acceptable, replace the relay.
6. Use jumper wires and a 12 Vdc power supply to attached to pins 85 and 86 to energize the relay.
7. Check the NO contacts by checking for continuity between pins 30 and 87. If the continuity is not acceptable, replace
the relay.

Relay Replacement
1. Turn the truck ignition switch off and disconnect the electric standby power supply if applicable.
2. Remove covers as needed to access the relays.
3. Remove the relay from its socket.
4. Insert the new relay into the relay socket.
5. Reinstall any covers that were removed.

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AC Components Model 20 and Model 50 Units Only

WARNING
Hazardous Voltage!
Model 20 and Model 50 units use high voltage AC for electric standby operation. Lethal voltage potentials can
exist on connections in the high voltage circuits. Take appropriate precautions and use extreme care when
testing the unit.

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Figure 23. AC Components in Condenser

1. Receptacle Box 7. Compressor

2. Electric Standby Power Receptacle 8. Transformer

3. Power Plug 9. Condenser Fan

4. Mains harness 10. Coil Solenoid

5. Control Box to Compressor harness 11. LPCO Switch

6. Control Box 12. Pressure Transducer

• Electric Motor Start Capacitor (115/1/60 and 208-230/1/
60 units only)
• Smoothing Capacitor

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Figure 24. AC Components in Control Box

1. F20 Fuse Holder 6. Electric Standby Power Relay

2. Compressor Motor Contactor 7. Start Relay

3. Compressor Motor Overload Relay 8. Smoothing Capacitor

4. Electric Motor Start Capacitor (115/1/60 and 208-230/1/60 9. Electronic Control Module
units only)

5. Battery Power Relay

Electrical Contactors
Test the contact points by checking the voltage drop across each set of points when the contactor is energized and the
system is operating. If the voltage drop across a set of points is more than 0.25 Vac, replace the contactor.
Test the contactor coil as follows:
1. Check the voltage to the coil. It should be at approximately 12 Vdc. If not, check for an open circuit.

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2. Check the voltage after the coil. It should be 0 volts. If not, check for an open or high resistance in the circuit to
ground. If the voltage is 0 but the contactor does not pull-in, the coil is probably open. Check the resistance to verify.
It should be approximately 48 ohms.

Compressor Motor Contactor

This contactor provides the AC power to the compressor motor. It is energized for Electric Standby Operation.

Compressor Motor Contactor Replacement

Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove the cover.
3. Disconnect the wires from the compressor motor contactor. Note which wires are attached to which terminals so
they can be reattached correctly.
4. Remove the compressor motor contactor mounting hardware and remove the compressor motor contactor.

Installation
1. Place the compressor motor contactor in position and install the mounting hardware.
2. Connect the wires to the compressor motor contactor. Make sure to connect the wires to the same terminals from
which they were removed.
3. Reinstall the cover.

Electric Heat Contactor – HC (Model 20 Option Only)

This contactor only used on Model 20 units with the Electric Heat Option. It provides AC power to the electric heat
element. It is energizes in the Heat Mode during Electric Standby Operation.

Electric Heat Contactor Replacement

Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove the cover.
3. Disconnect the wires from the electric heat contactor. Note which wires are attached to which terminals so they can
be reattached correctly.
4. Remove the electric heat contactor mounting hardware and remove the electric heat contactor.
Installation
1. Place the electric heat contactor in position and install the mounting hardware.
2. Connect the wires to the electric heat contactor. Make sure to connect the wires to the same terminals from which
they were removed.
3. Reinstall the cover.

Compressor Motor Overload Relay – OL

The compressor motor overload relay protects the compressor motor. It opens the circuit to the compressor motor if
the current exceeds the overload relay setting. The overload relay resets automatically. The overload relay setting
depends on the voltage and phase configuration of the unit (see the Specifications chapter).

Compressor Motor Overload Relay Replacement

Set Up
When an overload relay is replaced, the new overload relay must be set up to open at the correct amperage and reset
automatically. See the following procedure to set up a new overload relay.
1. Open the clear plastic cover.

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Figure 25. Open Cover

1. Lift Here to Open Cover

2. Use a small screwdriver to set the opening amperage. See the Specifications chapter for the correct overload relay
setting.
3. Use a small screwdriver to remove the tab marked with an “H” to access the switch used to set the overload relay to
reset automatically.
Figure 26. Set Amperage and Remove Tab

1. Set Opening Amperage

2. Remove Tab Marked “H”

4. Move the slide switch down until it clicks into place at the bottom of the slot (from which the tab marked “H” was
removed). This sets the overload relay to reset automatically.

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Figure 27. Move Switch Down

1. Switch Clicks into Place at Bottom of Slot

The new overload relay is now set up correctly. Note which wires go to which terminals when removing the old
overload relay so the wires are connected correctly when the new overload relay is installed.
Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove the condenser cover.
3. Disconnect the wires from the compressor motor overload relay. Note which wires are attached to which terminals
so they can be reattached correctly.
4. Remove the compressor motor overload relay mounting hardware and remove the compressor motor overload
relay.

Installation
1. Place the compressor motor overload relay in position and install the mounting hardware.
2. Connect the wires to the compressor motor overload relay. Make sure to connect the wires to the same terminals
from which they were removed.
3. Reinstall the condenser cover.

Transformer – T1
The transformer converts 230 Vac to 12 Vac to provide power to the . The converts the 12 Vac to 12 Vdc to supply power
to the 12 Vdc control circuits.

Transformer Testing
Test the transformer as follows:
1. Disconnect the 6-pin connector in the wire harnesses to the transformer.
2. Connect the electric standby power receptacle to an appropriate AC power supply.
3. Check for AC voltage between the wires in the 6-pin connector.
4. the continuity of the L1 wire to the CMC, the continuity of the standby power harness, and the power supply.
5. Disconnect the AC power supply.

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6. Reconnect the 6-pin connector in the wire harnesses to the transformer.

7. Reconnect the AC power supply.
8. Check for AC voltage between the X1 and X4 wires at the rectifier.
9. Approximately 12 Vac should be present between X1 and X4. If not, check the continuity of the X1 and X4 wires to
the transformer. If the X1 and X4 wires have continuity, the transformer is probably defective.

Transformer Replacement
Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove the cover.
3. Disconnect the wire harnesses connected to the transformer.
4. Remove the transformer mounting hardware and remove the transformer.
Installation
1. Place the transformer in position and install the mounting hardware.
2. Connect the wire harnesses to the transformer.
3. Reinstall the cover.

Bridge Rectifier – BR
The bridge rectifier converts the 11.7 Vac power from the transformer to 11.7 Vdc to supply power to the 12 Vdc control
circuits. The bridge rectifier is located on a heat sink below the left side of the condenser coil when viewed from the
front of the condenser.
Test the bridge rectifier as follows:
1. Connect the electric standby power receptacle to an appropriate AC power supply.
2. Check for AC voltage between the X1 and X4 wires at the rectifier.
3. Approximately 12 Vac should be present between X1 and X4. If not, check the continuity of the X1 and X4 wires to
the transformer, the transformer, and the AC circuits back to the power supply.
4. Check the rectifier output voltage (DC) between the 2R wire and the CH wire at the rectifier. If this voltage is less than
approximately 12 Vdc the rectifier bridge is defective.

Capacitors
Several capacitors are used in Model 20 and Model 50 units.
• Smoothing Capacitor (all voltages)
• Electric Motor Run Capacitor
• Electric Motor Start Capacitor

WARNING
Hazardous Voltage w/Capacitors!
Be careful when working with electrical circuits that contain capacitors. Some capacitors hold a significant
electrical charge that might cause burns or shocks if accidentally discharged. Capacitors must be discharged
before working on electrical circuits. If there is a risk of energized electrical contact, arc, or flash, technicians
MUST put on all PPE in accordance with OSHA, NFPA 70E, or other local, state, or country-specific
requirements for arc flash protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,
DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND ARC FLASHING
CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY RATED FOR INTENDED VOLTAGE.

T o s a f e l y d i s c h a r g e a c a p a c i t o r : Turn the unit off and disconnect the electric standby power supply. Connect a 20,000
ohm, 5-watt resistor across the capacitor terminals for five seconds. Use a multimeter to confirm the capacitor is fully
discharged.

Capacitor Testing
1. Turn the unit off and disconnect the electric standby power supply.

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2. Remove covers as needed to access the capacitor.

3. Visually check the capacitor for leaks, cracks, bulges or other signs of damage. If any damage is apparent, replace
the capacitor.
4. Discharge the capacitor as described above.
5. Disconnect the wires from the capacitor to remove it from the circuit.
6. Use a digital multimeter such as a Fuke 77 set to the Capacitance Measurement Mode.
7. Connect the multimeter test leads to the capacitor terminals and keep them connected for a few seconds to allow
the multimeter to obtain a reading.
8. The capacitance should be within 10% of the value listed in the Specifications chapter. If not, replace the capacitor.
9. Reconnect the wires that were disconnected and reinstall any covers that were removed when finished with the test.

Capacitor Replacement
Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove covers as needed to access the capacitor.
3. Discharge the capacitor as described above.
4. Disconnect the wires from the capacitor.
5. Remove the capacitor mounting hardware and remove the capacitor.
Installation
1. Place the capacitor in position and install the mounting hardware.
2. Connect the wires to the capacitor.
3. Reinstall any covers that were removed.

Start Relay – SR
The start relay is a normally closed (NC) single pole single throw (SPST) relay. It is used to open the circuit between the
start capacitor (SC) and the C1 circuit when the compressor motor gets up to speed after the compressor motor
contactor (CMC) is energized to supply AC power to the compressor motor.

Start Relay Testing

1. Turn the unit off and set thermostat so the unit will run in Cool.
2. Connect the electric standby power receptacle to an appropriate AC power supply.
3. Remove covers as needed to access the start relay.
4. Remove the cover from the start relay.
5. Turn the unit on and watch the start relay to see if it energizes. If not, check for AC voltage between the T1-02 and
the C1-03 wires at the B and J terminals on the start relay. If AC voltage is not present, check the continuity of the T1-
02 wire to the overload relay, and check the continuity of the C1-03 wire and the C1 circuits to the U2 terminal on the
compressor motor.
6. Turn the unit off and disconnect the AC power supply.
7. Disconnect the wires from the start relay.
8. Check for continuity between pins P and J on the start relay. If the continuity is not acceptable, replace the start
relay.
9. Check the coil resistance between pins P and J on the start relay. If the resistance not acceptable (see Specifications
chapter), replace the start relay.

Start Relay Replacement

Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove covers as needed to access the start relay.
3. Remove the relay from its socket.

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4. Disconnect the wires from the start relay. Note which wires are attached to which terminals so they can be
reattached correctly.
5. Remove the start relay mounting hardware and remove the start relay.
Installation
1. Place the start relay in position and install the mounting hardware.
2. Connect the wires to the start relay. Make sure to connect the wires to the same terminals from which they were
removed.
3. Reinstall any covers that were removed.

Compressor Motor
Testing 115/1/60 Units
1. Connect the electric standby power receptacle to an appropriate AC power supply.
2. Set the thermostat so the unit will run in Cool.
3. Start the unit and run it in Cool on electric standby.
4. Check for AC voltage between the T1A and T2A wires at the compressor motor contactor.
5. Approximately 115 Vac should be present. If not, check the compressor motor contactor, the continuity of the
standby power harness, and the power supply. If the compressor motor contactor is not being energized (pulling
down) see “Electric Standby Circuits” below.
6. Check for AC voltage between the T1A and T2A wires at the compressor motor overload relay.
7. Approximately 115 Vac should be present. If not, check the continuity of the T1A and T2A wires.
8. Check for AC voltage between the T1-01 and T2-01 wires at the compressor motor overload relay.
9. Approximately 115 Vac should be present. If not, check the continuity of the PO wire on the compressor motor
overload relay and the compressor motor overload relay.
10. Turn the unit off, disconnect AC power supply, and check the connections in the junction box on the compressor
motor for to verify they are clean and tight.
11. Check the continuity of the T1-01 and T2-01 wires from the compressor motor overload relay to the compressor
motor. If both wires have good continuity, check the start relay, the start capacitor, the run capacitors and the
associated circuits. If those components are good, the compressor motor is most likely faulty.

Testing 208-230/1/60 Units

1. Connect the electric standby power receptacle to an appropriate AC power supply.
2. Set the thermostat so the unit will run in Cool.
3. Start the unit and run it in Cool on electric standby.
4. Check for AC voltage between the T1A and T2A wires at the compressor motor contactor.
5. Approximately 208-230 Vac should be present. If not, check the compressor motor contactor, the continuity of the
standby power harness, and the power supply. If the compressor motor contactor is not being energized (pulling
down) see “Electric Standby Circuits” below.
6. Check for AC voltage between the T1A and T2A wires at the compressor motor overload relay.
7. Approximately 208-230 Vac should be present. If not, check the continuity of the T1A and T2A wires.
8. Check for AC voltage between the T1-01 and T2-01 wires at the compressor motor overload relay.
9. Approximately 208-230 Vac should be present. If not, check the continuity of the PO wire on the compressor motor
overload relay and the compressor motor overload relay.
10. Turn the unit off, disconnect AC power supply, and check the connections in the junction box on the compressor
motor for to verify they are clean and tight.
11. Check the continuity of the T1-01 and T2-01 wires from the compressor motor overload relay to the compressor
motor. If both wires have good continuity, check the start relay, the start capacitor, the run capacitor and the
associated circuits. If those components are good, the compressor motor is most likely faulty.

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Testing 208-230/3/60 Units

1. Connect the electric standby power receptacle to an appropriate AC power supply.
2. Set the thermostat so the unit will run in Cool.
3. Start the unit and run it in Cool on electric standby.
4. Check for AC voltage between the T1B, T2B, and T3B wires at the compressor motor contactor.
5. Approximately 208-230 Vac should be present. If not, check the compressor motor contactor, the continuity of the
standby power harness, and the power supply. If the compressor motor contactor is not being energized (pulling
down) see “Electric Standby Circuits” below.
6. Check for AC voltage between the T1B, T2B, and T3B wires at the compressor motor overload relay.
7. Approximately 208-230 Vac should be present. If not, check the continuity of the T1B, T2B, and T3B wires.
8. Check for AC voltage between the T1, T2, and T3 wires at the compressor motor overload relay.
9. Approximately 208-230 Vac should be present. If not, check the compressor motor overload relay.
10. Turn the unit off, disconnect AC power supply, and check the connections in the junction box on the compressor
motor for to verify they are clean and tight.
11. Check the continuity of the T1, T2, and T3 wires from the compressor motor overload relay to the compressor
motor. If all three wires have good continuity, the compressor motor is most likely faulty.

Compressor Motor Replacement

Removal
1. Turn the unit off and disconnect the electric standby power supply.
2. Remove the condenser cover.
3. Loosen and remove the compressor drive belt.
4. Remove the junction box cover from the compressor motor to access the wire connections.
5. Disconnect the wires from the compressor motor. Note which wires are attached to which terminals so they can be
reattached correctly.
6. Remove the compressor motor mounting hardware and remove the compressor motor.
Installation
1. Place the compressor motor in position and install the mounting hardware and the belt.
2. Adjust the belt to the proper tension (see Specifications).
3. Remove the junction box cover from the compressor motor to access the wire connections.
4. Connect the wires to the compressor motor. Make sure to connect the wires to the same terminals from which they
were removed.
5. Reinstall the junction box cover.
6. Reinstall the condenser cover.

Electric Standby Circuits

If the unit does not run in the electric standby mode use the following procedure.
Make sure the unit is connected to the proper power source.
Check the power cable receptacle for power. If power is there, check for power at the unit terminal plug.
If the contactor is pulled down and the overload relay is closed, but the standby compressor motor fails to start, the
trouble is probably in the standby compressor motor.
If the contactor is not pulling down proceed as follows:
1. Check the AC line voltage and the transformer input fuse F20. If the AC line voltage is acceptable and the
transformer input fuse is intact, go to step 2.
2. Measure the transformer output voltage (AC). The voltage reading should be approximately 12 Vac. If not, the
transformer is defective. If the transformer output voltage is acceptable, go to step 3.
3. Check the rectifier output voltage (DC) on the 2R wire at the smoothing capacitor (C1) and check for continuity to
ground on the CHK wire at the smoothing capacitor (C1). If this voltage is less than approximately 12 Vdc, and if the

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2R circuits to the bridge rectifier (BR) and the X1 and X4 circuits from the bridge rectifier (BR) to the transformer
have good continuity, the bridge rectifier (BR) is defective. If the rectifier output voltage is acceptable go to step 4.
4. Check fuse F16 on the X1 wire at the smoothing capacitor (C1).
5. Check the rectifier output voltage (DC) on the X1 wire (pin B8 at Connector 1 on PCB1 in the ECM). If voltage is not
present, check the continuity of the X1 wire from the smoothing capacitor (C1). If the rectifier output voltage is
acceptable, go to step 6.
6. Check the voltage on 2R wire at the electric standby power relay (ESR). If voltage is not present, check the continuity
of the 2R wire from the smoothing capacitor (C1). If the voltage on the 2R wire at the electric standby power relay
(ESR) is acceptable, go to step 7.
7. Check the voltage on the 2RB and 2RB1 wires at the electric standby power relay (ESR). If voltage is not present,
check the continuity of the 2RB wire. If the voltage on both the 2RB and 2RB1 wires is acceptable, go to step 8.
8. Check the voltage on the 2RB1 wire at the battery disconnect relay (BDR). If voltage is not present, check the
continuity of the 2RB1 wire from the electric standby power relay (ESR). If the voltage on the 2RB1 wire at the
battery disconnect relay (BDR) is acceptable, go to step 9.
9. Check for continuity to ground on the CH1 wire at the battery disconnect relay (BDR). If continuity to ground on the
CH1 wire at the battery disconnect relay (BDR) is not present, check the continuity of the CH1 wire from the battery
disconnect relay (BDR) to the chassis ground. If there is good continuity to ground on the CH1 wire at the battery
disconnect relay (BDR), go to step 10.
10. Check for continuity to ground on the SWS wire at the electric standby power relay (ESR). If continuity to ground is
not present, check the continuity of the SWS wire from the battery disconnect relay (BDR). If the SWS wire has good
continuity, go to step 11. If there is good continuity to ground on the SWS wire at the electric standby power relay
(ESR), go to step 12.
11. Check for continuity to ground on the CH4 wire at the battery disconnect relay (BDR). If the CH4 wire has good
continuity to ground, the battery disconnect relay (BDR) is probably defective. If continuity to ground on the CH4
wire at the battery disconnect relay (BDR) is not present, check the continuity of the CH4 wire from the battery
disconnect relay (BDR) to the chassis ground.
12. Check the voltage on the 2RA wire at the electric standby power relay (ESR). If voltage is not present, the electric
standby power relay (ESR) is probably defective. If the voltage on the 2RA wire at the electric standby power relay
(ESR) is acceptable, go to step 13.
13. Check the voltage on the PC1 wire at Pin 2 in the PSC1 Connector on PCB1 in the ECM. If voltage is not present,
check the continuity of the PC1 circuit to the terminal board (TB) and the 2RA circuit to the electric standby power
relay (ESR). If the voltage on the PC1 wire is acceptable, go to step 14.
14. Check the voltage on the CMC wire at the compressor contactor (CMC). If voltage is not present, check the continuity
of the CMC circuit to Pin 10 in Connector 2 on PCB1 in the ECM and Fuse 5 on the ECM. If the CMC wire has good
continuity and Fuse 5 is good, the ECM may be defective. If the voltage on the CMC wire is acceptable, go to step 15.
15. Check for continuity to ground on the CHE wire at the compressor motor contactor (CMC). If there is good continuity
to ground on the CHE wire at the compressor motor contactor (CMC), the compressor motor contactor is probably
defective. If continuity to ground on the CHE wire at the compressor contactor (CMC) is not present, go to step 16.
16. Check the continuity of the CHE wire from the compressor motor contactor (CMC) to the chassis ground.

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Evacuating and Charging the Refrigeration System
Refer to the Vehicle Powered Truck Installation Standards and Procedures TK 61588 (Section 10 – System Evacuation
Procedures) and Section 12 – System Charging Procedures) for service information about evacuating and charging the
refrigeration system

Checking the Refrigerant Charge

If the unit has an insufficient charge of refrigerant, the evaporator will be “starved” and the box temperature will rise
even though the unit is operating. Also, an insufficient charge does not circulate enough oil to properly lubricate the
compressor. The charge can be determined by inspection of the refrigerant through the sight glass with the following
conditions established:

Testing the Refrigerant Charge with an Empty Box

1. Install gauge manifold set on the on the engine driven compressor.
2. If the unit is equipped with Electric Standby, operate the unit in Cool on Electric Standby for 5 minutes.
a. Connect the power cord.
b. Turn the unit ON and place the unit in Cool Mode for 5 minutes.
c. Turn the unit OFF and disconnect the power cord.
3. Start the vehicle’s engine and operate it at 1000 RPM.
4. Turn the unit ON and place the unit in Cool Mode. Lower the setpoint(s) to the following:
• R-134a: 25 degrees F (-4 degrees C)
• R-404A: 0 degrees F (-18 degrees C)
• R-452A: 0 degrees F (-18 degrees C)
5. Operate the unit until the following box temperature(s) are reached:
• R-134a: 35 degrees F (2 degrees C)
• R-404A: 10 degrees F (-12 degrees C)
• R-452A: 10 degrees F (-12 degrees C)
6. Check to ensure the following discharge pressures are met or exceeded:
• R-134a: 180 psig (1241 kPa)
• R-404A: 275 psi (1896 kPa)
• R-452A: 275 psi (1896 kPa)
N o t e : Partially blocking the condenser grille may be necessary to achieve these pressures.
7. Inspect the sight glass.
• NO BUBBLES PRESENT: The system is full of refrigerant. Proceed to Step 8.
• BUBBLES PRESENT: The system is low on refrigerant. Proceed to the “Suction (Low Side) Bump Charging”
procedure listed below.
8. Verify the unit is not over charged. Elevate engine RPM to 3000-4000 RPM for three minutes. Verify that the unit
does not shutdown on high head pressure. If unit shuts down on high head pressure the system is overcharged.
Reduce the refrigerant charge amount until the unit no longer shuts down on high head pressure.
N o t e : If the condenser coil was covered in previous Step 6 leave the condenser coil covered for Step 8.

Testing the Refrigerant Charge with a Loaded Box

1. Install gauge manifold set on the on the engine driven compressor.
2. Run the unit in Cool on engine driven compressor operation.
3. Cover the condenser to drive any excess refrigerant from the condenser into the receiver tank.
4. As the head pressure rises, check the liquid line sight glass. There should be no bubbles in the flow of refrigerant

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through the liquid line sight glass. Bubbles in the refrigerant indicate the unit is low on refrigerant. Refer to the
“Suction (Low Side) Bump Charging” procedure listed below to top-off the system.
N o t e : If no bubbles are present, there is sufficient refrigerant in the unit for that load at that particular box
temperature. This test does not determine if the unit contains a full charge of refrigerant.

Suction (Low Side) Bump Charging

I m p o r t a n t : Failure to properly charge the system with refrigerant will result in immediate damage to the compressor.
1. Connect the gauge manifold set to the liquid port on the refrigerant bottle and purge the gauge manifold set (if not
already completed in the previous procedure).
2. Connect the gauge manifold set Low Side, blue hose, to a Suction (Low Side) service port (if not already completed
in the previous procedure).
N o t e : Select a service port that is as far away from the engine driven compressor as possible. Do NOT connect the
Suction (Low Side) hose to the Suction service port at the engine driven compressor. Compressor damage
may occur.
3. Connect the gauge manifold set High Side, red hose, to a Discharge (High Side) service port (if not already
completed in the previous procedure).
4. Start the vehicle’s engine and operate it at 1000 RPM.
5. Turn the unit ON and place the unit in Cool Mode. Lower the setpoints) to the following:
• R-134a: 25 degrees F (-4 degrees C)
• R-404A: 0 degrees F (-18 degrees C)
• R-452A: 0 degrees F (-18 degrees C)
6. Operate the unit until the following box temperature(s) are reached:
• R-134a: 35 degrees F (2 degrees C)
• R-404A: 10 degrees F (-12 degrees C)
• R-452A: 10 degrees F (-12 degrees C)
7. Check to ensure the following discharge pressures are met or exceeded:
• R-134a: 180 psig (1241 kPa)
• R-404A: 275 psi (1896 kPa)
• R-452A: 275 psi (1896 kPa)
N o t e : Partially blocking the condenser grille may be necessary to achieve these pressures.
8. Open the Low Side valve on the gauge manifold set for one second and close.
9. W a i t a m i n i m u m o f t e n s e c o n d s . Inspect the sight glass.
• NO BUBBLES PRESENT: The system is full of refrigerant. Proceed to Step 10.
• BUBBLES PRESENT: The system is low on refrigerant. Repeat Steps 8 and 9 until no bubbles are present in the
sight glass.
10. Close the gauge manifold valves and refrigerant bottle valve. Turn off the unit and shut off the vehicle’s engine.

Checking Compressor Oil Charge

The compressors are furnished with the amount of oil shown in the Specifications chapter. The oil level in the
compressor will change after the compressor is initially run, making any level measurements inaccurate.
To ensure an adequate oil supply, the following procedure must be followed whenever the refrigerant charge is lost or
removed from a unit:
1. Install a compressor on the system having a residual oil supply and self-lubricating system such as a TK 214 model.
Connect an oil separator on the discharge or suction line to collect and drain out circulated oil.
N o t e : A suction line oil separator can be improvised by installing a suction filter upside down in the suction line
near the compressor. Cap off both access ports, and use the lower one to drain off the accumulated oil.
2. Place a normal amount of oil in the cleanup compressor before operating.
3. Charge with the recommended amount of refrigerant for your model. Refer to the Specifications Chapter for

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recommended refrigerant amount.

4. Operate at a low speed (600 to 800 rpm) for 2 hours, or until the compressor oil level reaches a minimum allowable
level, whichever occurs first. Drain the collected oil from the oil separator as it fills, taking care to not allow any
collected oil to recirculate.
5. Prepare the original compressor that was removed from the unit (or a replacement) by draining out any existing oil
and replacing the oil with the amount of oil shown in the Specifications chapter.
6. Install the original compressor (or its replacement), and proceed with the manual evacuation and refrigerant
charging procedure.

Refrigeration System Checks

1. Connect a gauge manifold set to the suction and discharge service ports.
2. Check the system pressures and the refrigerant flow in cool, heat (Model 30 and 50 units only), and defrost. The
suction and discharge pressures should be within the normal ranges for a standard unit. Check the temperatures of
the refrigeration lines by hand to check the refrigerant flow. See the individual test for a component if you suspect it
is not functioning properly.

Cleanup Procedure for Small Truck Units

N o t e : Please refer to Service Bulletin SB_1165 for more information on the new VP Clean up procedure.

Tools Required
• Motor-driven TK 214 “Flushing Compressor”
• Suction Line Filter (P/N 2040498 with Filter P/N 662292)
• Pipes (In Place of Oil Separator, Check Valve, Oil Separator and Standby Compressor)

Clean-up Procedure
1. Make sure all hose routing is correct.
2. Make sure that the oil trap is correctly installed.
3. Recover the contaminated refrigerant from the system.
4. Remove the lines from the compressors (engine driven and standby).
5. Flush each compressor using the flushing compressor and an HFC refrigerant. (Always recover the refrigerant
before disconnecting the flushing compressor.)

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Figure 28. Connecting Flushing Compressor to Unit

1. Remove Internal Parts From Expansion Valve

2. Disconnect and Cap (If So Equipped)

3. Replace Drier With Tube

4. Discharge Line

5. Flushing Compressor

6. Suction Line

7. Suction Line Filter

8. Recovered Oil

6. Remove any check valves (or check valve seats) from system to ensure flow in all directions.
7. Remove the oil separator and install a connecting pipe.
8. Remove the internal parts from the expansion valve.
9. Open any suction pressure regulator valves to their highest setting.
10. Install a temporary suction line filter (P/N 2040498 and P/N 662292) in the suction line.
11. Install a connecting pipe in place of the standby compressor.
12. Connect the flushing compressor system to the engine driven compressor discharge and suction lines (see
illustration).
13. Evacuate the system and check for leaks. Continue to evacuate to remove moisture and air.
14. Install HFC refrigerant and run the flushing compressor to flush the system. Energize (open) the defrost solenoid
during 30% to 40% of the clean-up. Solid contaminants will collect in the suction line filter. Oil from the system and
from the flushing compressor will drain out of the suction line filter. (Add compressor oil as required.) Refrigerant
oil in the flushing compressor will absorb acids from the system.
15. Test the recovered compressor oil for acid contamination.
16. Continue flushing until the compressor oil is clean.

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Putting the Unit Back Into Operation

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

Putting the Unit Back Into Operation

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

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N o t e : It is generally good practice to replace the filter drier whenever the high side is opened or when the low side is
opened for an extended period of time.

WARNING
Risk of Injury!
Disconnect the power supply before servicing the unit to prevent personal injury.

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Figure 29. Condenser Components Model 10

1. Service Port Valve 8. Drier (Dehydrator)

2. Pressure Transducer 9. Receiver Tank

3. Oil Separator 10. Shut-off Valve

4. Suction Tube 11. Sightglass

5. Liquid Injection Solenoid (LIS) 12. Solenoid Coil

6. Low Pressure Cut Out Switch (LPCO) 13. Solenoid Valve

7. Condenser Coil

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Figure 30. Condenser Components Model MAX 50

1. Service Port Valve 12. Solenoid Coil

2. Pressure Transducer 13. Solenoid Valve

3. Oil Separator 14. Check Valve

4. Check Valve 15. Shut-off Valve

5. Liquid Injection Solenoid (LIS) 16. Accumulator Tank

6. Hot Gas Solenoid (HGS) 17. Low Pressure Cut Out Switch (LPCO)

7. Condenser Coil 18. Pressure Regulator Valve

8. Drier (Dehydrator) 19. Suction Valve

9. Receiver Tank 20. Discharge Valve

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10. Shut-off Valve 21. Compressor

11. Sightglass

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Figure 31. Condenser Components Model MAX 50 Spectrum with Bypass Valve

1. Service Port Valve 14. Check Valve

2. Pressure Transducer 15. Shut-off Valve

3. Oil Separator 16. Accumulator Tank

4. Check Valve 17. Low Pressure Cut Out Switch (LPCO)

5. Liquid Injection Solenoid (LIS) 18. Pressure Regulator Valve

6. Hot Gas Solenoid (HGS) 19. Suction Valve

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7. Condenser Coil 20. Discharge Valve

8. Drier (Dehydrator) 21. Compressor

9. Receiver Tank 22. Relief Valve

10. Relief Valve 21. Compressor

11. Sightglass 22. Pressure Control Switch

12. Solenoid Coil 23. Solenoid Valve Base

13. Solenoid Valve

Figure 32. Single Temperature Evaporator Components

1. Hot Gas Solenoid (HGS) 4. Expansion Valve

2. Hot Gas Solenoid (HGS) Coil 5. Heat Exchanger

3. Evaporator Coil

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Figure 33. Multi-Temperature Evaporator Components

1. Hot Gas Solenoid (HGS) 4. Expansion Valve

2. Hot Gas Solenoid (HGS) Coil 5. Heat Exchanger

3. Evaporator Coil 6. Service Port Valve

Engine Driven Compressor

Removal
1. Recover the refrigerant charge from the system.
2. Loosen and remove the compressor drive belt.
3. Disconnect the clutch and liquid injection switch wires (if used).
4. Disconnect the discharge and suction lines.

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5. Keep the compressor ports and the suction and discharge lines for the compressor covered to prevent
contamination of system components.
6. Remove the compressor mounting screws and remove the compressor.

Installation
N o t e : Any compressor installed in this system must contain 4 oz. (118 ml) of POE 120 compressor oil. Always check to
make sure that the compressor contains the proper amount and type of oil. Follow the system cleanup
procedures to remove old oil from the system.
1. Place the compressor in position and install the mounting screws and the belt.
2. Adjust the belt tension to the vehicle manufacturer specifications.
3. Connect clutch and liquid injection switch wires, and the refrigeration hoses. Pour the correct amount of oil for the
unit (see Specifications chapter) into the suction hose before installation.
4. Pressurize the system and test for leaks.
5. Evacuate the system and recharge.

Electric Standby Compressor

Removal
1. Recover the refrigerant charge from the system.
2. Remove the condenser cover.
3. Disconnect and remove the transformer (Only disconnection needed in large V-Series Units).
4. Loosen and remove the compressor drive belt.
5. Disconnect the compressor clutch wires.
6. Disconnect the discharge, suction and oil return lines.
7. Keep the compressor ports and the suction and discharge tubes for the compressor covered to prevent
contamination of system components.
8. Remove the compressor mounting bolts and remove the compressor.

Installation
N o t e : Any compressor installed in this system must contain 4 oz. (118 ml) of POE 120 compressor oil. Always check to
make sure that the compressor contains the proper amount and type of oil. Follow the system cleanup
procedures to remove old oil from the system.
1. Place the compressor in position and install the mounting bolts and the belt.
2. Adjust the belt to the proper tension (see Specifications).
3. Connect the discharge and suction tubes.
4. Connect the compressor clutch wires.
5. Reinstall the transformer (if removed).
6. Pressurize the system and test for leaks.
7. Reinstall the condenser cover.
8. Evacuate the system and recharge.

Condenser Coil
Removal
1. Recover the refrigerant charge.
2. Remove the condenser cover and fan shroud.
3. Remove the bridge rectifier.
4. Unsolder the inlet and liquid lines.

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5. Drill out the 12 mounting rivets.

6. Remove the condenser coil.

Installation
1. Clean the tubes for soldering.
2. Place the coil in the unit and rivet the coil in place using 12 TK specified rivets (see the appropriate Parts Manual).
3. Solder the inlet and liquid line connections.
4. Pressurize the system and test for leaks.
5. Evacuate the system.
6. Reinstall the bridge rectifier.
7. Reinstall the fan shroud and condenser cover.
8. Recharge the unit with the proper refrigerant.

Drier
Removal
1. Recover the refrigerant charge.
2. Remove the condenser cover.
3. Disconnect the ORS nuts at the end of the drier and sight glass.
4. Loosen the mounting hardware and remove the drier and sight glass.
5. Separate the drier and sight glass.

Installation
1. Coat the new O-rings with refrigerant oil (same type that is used in the system) and place the new O-rings in the
ORS fittings on the ends of the drier.
2. Install the sight glass on the outlet end of the drier.
3. Install the new drier and tighten the mounting band.
4. Install and tighten the ORS nuts. Hold the drier with a back-up wrench on the hex behind the ORS fitting.
5. Pressurize the system and test for leaks.
6. Evacuate the system.
7. Reinstall the condenser cover.
8. Recharge the unit with the proper refrigerant.

Discharge Pressure Transducer (DPT)

Removal
1. Remove the condenser .
2. Disconnect the wires and remove the transducer.

Installation
1. Install and tighten the transducer and reconnect the wires.
2. Pressurize the system and test for leaks.
3. Install the condenser .

Hot Gas Solenoid (HGS) Test

1. Install a gauge manifold set on the engine driven compressor.
2. Disconnect the 2-pin connector with the LIS and CLU wires in main wire harness from wires to the liquid injection

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switch at the engine driven compressor.

3. On Model 30 and 50 units disconnect the 2-pin connector with the 26A2 and CHS ( or 26 and CHM depending on
your unit) wires in main wire harness from the wires to the condenser inlet solenoid (PS5).
4. Set the thermostat(s) on the lowest setting(s).
5. Start and run the unit in Cool on the engine driven compressor until the suction pressure stabilizes.
6. Check the temperatures of the refrigeration lines on both sides of the hot gas solenoid (HGS) by hand. A
temperature difference between the two sides of the hot gas solenoid (HGS) indicates it is leaking.
7. Use the In-Cab Control Box to place the unit in defrost.
N o t e : The defrost termination switch must be closed for the unit to enter defrost. Use a jumper wire to connect the
12 and CHB circuits in the main wire harness at the 2-pin connector for the defrost termination switch if the
evaporator temperature is not low enough to close the defrost termination switch.
8. The suction pressure should rise. If the suction pressure does not rise, the hot gas solenoid (HGS) is not opening.
Check the continuity of the wiring and the resistance of the hot gas solenoid (HGS) coil before assuming the
solenoid is faulty. See the Specifications chapter for the solenoid coil resistance.
9. Reconnect the wires that were disconnected and remove the gauge manifold set when finished with the test.

Liquid Injection Solenoid (LIS) Test

See “Testing Liquid Injection Solenoid Valve and Metering Orifice” under Liquid Injection System in the Electrical
Maintenance Chapter.

Condenser Inlet Solenoid (CIS) Test (Model 30 and 50 Only)

1. Install a gauge manifold set.
2. Set the thermostat(s) on the lowest setting(s).
3. Start and run the unit in Cool on the engine driven compressor until the suction pressure stabilizes.
4. Check the temperatures of the refrigeration lines on both sides of the condenser inlet solenoid (CIS) by hand. Both
sides should be hot. If not, the CIS might be stuck closed.
5. Set the thermostat on the highest setting to make the unit shift to Heat. On SPECTRUM units set both zones to the
highest setting.
6. The suction pressure should rise and the discharge pressure should fall as the condenser inlet solenoid (CIS) closes,
and the hot gas solenoid (HGS) and liquid injection solenoid (LIS) open when the unit shifts to heat.
7. Let unit run in Heat until the suction and discharge pressures stabilize.
8. Check the temperatures of the refrigeration lines on both sides of the condenser inlet solenoid (CIS) by hand. Both
sides should be about the same temperature, but should not be hot.
• If both sides are hot, the condenser inlet solenoid (CIS) is probably not closing. Check the continuity of the
wiring, the hot gas heat relay/heat option relay/RY5 relay, and the resistance of the condenser inlet solenoid
(CIS) coil before assuming the solenoid is faulty. See the Specifications chapter for the solenoid coil resistance.
• If the side of the condenser inlet solenoid (CIS) going to the condenser is significantly colder than the side
coming from the oil separator, the condenser inlet solenoid (CIS) is probably leaking.
9. Remove the gauge manifold set when finished with the test.

CPR Bypass Solenoid Test

Solenoid Valve Replacement
N o t e : Valves that have nylon seats must be disassembled before soldering.

Removal
1. Recover the refrigerant charge.
2. Remove covers as necessary to access the solenoid valve.
3. Remove the coil and disassemble the valve if unsoldering the valve.

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4. Unsolder or disconnect the refrigeration lines from the valve, and remove the valve from the unit. Note the direction
of the flow arrow on the valve.

NOTICE
Equipment Damage!
Use a heat sink to prevent damaging the valve when soldering.

Installation
1. Clean the tubes for soldering if necessary.
2. Remove the coil and disassemble the valve if soldering.
3. Place the valve in position with the flow arrow pointing in the direction noted when removed.
4. Solder or connect the inlet and outlet connections. After the valve cools, assemble the valve and install the coil.

NOTICE
Equipment Damage!
Use a heat sink to prevent damaging the valve when soldering.

5. Pressurize the refrigeration system and test for leaks.

6. Evacuate the system.
7. Reinstall any covers .
8. Recharge the unit with the proper refrigerant.

Oil Separator
The oil separator must be replaced if a compressor has failed and is being replaced. Also check the oil return line to
make sure it is not plugged by blowing air through it when replacing the oil separator.

Removal
1. Recover the refrigerant charge.
2. Remove the condenser cover / grille.
3. Disconnect the ORS nuts at the ends of the oil separator.
4. Loosen the mounting hardware and remove the oil separator.

Installation
1. Coat the new O-rings with refrigerant oil (same type that is used in the system) and place the new O-rings in the
ORS fittings on the ends of the oil separator.
2. Install and tighten the inlet and outlet ORS nuts. Hold the oil separator with a backup wrench on the hex behind the
ORS fitting.
3. Pressurize the system and check for leaks.
4. Evacuate the system.
5. Reinstall the condenser cover / grille.
6. Recharge the unit with the proper refrigerant.

Splice Fitting
The splice fitting is used on all units except the Model 20 units with R-134a. It is mounted in the suction line near the
engine driven compressor and has two 1/4 SAE flare access fittings. The liquid injection metering orifice and the liquid
injection line from the liquid injection solenoid are attached to one of the access fittings on MAX units. The oil return
line from the oil separator is attached to the other access fitting on Model 10 and Model 30 units.
I m p o r t a n t : Make sure that a liquid injection metering orifice is installed on the fitting to which the liquid injection line is
attached, and that a metering orifice is not installed on the fitting to which the oil return line is attached.

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Discharge Check Valve (Model 20 and 50 Only)

Testing the Discharge Check Valve
Model 20 and 50 units are equipped with a discharge check valve. It isolates the engine driven compressor from the
electric standby compressor, ensuring the compressor oil and refrigerant do not migrate between compressors. The
check valve should be tested when the system is initially charged and operating, and anytime the system has been
opened for service or repair. Testing the check valve requires two gauge manifold sets.
1. Disconnect the liquid injection solenoid valve wires.
2. With the unit off, install a gauge manifold set on each compressor.
3. Observe the gauge manifold readings of the electric standby compressor. If the high side and low side readings are
not the same, open the gauge manifold valves and equalize the pressures. Close the gauge manifold valves.
4. Set the thermostat so the unit will run in cool.
5. Start the truck and run the unit in Cool on the engine driven compressor.
6. Observe the gauge manifold readings of the engine driven compressor. The head pressure should increase and the
suction pressure should decrease.
7. 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 to the standby compressor is leaking internally.
8. Turn the unit off and shut off the truck engine. Connect the remote control box to an appropriate electric power
source.
9. Observe the gauge manifold reading of the engine driven compressor. If the high side and low side readings are not
the same, open the gauge manifold valves and equalize the pressures. Close the gauge manifold valves.
10. Set the thermostat so the unit will run in cool.
11. Start the unit and run it in Cool on electric standby.
12. Observe the gauge manifold readings of the electric standby compressor. The head pressure should increase and
the suction pressure should decrease.
13. Observe the gauge manifold readings of the engine driven compressor. The high side pressure should remain the
same as the pressure in step 9 after the high and low sides were equalized. If the high side pressure is increasing or
has increased noticeably, the discharge check valve to the engine driven compressor is leaking internally. Stop the
unit.
14. Remove the gauge manifold sets and the electric standby power source. Connect the wires to the liquid injection
solenoid valve.
15. If the discharge check valve assembly is leaking internally it should be replaced, refer to the replacement procedure.

Discharge Check Valve Replacement

Removal
1. Recover the refrigerant charge.
2. Remove the condenser cover.
3. Disconnect the check valve assembly from the standby compressor outlet, the oil separator, and the discharge line
from engine driven compressor.

Installation
1. Coat the new O-rings with refrigerant oil (same type that is used in the system) and place the new O-rings in
position.
2. Place the check valve in position.
3. Connect the discharge line from engine driven compressor to the check valve assembly.
4. Connect the oil separator to the check valve assembly.
5. Connect the check valve assembly to the standby compressor outlet.
6. Pressurize the system and test for leaks.
7. Reinstall the condenser cover.

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8. Evacuate and recharge the system.

Expansion Valve Assembly

Refer to Expansion Valve Check/Adjustment in Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK
5984 for information checking and adjusting the expansion valve.

Checking Superheat
1. Examine and/or clean the evaporator and condenser coils.
2. Attach an accurate compound gauge to the suction access port nearest to where the equalizer line is connected to
the suction line. See the drawing below, which shows a typical evaporator.
3. Attach an accurate thermometer sensor to the suction line beside the suction access port. Secure it and insulate it
well.
Figure 34. Checking Superheat

1. Equalizer Line

2. Attach Compound Gauge to Suction Access Port

3. Attach Thermometer Sensor Here and Insulate

4. Run the unit with the engine driven compressor.

5. Defrost the evaporator.
6. Run the unit in Cool until the box temperature approaches 0 F (-18 C).
7. Cover the condenser as needed to maintain a discharge pressure of 160-175 psig (11 to 12 bar) for R-134a, or 290-
310 psig (20 to 21 bar) for R-404A/R-452A.
8. Read the suction line pressure and temperature simultaneously. Make several readings approximately every 2
minutes.

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9. The superheat should be between 6 °F (-3 °C) and 12 °F (-7 °C) at 0 °F (-18 °C) box temperature.
Calculate superheat according to the sample below for R-134a.
2 2 ° F ( - 6 ° C ) = Suction Line Temperature
1 2 p s i g ( 8 3 k P a ) = Suction Line Pressure
Convert equalizer line pressure to temperature using a pressure/temperature chart. F o r R - 1 3 4 a 1 2 p s i g ( 8 3 k P a ) =
10 °F (-12 °C)
Superheat = 22 °F - 10 °F = 12 °F
Superheat = -6 °C - (-12 °C) = 6 °C

Expansion Valve Replacement

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. Unsolder the liquid line and the distributor from the expansion valve.
N o t e : The brazing is tin (Zn) type.
6. Remove the expansion valve from the unit.
Installation
1. Install the expansion valve assembly in the unit.
2. Braze the liquid line and the distributor to the expansion valve.
3. Connect the equalizer line to the expansion valve.
4. Clean the suction line to a bright, polished condition. Install the feeler bulb clamps and the feeler bulb on the side of
the suction line in its former position. The feeler bulb must make good contact with the suction line or operation will
be faulty. Wrap the bulb with insulating tape.
Figure 35. Location of Expansion Valve Bulb with Evaporator Installed on Ceiling

Figure 36. Completely Wrap Bulb with Tape

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5. Pressurize the refrigeration system and test for leaks.

6. If no leaks are found, evacuate the system.
7. Connect the evaporator fan motor wires. Install the evaporator cover.
8. Recharge the unit with the proper refrigerant.

Low Pressure Cutout Switch (LPCO)

If the suction pressure drops below 5 to 11 in. Hg of vacuum (-17 to -37 kPa), it opens the LPCO circuit to the controller
to stop the unit.

Low Pressure Cutout Switch Test

1. Install a gauge manifold at the compressor.
2. Disconnect the 2-pin connector with the LPCO and CHV/CHJ (depending on unit) wires in main wire harness from
wires to the low pressure cutout switch.
3. Set the thermostat(s) on the lowest setting.
4. Start and run the unit in Cool.
5. Check the continuity between the low pressure cutout switch wires. The low pressure cutout switch should be
closed when the suction pressure is above 5 to 11 in. Hg of vacuum (-17 to -37 kPa). If the suction pressure falls
below 5 to 11 in. Hg of vacuum (-17 to -37 kPa), the low pressure cutout switch should open.
6. Reconnect the wires that were disconnected and remove the gauge manifold set when finished with the test.

Low Pressure Cutout Switch Replacement

Removal
1. Recover the refrigerant charge.
2. Remove the evaporator cover.
3. Disconnect the wires and remove the switch.

Installation
1. Install and tighten the switch and reconnect the wires.
2. Pressurize the refrigeration system and test for leaks.
3. If no leaks are found, evacuate the system.
4. Connect the evaporator fan motor wires and install the evaporator cover.
5. Recharge the unit with the proper refrigerant.

Suction Pressure Regulator Valve

Model 20 and 50 units are equipped with a suction pressure regulator valve. The suction pressure regulator valve is
used to limit the load on the electric standby compressor. This also affects the current draw of the compressor motor. If
the suction pressure gets too high, it can cause the thermal motor protector to open. Monitor the current drawn of the
compressor motor when making this adjustment and keep it at least 1.5 amps below the Full Load (Amps) rating for the
compressor motor (see the Specifications chapter).

Suction Pressure Regulator Valve Test

1. Install a gauge manifold set on the electric standby compressor. Attach an additional compound gauge to the
suction service port on the engine driven compressor to monitor suction pressure at the inlet to the suction pressure
regulator.
2. Connect the unit power receptacle to an appropriate electric power source.
3. Place a jumper wire between the 12 and CHB wires at the defrost termination switch to ensure the unit will run in
Defrost.
4. Start the unit and run it in Defrost on the electric standby compressor until the pressure on the additional compound
gauge attached to the suction service port stabilizes at a pressure above 45 psig (310 kPa).

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5. Start the unit and run it in Defrost on the electric standby compressor until the pressure on the additional compound
gauge attached to the suction service port stabilizes at a pressure above 45 psig (310 kPa).
6. Remove the gauge manifold set, the additional compound gauge, and the jumper wire when finished with the test.

Suction Pressure Regulator Valve Replacement

Removal
1. Recover the refrigerant charge.
2. Remove the mounting hardware from the suction pressure regulator valve.
3. Unsolder the suction pressure regulator valve from the suction tubes.

Installation
1. Clean the tubes for soldering.
2. Place the valve in position and solder the connections.
3. Pressurize the refrigeration system and test for leaks.
4. If no leaks are found, evacuate the system.
5. Recharge the unit with the proper refrigerant.

Accumulator (Model 30 and 50 Only)

Removal
1. Recover the refrigerant charge.
2. Remove the mounting hardware from the accumulator.
3. Unsolder the accumulator and remove it from the accumulator module.

Installation
1. Clean the tubes for soldering.
2. Place the accumulator in position and solder the connections.
3. Install the mounting hardware.
4. Pressurize the system and test for leaks.
5. Evacuate and recharge the system.

Liquid Line Check Valve (Model 30 and 50 Only)

The liquid line check valve is located in the accumulator module. It prevents refrigerant from moving into the condenser
when a Model 30 or 50 unit is running in Heat of Defrost.

Liquid Line Check Valve Test

1. Install a gauge manifold set.
2. Set the thermostat on the lowest setting.
3. Start and run the unit in Cool on the engine driven compressor until the suction pressure stabilizes.
4. Check the temperatures of the refrigeration lines on both sides of the liquid line check valve by hand. A temperature
difference between the two sides of the liquid line check valve indicates it is not opening completely.
5. Set the thermostat on the highest setting to make the unit shift to Heat.
6. Let unit run in Heat until the suction and discharge pressures stabilize.
7. Check the temperatures of the refrigeration lines on both sides of the liquid line check valve by hand. A temperature
difference between the two sides of the liquid line check valve indicates it is leaking.
8. Remove the gauge manifold set when finished with the test.

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Liquid Line Check Valve Replacement

Removal
1. Recover the refrigerant charge.
2. Remove the accumulator module cover and the evaporator cover.
3. Disconnect the ORS nuts at the ends of the check valve assembly.
4. Remove the nut that fastens the check valve assembly to the accumulator module frame and remove the check
valve assembly from the unit.

Installation
1. Place the check valve assembly in position and install the nut that fastens it to the accumulator module frame.
2. Coat the new O-rings with refrigerant oil (same type that is used in the system) and place the new O-rings in the
ORS fittings for the ends of the check valve assembly.
3. Install and tighten the inlet and outlet ORS nuts. Hold the tubes with a backup wrench on the hex behind the ORS
fitting.
4. Pressurize the system and test for leaks.
5. Reinstall the accumulator module cover and the evaporator cover.
6. Evacuate and recharge the system.

Replacing Refrigerant Hoses (Speedy Clip System)

Refer to the Vehicle Powered Truck Installation Standards and Procedures Section 6 – Refrigerant Hose and Fittings
Standards for service information about replacing refrigerant hoses.

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Compressor Failures
Whenever a compressor fails check the compressor speed to verify it is within our guidelines. If the compressor speed
exceeds guidelines, a larger pulley needs to be install on the compressor. See Service Bulletin SB644 and the Vehicle
Powered Truck Installation Standards and Procedures Section 5 – Compressor Selection and Installation Standards for
detailed information.

Compressor Test
1. Rotate the compressor shaft by hand. It should rotate smoothly without catching or binding. If not, replace the
compressor.
Figure 37. Rotate Compressor Shaft

2. Spin the pulley with the clutch de-energized. The pulley should spin freely with no wobbling or roughness. If not, it
should be replaced.
3. Check the clutch air gap. It should be 0.016-0.03 inches (0.4-0.8 mm). The clutch might not engage if the air gap is
excessive. See Setting Clutch Air Gap later in this chapter for details.
4. Check the clutch coil resistance. See the Specifications chapter for the coil resistance.
5. Check for voltage between the CLU (or CLU1 depending on your unit) wire at the compressor clutch and the
compressor body when the unit is in Cool and the compressor should be running. A minimum of 11.5 Vdc should be
present. If not, check the CLU circuit back to the ECM and fuse F5. Also check that there is good continuity between
the compressor body and the chassis ground (CH).
N o t e : The engine driven compressor must be equipped with a ground strap when installed. Refer to Ground Strap
Installation in Section 5 – Compressor Selection and Installation Standards of the Vehicle Powered Truck
Installation Standards and Procedures TK 56430 for detailed information about the ground strap.
6. Check the compressor discharge pressure. A good compressor should be able to raise the discharge pressure to 200
psig (1379 kPa) for R-134a, or 350 psig (2413 kPa) for R-404A/R-452A, with the condenser covered.
I m p o r t a n t : This test must be performed with a full system charge. Confirm the system is fully charged before
proceeding.
a. Install a gauge manifold set on the compressor being tested.
b. Set thermostat on the lowest setting.
c. Start and run the unit in Cool with the compressor being tested.
d. Cover the condenser to raise the discharge pressure.
e. A good compressor should be able to raise the discharge pressure to the following:
• R-134a: 200 psig (1379 kPa)
• R-404A/R-452A: 350 psig (2413 kPa)

TK 61377-18-MM-EN 93
Compressor Maintenance

I m p o r t a n t : This test should only be run for a short time. Shut the system down immediately once the target
pressure is reached.

Belt Tensions
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.
Check the pulley and belt alignment by referring to “Belt Alignment” in Section 5 of the Vehicle Powered Truck
Installation Standards and Procedures- TK 61588. Double check by making sure the belt goes from pulley to pulley in
perfect alignment with no indication of a sideward bend.
Adjust the belt tension to vehicle manufacturer specifications. Check the belt tension again after 36 to 48 hours of initial
operation of the unit because the belt may stretch slightly during the first hours of use. Remember, good alignment and
proper belt tension ensure long belt life

Electric Standby Compressor Belt

Loosen the four mounting bolts on the end of the electric motor. Move electric motor (rotate it on the gyrator axis) to
obtain a belt tension of 43 to 63 on TK Gauge P/N 204-427. Tighten the electric motor mounting bolts and recheck the
belt tension. Readjust the belt tension if necessary. Check the belt tension again after 36 to 48 hours of initial operation
of the unit because the belt may stretch slightly during the first hours of use.

94 TK 61377-18-MM-EN
Structural Maintenance
Micro-Channel Coil Cleaning Recommendations
Cleaning Intervals
• The coils should be cleaned a Minimum of once a year.
• It is recommended that any time the unit is in for service or maintenance that the coils be inspected and cleaned if
needed.
• The coil should be cleaned if there are visible accumulations that obstruct the view of the fins or tubes of the coil.
• The coils should be cleaned if there is debris imbedded in the tubes and fins.
The area and conditions in which the unit operates will dictate the cleaning intervals and method(s) needed.

Cleaning Methods
N o t e : Listed in order of recommended method.
• Take a cloth or towel and wipe the air side of the coil going with the fins, across the tubes. See (Figure 39, p. 97) for
results. The coil will clean in a manner similar to the way lint cleans from the lint trap of a household clothes dryer.
• Use a soft bristled brush (DO NOT USE A WIRE BRUSH) and brush the coil going with the fins, across the tubes. The
coil will clean in a manner similar to the way lint cleans from the lint trap of a household clothes dryer.
• A vacuum with a soft attachment can be used to suck the debris off the face as well as in the fins and tubes from the
air side of the coil.
• Compressed air can be used and will work best when blown thru the coil from the non-air side when possible.
Blowing thru from the airside may imbed debris in the coil that was only on the surface. It is recommended to start
with one of the first three options before using compressed air if the non-air side is not accessible. The angle at
which the air should be directed at the coil should not be less than 75 degrees (Figure 40, p. 97).
• Power water sprayer may be used in pressures under 600 psi. Water will work best when blown thru the coil from
the non-air side when possible. Spraying thru from the airside may imbed debris in the coil that was only on the
surface. It is recommended to start with one of the first three options before using water if the non-air side is not
accessible. The angle at which the water should be directed at the coil should not be less than 75 degrees (Figure
40, p. 97).

TK 61377-18-MM-EN 95
Structural Maintenance

Notes:
1. Chemicals to aid in cleaning WILL VOID WARRANTY and are NOT RECOMMENDED.
2. In some instances, it may take a combination of two methods to result in a clean coil. Such as, first wiping
the coil to clean the surface and then using a vacuum, water or compressed air to clean down in the fins. This
will depend on the type of debris that needs to be cleaned from the coil.
3. Do not allow the coil to come into contact with any hard vacuum nozzle, air nozzle, or any other tool. This will
damage the tubes of the coil.
4. The use of cleaning agents or detergents is strongly discouraged due to the possibility of degradation of the
construction. If using a power washer, the nozzle pressure should not exceed 600 psi (41 bar). For the best
results, spray the coil perpendicular to the face of the coil. The spray nozzle should be kept between 1 inch
and 3 inches (25 to 75 millimetres) from the coil surface.
5. If necessary to use a chemical cleaner or detergent use a cleaner that does not contain any hydrofluoric acids
and is between 7 and 8 on the pH scale. Ensure dilution instructions provided by the detergent supplier are
followed. In case of doubt about the compatibility of the detergent with the type of materials listed above,
always ask the supplier for a written confirmation of the compatibility. Should a chemical cleaner be
required, it is MANDATORY that all components are thoroughly rinsed with water even if the instructions of
the cleaner specify that it is a “no rinse” cleaner.

NOTICE
Equipment Damage!
Failure to comply with above mentioned guidelines will lead to a shortened life of the equipment to an
indeterminable degree.

6. The repeated transportation of meat and fish waste can cause extensive corrosion to the evaporator coils
and evaporator section tubing over time due to ammonia formation and can reduce the lifespan of the coils.
Appropriate additional measures should be taken to protect the coils against the aggressive corrosion that
can result from transportation of such products.
Figure 38. Coil Before Cleaning

96 TK 61377-18-MM-EN
 Structural Maintenance

Figure 39. Coil after Wiping Right Hand Side with Cloth

Figure 40. Source Angle for Cleaning with Air or Water

Unit Mounting Bolts

Periodically check and torque the unit mounting bolts.
Figure 41. Evaporator

TK 61377-18-MM-EN 97
Structural Maintenance

Figure 42. ES Evaporator Mounting Bolts (Cover Removed)

Figure 43. Condenser

98 TK 61377-18-MM-EN
 Structural Maintenance

Figure 44. Condenser Mounting Bolts (Unit Rear View)

TK 61377-18-MM-EN 99
Over-the-Road Mechanical Diagnosis
CONDITION POSSIBLE CAUSE REMEDY

Unit turned On—In-Cab Control Box Vehicle ignition switch is not on Turn the vehicle ignition switch on
display does not come on
Vehicle Ignition Switch Fuse F14 blown Check for short circuits and replace fuse

Dead or disconnected vehicle battery Service the vehicle battery

In-Cab Control Box harness disconnected Check In-Cab Control Box harness and repair or
or faulty replace

In-Cab Control Box faulty Repair or replace

ECM faulty Repair or replace

Unit turned On—In-Cab Control Box Battery Power Supply Fuse F21 blown Check for short circuits and replace fuse
display comes on but unit does not
operate Battery Power Relay (BPR) faulty Check BPR

Electric Standby Power Relay (ESR) Check ESR

faulty

Fuse F5 blown Check for short circuits and replace fuse

Compressor clutch faulty Check compressor clutch

ECM faulty Repair or replace

100 TK 61377-18-MM-EN
Electric Standby Mechanical Diagnosis
CONDITION POSSIBLE CAUSE REMEDY

Unit turned On—In-Cab Control Box Unit not connected to Standby power or Connect power cord. Verify that the Electric Standby
display does not come on Standby power is turned off. power is turned on and is the correct voltage.

Transformer AC Power Supply Fuse F20 Check for short circuits and replace fuse
blown

Faulty transformer Check transformer

Faulty bridge rectifier Check bridge rectifier

Controller Standby Power Supply Fuse Check for short circuits and replace fuse
F16 blown

In-Cab Control Box harness disconnected Check In-Cab Control Box harness and repair or
or faulty replace

In-Cab Control Box faulty Repair or replace

ECM faulty Repair or replace

Unit turned On—In-Cab Control Box No standby power to compressor motor Provide power to unit; check power at:
display comes on but compressor 1. Motor contactor hot side
motor does not run 2. Motor contactor load side (contactor closed)
3. Overload relay
4. Motor terminals

Electric Standby Power Relay (ESR) Check ESR

faulty

Fuse F5 blown Check for short circuits and replace fuse

Compressor Motor Contactor (CMC) Check CMC

faulty

Open or faulty overload relay Determine cause and reset or replace overload relay

Compressor motor faulty Check compressor motor

ECM faulty Repair or replace

Compressor motor hums but does not Locked rotor (overload relay will open Remove interference or replace motor
run after a period of time)

Locked compressor Replace compressor

Low line voltage or no voltage on one leg Check power source for correct voltage, phase, and
frequency. Bring voltage up to within 10% of motor
rating

Capacitor faulty Check capacitors (on single phase units)

Start Relay (SR) faulty Check SR (on single phase units)

Compressor motor runs but Electric standby compressor belt loose Check belt tension
compressor does not
Compressor clutch faulty Check compressor clutch

TK 61377-18-MM-EN 101
Refrigeration Diagnosis
CONDITION POSSIBLE CAUSE REMEDY

Unit short cycles Shortage of refrigerant (low pressure Repair leak and recharge
cutout)

Restricted expansion valve Clean expansion valve

Refrigerant overcharge (high discharge Remove excess charge

pressure)

Cycling on high discharge pressure Check condenser air flow and fan

Dirty condenser coil Clean coil

Defrost timer set too low for application. Adjust timer to higher interval

Unit operates long or continuously Shortage of refrigerant Repair leak and recharge

Dirty condenser Clean condenser

Air in system Evacuate and recharge system

Compressor inefficient Replace compressor

Plugged expansion valve Clean expansion valve

Iced or plugged evaporator 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

Door seals worn Repair/replace

Excessive superheat at expansion valve Adjust superheat

ECM faulty Repair or replace

Box temperature too high Thermostat setpoint too high Reset thermostat

Refrigerant shortage Repair leak and recharge

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 or Adjust superheat

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

Restricted dehydrator Replace

Head pressure too low Refrigerant shortage Repair leak and recharge

Expansion valve or strainer plugged Clean or replace

Compressor inefficient Replace compressor

102 TK 61377-18-MM-EN
 Refrigeration Diagnosis

CONDITION POSSIBLE CAUSE REMEDY

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, admitting Adjust expansion valve
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 Replace

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

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

Plugged expansion valve strainer Clean strainer

Sensor bulb lost charge Replace expansion valve

TK 61377-18-MM-EN 103
Refrigeration Diagnosis Chart
Unit Not Heating (Model 30/50)

Unit cools in defrost cycle

Suction line frosting back

Unit operating in vacuum

SYMPTOM
High suction pressure

Unit not refrigerating

Low suction pressure

No suction pressure

Sight glass / empty

High head pressure

Low head pressure

Unit not defrosting

Noisy compressor
No head pressure
Rapid cycling

POSSIBLE CAUSES

• • • • Overcharge of refrigerant

• • • • • • • Shortage of refrigerant

• • • • • • • • No refrigerant

• Air through condenser too hot (ambient)

• Air flow through condenser restricted

• • Air through condenser too cold (ambient)

• • • Air in refrigerant system

• Air short cycling around evaporator coil

• • • • Air through evaporator restricted

• • • • • • Evaporator needs defrosting

• 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

• • • • Liquid refrigerant entering compressor

• • • Restricted line on the low side

• • • • Restricted line on the high side

• • • • Restricted dehydrator

• • • • Loose or broken electrical connections

104 TK 61377-18-MM-EN
 Unit Not Heating (Model 30/50)
Refrigeration Diagnosis Chart

Unit cools in defrost cycle

Suction line frosting back

Unit operating in vacuum

SYMPTOM
High suction pressure

Unit not refrigerating

Low suction pressure

No suction pressure

Sight glass / empty

High head pressure

Low head pressure

Unit not defrosting

Noisy compressor
No head pressure
Rapid cycling

POSSIBLE CAUSES

• Condenser fan motor not operating

• • • • • • Evaporator fan motor not operating

• • • • • • Reverse fan rotation

• • • • Faulty Hot Gas Solenoid

• • • Faulty Condenser Inlet Solenoid

• • Faulty Liquid Injection Solenoid

• • • Faulty CPR Bypass Solenoid

• • Faulty Liquid Line Check Valve

TK 61377-18-MM-EN 105
Diagram Index
The following table lists the diagrams that are relevant to this unit.
The diagrams are available on EMEA Info Central.

Drawing No. Drawing Title

1E77100 V-500 Refrigeration Diagram

2E31651 V-600 Refrigeration Diagram

2E28292 V-500/V-600 MAX Single Temperature and V-500 DSPECTRUM DSR-III unit Wiring Diagram

2E28293 V-500/V-600 MAX Single Temperature and V-500 SPECTRUM DSR-III unit Schematic Diagram

106 TK 61377-18-MM-EN
 Notes

TK 61377-18-MM-EN 107
Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable
transport temperature control solutions. Thermo King has been providing transport temperature control solutions
for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since
1938. For more information, visit www.thermoking.com or www.tranetechnologies.com.

Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications
without notice. We are committed to using environmentally conscious print practices.

TK 61377-18-MM-EN 28 Feb 2019

Supersedes TK 61377-18-MM-EN (November 2015) ©2019 Trane Technologies