51878-1-OP V-500 10-20, V-500 MAX 10-20 (Rev 0, 11-04)

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    Copyright 1999 Thermo King Corp., Minneapolis, MN, USA

    Printed in USA

    V-500 10/20, V-500 MAX 10/20

    TK 51878-1-OP (Rev. 0, 11/04)

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    Disclaimer

    This manual is published for informational purposes only. Thermo King Corporation makes no

    representations or warranties, express or implied, with respect to the information, recommendations and

    descriptions contained in this manual and such information, recommendations and descriptions should

    not be regarded as all-inclusive or covering all contingencies. If you have questions or require further

    information, please contact your local Thermo King dealer.

    The procedures described herein should be undertaken only by qualified personnel. Failure to implement

    these procedures correctly may cause damage to the Thermo King unit or other property or personal

    injury.

    Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence

    and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or any

    other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting

    from any actions by any person that are contrary to this manual or any of the information,

    recommendations or descriptions contained herein or the failure of any person to implement the

    procedures described herein correctly or to follow caution and safety decals located on the Thermo King

    unit.

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    Table of ContentsTable of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

    List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

    Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

    Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

    Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

    Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

    First AidRefrigerant . . . . . . . . . . . . . . . . . . . . . . 11

    First AidRefrigerant Oil . . . . . . . . . . . . . . . . . . . 11Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

    Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

    Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 15

    Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16The evaporator is mounted on the ceiling inside the truck

    box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

    In-Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . .

    Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . .

    Evaporator Drain Tube Heaters . . . . . . . . . . . . . . . . . Electric Standby Operation . . . . . . . . . . . . . . . . . . . .

    Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . .

    In-Cab Control Box Description . . . . . . . . . . . . . . . Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    Display Descriptions . . . . . . . . . . . . . . . . . . . . . .

    Operating Instructions . . . . . . . . . . . . . . . . . . . . . .

    Cab Control Box Operating Instructions . . . . . . . . . . Displaying Return Air Temperature . . . . . . . . . . . Display Setpoint Temperature . . . . . . . . . . . . . . .

    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Enter Setpoint Temperature. . . . . . . . . . . . . . . . .

    Defrost Mode Operation . . . . . . . . . . . . . . . . . . . Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . .

    Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat Operation . . . . . . . . . . . . . . . . . . . . . . . .

    http://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdf
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    Table of Contents

    4

    Loading and Enroute Inspections . . . . . . . . . . . . . . 39

    Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . . 39Inspecting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

    Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

    Maintenance Inspection Schedule . . . . . . . . . . . . . . 49

    Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

    Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

    Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

    Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 63

    Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 65

    Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 66

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    List of FiguresFigure 1:Fan Warning . . . . . . . . . . . . . . . . . . . . . . . . . 12

    Figure 2:Caution: High Voltage . . . . . . . . . . . . . . . . . . 12Figure 3:Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . . 12

    Figure 4:V-500 Condenser Unit . . . . . . . . . . . . . . . . . 14Figure 5:Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 16

    Figure 6:In-Cab Control Box . . . . . . . . . . . . . . . . . . . . 16Figure 7:Unit Components (Model 20) . . . . . . . . . . . . 21Figure 8:Condenser Electric and Capacitor Boxes

    (Model 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Figure 9:Standard Evaporator . . . . . . . . . . . . . . . . . . . 23

    Figure 10:Evaporator with Hot Water and Electric HeatOptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

    Figure 11:M-13 In-Cab Control Box . . . . . . . . . . . . . . 25Figure 12:Display Screen . . . . . . . . . . . . . . . . . . . . . . 26

    Figure 13:On/Off Key & LED . . . . . . . . . . . . . . . . . . .

    Figure 14:Celsius/Fahrenheit LED . . . . . . . . . . . . . . . Figure 15:Setpoint Key & Dial . . . . . . . . . . . . . . . . . .

    Figure 16:Misc. LEDs . . . . . . . . . . . . . . . . . . . . . . . . Figure 17:Defrost Key & LED . . . . . . . . . . . . . . . . . . .

    Figure 18:M-13 In-Cab Control Box . . . . . . . . . . . . . . Figure 19:Setpoint Key . . . . . . . . . . . . . . . . . . . . . . . Figure 20:Entering Setpoint . . . . . . . . . . . . . . . . . . . .

    Figure 21:On/Off Key and Defrost Key . . . . . . . . . . . Figure 22:Electric Power Receptacle . . . . . . . . . . . . .

    Figure 23:Thermostat Algorithm . . . . . . . . . . . . . . . . Figure 24:Loading Considerations . . . . . . . . . . . . . . .

    Figure 25:Condenser and Standby Compressor SeriaNumber Locations . . . . . . . . . . . . . . . . . . . . . . . . . . .

    http://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdf
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    List of Figures

    6

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    Introduction

    8

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    Safety PrecautionsThermo King recommends all services be performed by a

    Thermo King dealer. However, there are several general safetypractices you should be aware of:

    DANGER: Never operate the unit with the discharge

    valve closed because it could cause the compressor to

    explode, causing death or serious injury.

    WARNING: Always wear goggles or safety glasses

    when working with or around the refrigeration

    system or battery. Refrigerant or battery acid cancause permanent damage if it comes in contact with

    your eyes.

    WARNING: Keep hands and loose clothing clear of

    fans and belts at all times when the unit is operating

    or when opening or closing compressor service

    valves.

    WARNING: Exposed coil fins can cause painful

    lacerations. Service work on the evaporator orcondenser coils is best left to a certified Thermo Ki

    technician.

    CAUTION: Use extreme caution when drilling ho

    in the unit. Drilling into electrical wiring or

    refrigerant lines could cause a fire. Never drill int

    structural components.

    WARNING: Turn all unit On/Off switches to the O

    position before opening doors or inspecting any pa

    of the unit.

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    Safety Precautions

    10

    Electrical Hazard

    Refrigerant OilObserve the following precautions when working with or

    around refrigerant oil:

    RefrigerantAlthough fluorocarbon refrigerants are classified as safe,

    observe caution when working with refrigerants or around

    areas where they are being used in the servicing of your unit.

    WARNING: Disconnect the high voltage power cable

    before working on the unit. Units with electric

    standby present a potential electrical hazard.

    WARNING: Always wear goggles or safety glasses to

    protect eyes from refrigerant oil contact.

    WARNING: Protect skin and clothing from

    prolonged or repeated contact with refrigerant oil.

    Rubber gloves are recommended.

    WARNING: Wash thoroughly immediately after

    handling refrigerant oil to prevent irritation.

    DANGER: Fluorocarbon refrigerants may produce

    toxic gases. In the presence of an open flame or

    electrical short, these gases are severe respiratory

    irritants CAPABLE OF CAUSING DEATH.

    DANGER: Fluorocarbon refrigerants tend to

    displace air and can cause oxygen depletion which

    could result in DEATH BY SUFFOCATION. Provide

    adequate ventilation in enclosed or confined areas.

    WARNING: Fluorocarbon refrigerants evaporate

    rapidly, freezing anything they contact if accidentally

    released into the atmosphere from the liquid state.

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    Safety Precautions

    First Aid

    First AidRefrigerant

    Eyes: For contact with liquid, immediately flush eyes withlarge amounts of water. Seek prompt medical attention.

    Skin: Flush areas with large amounts of warm water. Do notapply heat. Wrap burns with dry, sterile, bulky dressing to

    protect from infection or injury. Seek prompt medical

    attention.

    Inhalation: Move victim to fresh air and restore breathing ifnecessary. Stay with victim until emergency personnel arrive.

    First AidRefrigerant Oil

    Eyes: Immediately flush eyes with large amounts of waterat least 15 minutes while holding the eyelids open. Get prom

    medical attention.

    Skin: Remove contaminated clothing. Wash thoroughly wi

    soap and water. Get medical attention if irritation persists.

    Inhalation: Move victim to fresh air and restore breathing

    necessary. Stay with victim until emergency personnel arriv

    Ingestion: Do not induce vomiting. Immediately contactlocal poison control center or physician.

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    Safety Precautions

    12

    Safety Decals

    Figure 1: Fan Warning

    Figure 2: Caution: High Voltage

    Figure 3: Belt Warning

    AMA145

    AMA147

    AMA146

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    Unit Description

    IntroductionThe Thermo King V-500 10/20 and V-500 MAX truckrefrigeration systems are two piece units. The unit is designed

    for medium-sized trucks and vans carrying fresh produce and

    frozen and deep frozen goods.

    The condenser is mounted on the front of the truck box or

    container. The evaporator is mounted on the cargo

    compartment ceiling. The main compressor is powered by the

    vehicle engine via a belt. The unit is connected to the

    compressor by refrigeration hoses. In electric standby

    operation models, the second compressor is driven by an

    electric motor.

    Control circuits operate on 12 VDC supplied by the truck

    batteries for over-the-road operation. The refrigeration system

    is protected by a high pressure cutout and a low pressure

    cutout.

    The in-cab control includes an on/off switch, manual defros

    switch, thermometer, thermostat, thermostat adjustments an

    indicator lights.

    The operating mode is selected automatically: When the uni

    connected to an electric power source, engine-driven operat

    is automatically blocked. If the vehicle engine is started up

    while the power cable is still connected to the electric powe

    source, the unit will continue to operate in electric standby

    mode. It is not possible to start the engine-driven compress

    until the power cable is disconnected from the unit.There are two basic models:

    Model 10: Cool and defrost on truck engine driven

    compressor operation.

    Model 20: Cool and defrost on both truck engine drive

    compressor operation and electric standby compressor

    operation.

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    Unit Description

    14

    Figure 4: V-500 Condenser Unit

    Unit Features M-13 In-Cab Control Box with Digital LED Thermometer

    (Standard)

    Digital Thermometer Electronic Thermostat (Standard)

    Defrost Timer (Standard)

    Defrost Thermostat

    Hot Gas Defrost (Standard)

    Manual Defrost Switch (Standard)

    Oil Separator (Standard)

    Liquid Injection

    Main Compressor TM 16 XD

    Electric Compressor, Model 20

    Evaporator Drain Heaters, Max Units

    Electric/00Water Heat, Model 20

    Water Heat, Model 10

    AMA508

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    Unit Description

    Refrigeration SystemRefrigeration hoses or lines are used to connect the condenser,

    the evaporator, the compressor and any other components.

    Model 20 units have another compressor and an electric motor

    mounted in the condenser section for electric standby

    operation.

    The engine compressor is driven by a belt from the engine. The

    electric standby compressor is connected in parallel with the

    engine-driven compressor. The standby compressor is

    hermetically sealed with its electric motor. Both compressors

    use the same refrigeration system circuit. Check valves isolate

    one compressor from the other during operation.

    Compressor operation is controlled by the thermostat, whichenergizes the compressor clutch during engine operation or

    starts the electric motor and energizes the compressor clutch on

    electric standby operation. The refrigeration system is

    protected by a high pressure cutout switch and a low pressure

    cutout switch.

    When plugged into standby power, engine operation is

    automatically locked out. If the truck engine is turned on wh

    the power cord is still plugged into a power receptacle, the u

    will remain working in electric mode; the engine driven

    compressor cannot be started until the power cord is unplugg

    from the unit as the selection of engine operation or standby

    operation is automatic.

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    Unit Description

    16

    Figure 5: Evaporator

    Evaporator

    The evaporator is mounted on the ceiling inside the truck box.

    Control CircuitsThe control circuits operate on 12 VDC supplied by the truck

    batteries for engine operation. On standby operation, the power

    is rectified from an AC transformer.

    Figure 6: In-Cab Control Box

    In-Cab Control BoxUnit operation is controlled with an in-cab control box, which

    is mounted in the truck cab. It includes an On-Off switch,

    manual defrost switch, thermometer, thermostat, thermostat

    adjustment, and indicator lights.

    The TC unit has an additional cab control box to operate the

    second compartment. It is switched on and off from the main

    cab control box and includes a thermometer, thermostat,

    thermostat adjustment and indicator lights.

    AMA510

    AJA1772

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    Unit Description

    RefrigerantThe V-500-10 and V-500-20 units use R-134a refrigerant. The

    V-500 MAX-10 and V-500 MAX-20 units use R-404A

    refrigerant.

    Liquid Injection SystemAll V-500 models have a liquid injection system to limit

    discharge temperature of the engine driven compressor. If the

    discharge gas leaving the compressor reaches a temperature of

    230 5 F (110 3 C) the liquid injection switch closes,

    providing voltage to the liquid injection solenoid. The solenoid

    opens a valve, allowing liquid refrigerant to flow from the

    liquid line near the drier inlet to the metering orifice attached to

    the suction line fitting on the engine driven compressor. 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 Tube HeatersEvaporator heaters are used in MAX units to avoid drain tu

    blockage because of ice accumulation inside the evaporator

    One heater is located inside each drain tube. These resistive

    wire heaters melt the ice while the unit is in DEFROST mo

    Electric Standby OperationDuring electric standby operation, the thermostat controls t

    operation of the unit by energizing and de-energizing the

    power relay, the electric relays, and the heat contactor. The

    thermostat places the unit in cool by energizing the motor

    contactor and the electric relays.

    The thermostat places the unit in null by de-energizing all t

    relays and contactors. The thermostat places the unit in heat

    energizing the heat contactor.

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    Unit Description

    18

    When the power relay and the electric relays are energized,

    they close contacts that energize the fan relay, the motor

    contactor, and the electric standby compressor clutch.

    When the heat contactor is energized, it energizes the electric

    evaporator heaters and the fan relay.

    Oil SeparatorAn oil separator is a standard feature. The oil separator

    separates compressor oil from the refrigerant 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.

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    Unit Description

    Protection FeaturesHigh Pressure Cutout Switch: The High Pressure CutoutSwitch is a pressure sensitive switch. If the discharge pressure

    rises above the switchs opening pressure, the switch stops the

    unit. When the discharge pressure falls below the switchs

    closing pressure, the switch closes to restart the unit.

    Condenser Fan Pressure Switch: This switch helps the

    unit to keep the condenser head pressure higher in cool

    ambients and on-road. This feature allows better control of the

    head pressure and the thermostatic expansion valve, and at the

    same time increases the evaporator pressure. Defrost is carried

    out quicker in cool ambients and on-road.

    Low Pressure Cutout Switch: This switch is a pressure

    sensitive switch located in the suction line. If the pressure falls

    below acceptable limits, the switch stops unit operation.

    U it D i ti

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    Unit Description

    20

    Fuses

    Fuse 1: Protects the evaporator fan motor (EFM1) from

    possible overload.

    Fuse 2: Protects the evaporator fan motor (EFM2) frompossible overload.

    Fuse 3: Protects:

    The engine-driven compressor clutch coil.

    Condenser solenoid valve coil (heating option).

    Hot gas solenoid valve coil.

    Fuse 5: Protects the condenser fan motor (CFM1) from

    possible overload.

    Fuse 6: Protects the condenser fan motor (CFM2) from

    possible overload.

    Fuse 7: Protects the evaporator fan motor (EFM3) from

    possible overload.

    Fuse 4/1: Protects the in-cab control box from possible

    overload. It is located inside the in-cab control box.

    (Fuses 1, 2, 3 5, 6 and 7 are located on the printed circuit

    board.)

    Electric Standby Operation Fuses:

    Fuse 4 protects the in-cab control box when the unit is in

    electric standby mode. Fuse 4 is located on the printed circuitboard (inside the cab control).

    Fuse 8 is located in the electric box and protects the

    transformer from possible overload.

    U it D i ti

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    Unit Description

    Figure 7: Unit Components (Model 20)

    1

    6

    11

    AMA511

    2

    3

    4

    57

    8

    12

    9

    10

    1. Filter-Drier 5. Oil Separator 9. Transformer Cover

    2. Liquid Sight Glass 6. Electric Standby Compressor 10. Condenser Fans

    3. Liquid Injection Valve 7. Condenser Coil 11. AC Compressor Electric Box

    4. Liquid Tank 8. Rectifier Heat Sink 12. Defrost Valve

    Unit Description

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    Unit Description

    22

    Figure 8: Condenser Electric and Capacitor Boxes (Model 20)

    AMA512

    3

    1

    4

    2

    AMA519

    1. PC Board 3. Heat Option Contactor

    2. Motor Contactor 4. Capacitor Box, single phase only

    Unit Description

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    Unit Description

    Figure 9: Standard Evaporator

    AMA513

    1

    2

    4

    3

    AMA5

    1. Evaporator Fans 3. Air Temperature Sensor

    2. Expansion Valve 4. Defrost Switch

    Unit Description

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    Unit Description

    24

    Figure 10: Evaporator with Hot Water and Electric Heat Options

    AMA525

    1

    2 3

    4

    1. Hot Water Heat Defrost Coil 3. High Temperature Limit Switch

    2. Electric Heat Element 4. Air Temperature Sensor

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    In-Cab Control Box DescriptionUnit operation is controlled with an in-cab control box, which

    is mounted in the truck cab. It includes an on-off key, manual

    defrost key, setpoint key, thermometer, thermostat, thermostat

    adjustment, and indicator lights.

    Figure 11: M-13 In-Cab Control Box

    AJA1772

    In-Cab Control Box Description

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    In Cab Control Box Description

    26

    DisplayThe display consists of a display screen, keys and indicator

    LEDs. The display screen shows the return (box) air

    temperature. The screen will display the setpoint temperature if

    the setpoint key is pressed.

    1. Keys

    2. Display Screen

    Figure 12: Display Screen

    AJA17721 1 2 1

    In-Cab Control Box Description

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    In Cab Control Box Description

    Display DescriptionsThis section describes the display screen, keys andLED

    indicators.

    1. ON-OFF KEY

    It is used to Start/Stop the unit. The internal return air

    temperature will be automatically displayed.

    2. ON LED Indicator

    When on, it indicates that the unit has been started by

    pressing the on-off key.

    Figure 13: On/Off Key & LED

    1

    2AJA1802

    In-Cab Control Box Description

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    p

    28

    Figure 14: Celsius/Fahrenheit LED

    3. Celsius LED Indicator

    When on, it indicates the temperature being displayed is in

    Degrees Celsius.

    4. Minus Sign

    Indicates the temperature being displayed is below zero.

    5. Fahrenheit LED Indicator.

    When on, it indicates the temperature being displayed is in

    Degrees Fahrenheit.

    6. Setpoint Adjust Dial

    It is used to adjust the setpoint temperature.7. Setpoint Key

    It is used to display the setpoint temperature.

    Figure 15: Setpoint Key & Dial

    3

    4

    5AJA1803

    6

    77

    AJA1804

    In-Cab Control Box Description

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    p

    Figure 16: Misc. LEDs

    8. Power Cord LEDWhen on, it indicates the unit is plugged to the A.C.

    voltage power supply.

    9. AC Overload LED

    When on, it indicates the unit has been stopped by the AC

    Overload Relay.

    Figure 17: Defrost Key & LED

    10. Unit Operation LEDWhen on, it indicates the unit is cooling.

    When the unit is Stopped by the Thermostat, HPCO or

    LPCO, the Unit Operation LED must be OFF and th

    ON LED Indicator must remain ON.

    11. Defrost LED Indicator

    When on, it indicates the unit is working on Defrost Mo

    12. Manual Defrost Key

    It is used to initiate the Defrost Cycle manually.

    8

    10

    9

    AJA1805

    11

    12AJA1806

    In-Cab Control Box Description

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    Operating InstructionsThermo King has applied the newest technological advances to

    develop compact devices that controls unit functioning and

    displays operating information quickly and accurately. Thisnew Cab Control Box is designed to be used in both new and

    existing Thermo King units.

    There is nothing complicated about learning to operate the Cab

    Control Boxes manufactured by Thermo King, but you will

    find that a few minutes studying the contents of this manual

    will be time well spent.

    This manual is published for informational purposes only and

    the information furnished herein should not be considered asall-inclusive or meant to cover all contingencies.

    In-Cab Control Boxes manufactured by Thermo King can

    work with 12 VDC units.

    You can also display at your convenience the thermometer &

    the set point temperature in both Celsius or Fahrenheit degrees.

    To set the voltage & the Celsius/Fahrenheit selectors, contact

    your nearest Thermo King dealer.

    Figure 18: M-13 In-Cab Control Box

    AJA1772

    Operating Instructions

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    32

    Cab Control Box OperatingInstructions

    Displaying Return Air TemperatureDuring normal operation (unit is ON and cooling), the ON

    LED Indicator, the Unit Operation LED and

    Celsius/Fahrenheit LED Indicator should be ON; the return air

    temperature should be displayed on the screen. (See Figure

    21.)

    Display Setpoint Temperature1. During normal operation, press the Setpoint Key to

    display the Setpoint Temperature. (See Figure 19.)

    1. Setpoint Key

    Figure 19: Setpoint Key

    1

    AJA1809

    Operating Instructions

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    Enter Setpoint Temperature.1. Press the Setpoint Key. The Setpoint Temperature will

    displayed on the screen. (See Figure 20.)

    2. At the same time, turn the Setpoint Adjust Dial until th

    display shows desired temperature.(See Figure 19.)

    3. Release the Setpoint Key. The box temperature will be

    displayed on the screen. (See Figure 19.)

    Defrost Mode Operation

    Initiate a Manual Defrost: Pressing the Manual DefrostKey will start the defrost cycle if the evaporator coil

    temperature is below 2.2 C (36 F). The defrost LED

    will go ON. The unit will return to the cool mode automatica

    when the defrost cycle is finished. (See Figure 21.)

    1. Setpoint Adjustable Dial

    2. Setpoint Key

    Figure 20: Entering Setpoint

    1

    2AJA1807

    CAUTION: The Setpoint Temperature can be

    changed by turning Setpoint Adjust Dial when

    Setpoint Key is not pressed.

    Operating Instructions

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    34

    Initiate a Automatic Defrost: The defrost timer will

    initiate a defrost cycle if the evaporator coil temperature is

    below 2.2 C (36 F). The defrost LED will go ON. The unit will

    return to the cool mode automatically when the defrost is

    finished.(See Figure 21.)

    Stop the Defrost Cycle: Press and release the On-Off Keytwice to stop the defrost cycle. Weekly Pretrip Inspection

    The following Weekly Pretrip Inspection should be completed

    before loading the truck. While the weekly inspection in not a

    substitute for regularly scheduled maintenance inspections, it is

    important part of the preventive maintenance program

    designed to head off operating problems before they happen.

    1. LEAKS. Inspect for refrigerant leaks and worn refrigerantlines. Check for proper refrigerant charge level.

    2. BELTS. Inspect for cracks, wear and proper belt tension.

    3. MOUNTING BOLTS. Inspect bolts for proper tightening.

    4. ELECTRICAL. Electrical connections should be securely

    fastened. Wires and terminals should be free of corrosion,

    cracks or moisture.

    2

    1AJA1808

    1. On/Off Key

    2. Manual Defrost Key

    Figure 21: On/Off Key and Defrost Key

    Operating Instructions

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    5. DEFROST DRAINS. Check the defrost drain hose and

    fittings to be sure that they are open so condensate can run

    out during defrosting. Check the bottom end of drain hose

    to be sure that is not plugged or crushed.

    6. STRUCTURAL. Visually check for physical damage.

    7. REFRIGERANT CHARGE. Start the unit. Check the

    sight glass level with the compressor running.

    Engine Operation

    1. Start the truck engine.

    2. Press the on-off switch on the cab control box, the

    ON/OFF LED must go ON.

    3. Dial the thermostat setting above and below the box

    temperature to check thermostat operation on the cab

    control box.

    4. Set the thermostat at the desired temperature, allow the

    unit to run for one-half to one hour (longer if possible)

    before loading the truck. Pre-cooling will remove residual

    body heat and moisture from the box interior and provide

    a good test of the refrigeration system

    5. When the unit has finished pre-cooling the truck interio

    (evaporator temperature dropped below 36 F (2.2 C),

    initiate a defrost cycle with the manual defrost switch. T

    defrost cycle should end automatically.

    Operating Instructions

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    36

    Electric Standby Operation

    1. Connect the external power supply to the power

    receptacle. Make sure that the power supply voltage is

    correct for the unit. The power cord led should go ON.

    2. Press the on-off switch in the cab control box, the ONLED should go ON.

    3. Dial the thermostat setting above and below the box

    temperature to check thermostat operation on the cab

    control box.

    Figure 22: Electric Power Receptacle

    4. Set the thermostat at the desired temperature, allow the

    unit to run for one-half to one hour (longer if possible)

    before loading the truck. Pre-cooling will remove residual

    body heat and moisture from the box interior and provide

    a good test of the refrigeration system

    5. When the unit has finished pre-cooling the truck interior

    (evaporator temperature dropped below 36 F (2.2 C),

    initiate a defrost cycle with the manual defrost switch. The

    defrost cycle should end automatically.

    NOTE: Even though the truck engine is started the unit will

    work on Electric Standby if the power cord is plugged in.

    Operating Instructions

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    Unit OperationUnits cycle between Cool and Null to maintain the box

    temperature at the thermostat setpoint. The operating modes

    are: Cool, Null, and Defrost.

    The thermostat controls the operation of the unit by energizingand de-energizing the Power Relay (PR). When PR is

    energized it energizes the evaporator fans, the condenser fans,

    and the compressor clutch (or the compressor motor contactor

    during electric stand-by operation).

    The condenser fan is also controlled by the condenser fan

    pressure switch (CFPS) on R-134a units. This normally open

    switch monitors the compressor discharge pressure. When the

    discharge pressure rises to 180 psi (1241 kPa) the switch closesand energizes the condenser fan. When the discharge pressure

    drops below 130 psi (896 kpa) the switch opens and

    de-energizes the condenser fan.

    Thermostat Operation

    Cool

    The thermostat energizes the (PR) at box temperatures high

    than 5.4 F (3.0 C) above setpoint. The thermostat keeps PRenergized while the box temperature is higher than setpoint

    The fans and the compressor run and the unit cools.

    Null

    The thermostat de-energizes PR at box temperatures lower

    than setpoint. The thermostat keeps PR de-energized while

    box temperature is lower than 5.4 F (3.0 C) above the setpo

    temperature. When PR is de-energized and the unit does nooperate. On TC units PR is de-energized only when the

    condition is required from both thermostats.

    Operating Instructions

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    38

    Figure 23: Thermostat Algorithm

    Defrost

    The defrost cycle can be initiated any time the evaporator coil

    temperature is below 36 F (2.2 C). Defrost is initiated

    automatically by the defrost timer, or manually by pressing the

    manual defrost switch.The defrost relay energizes the defrost solenoid valve (and the

    condenser solenoid valve on units equipped with the heat

    option) to route hot refrigerant gas to the evaporator when PR

    is energized. The defrost relay also interrupts power to the

    evaporator and condenser fans during defrost.

    The defrost cycle will continue until the evaporator coil

    temperature rises 8.9 C (48 F), causing the defrost termination

    switch to open ending the defrost cycle. Defrost cycle can be

    also terminated stopping the unit pressing the ON/OFF Switch

    twice.

    Temperature

    DropTemperature

    Rise

    3.0 C (5.4 F)

    Above Setpoint

    Setpoint

    NULL

    COOL

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    001

    Loading and Enroute InspectionsThermo King refrigeration units are designed to maintain the

    required temperature for the product being carried during its

    time in transit. Because of the units unique design, special careis required during loading to prevent cargo spoilage.

    Pre-Loading Inspection1. Inspect all door seals, including vent doors, for condition

    and a tight seal with no air leakage.

    2. Inspect the cargo compartment inside and out for damaged

    or loose skin and insulation.

    3. Inspect the inside of the cargo compartment for damaged

    walls, air ducts, floor channels or T flooring, clogged

    defrost drain tubes, and clogged or damaged floor

    channels which could block the air return, creating

    isolated areas in the load that are warmer than the desired

    temperature.

    4. Pre-cool the cargo compartment. Adjust the setpoint to

    desired cargo temperature and allow the unit to run a

    minimum of 30 to 60 minutes (longer if possible) befoloading. Check to be certain the setpoint temperature is

    correct for the cargo.

    Pre-cooling before loading will remove residual heat a

    moisture from the cargo compartment and prepare it to

    receive the refrigerated load. Pre-cooling also provides

    good test of the refrigeration system.

    5. Make sure products are pre-cooled to the proper

    temperature before loading. Any variance should be noon the manifest.

    6. Supervise product loading to make sure that there is

    sufficient air space around and through the load so air fl

    is not restricted.

    Loading and Enroute Inspections

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    40

    Figure 24: Loading Considerations

    1. Unit Inspection

    2. Good Outside Air Circulation

    3. Gaskets Equally Compressed

    4. Clear Defrost Drains5. Tight Doors

    6.Good Air Circulation AroundLoad

    7.Interior and Exterior Walls andInsulation in Good Condition

    8.Cargo at Proper TemperaturePrior to Loading

    1

    6

    AMA526

    2 3 4

    5

    7

    8

    7

    Loading and Enroute Inspections

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    Inspecting the LoadNever assume that the product has been loaded properly. Watch

    for and perform the following tasks. It takes only a few

    minutes and could save you or your employer considerable

    time and money later on.1. Make sure the unit is off before opening the cargo

    compartment doors. During operation, the unit blows out

    refrigerated air, and draws in outside air.

    NOTE: The unit can be run with the doors open if the

    truck is backed into a refrigerated warehouse with tight

    door seals.

    2. Perform a final check of the load temperature. If the load

    is too hot or too cold, make a final notation on themanifest.

    3. While inspecting to see that the cargo is loaded proper

    make sure the evaporator inlets and outlets are not

    blocked.

    4. Close or supervise the closing of the cargo compartme

    doors. Make sure they are securely locked.

    5. Check to make sure the unit setpoint is set at the desire

    temperature as listed on the manifest.

    6. If the unit was stopped, restart using the appropriate

    starting procedure outlined in this manual.

    7. Repeat the after-start inspection.

    8. Defrost the unit 30 minutes after loading by starting a

    manual defrost cycle.

    CAUTION: Make sure cargo is pre-cooled to the

    proper temperature before loading. The unit is

    designed to maintain temperature, not cool an

    above-temperature load.

    Loading and Enroute Inspections

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    42

    Enroute InspectionsNOTE: Enroute inspections are recommended every four

    hours for the prevention of damage to the cargo.

    1. Note the setpoint to make certain no one has altered the

    setting since picking up the load.

    2. Note the return air temperature reading. It should be

    within the desired temperature range. If the return air

    temperature reading is not within the desired temperature

    range, it indicates one of the following:

    a. The unit has not had sufficient time to pull down the

    temperature. Refer to log, if possible, for history of

    load (for example, above temperature load, properly

    pre-cooled cargo compartment, length of time onroad).

    b. The unit is in defrost or has just completed defrost.

    NOTE: You can cancel defrost by turning the unit off,

    then restarting the unit.

    c. The evaporator is plugged with frost. Initiate a manual

    defrost cycle. The defrost cycle will be automatically

    terminated.

    d. Improper air circulation within the cargo

    compartment. Inspect the cargo compartment (if

    possible) to determine if the evaporator fans are

    working and properly circulating the air. Poor air

    circulation can be due to improper loading of the

    cargo or shifting of the load.

    WARNING: The unit may START automatically AT

    ANY TIME while it is turned ON. Make sure to turn

    the unit OFF before opening unit doors or inspecting

    any part of the unit.

    Loading and Enroute Inspections

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    e. The unit may have a low refrigerant charge. If liquid

    is not showing in the unit receiver tank sight glass, the

    refrigerant charge may be low. Adding refrigerant or

    repairing the refrigeration system requires a

    competent mechanic. Refer such problems to the

    nearest Thermo King dealer or authorized ServiceCenter, or call the Thermo King Cold Line telephone

    number shown on the inside back cover of this

    manual for referral.

    NOTE: If the temperature in the compartment is not

    within the desired temperature range, repeat the Enroute

    Inspection every 30 minutes until the compartment

    temperature comes within the desired temperature range.

    3. Initiate a Manual Defrost cycle after each Enroute

    Inspection.

    CAUTION: Stop the unit if the compartment

    temperature remains outside the desired temperatu

    range from the setpoint on two consecutive 30 minu

    inspections. Contact the nearest Thermo King

    Service Center or your company office immediately

    Take all necessary steps to protect and maintain

    proper load temperature.

    Loading and Enroute Inspections

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    Specifications

    GENERAL

    Main Compressor SELTEC TM-16XD

    Electrical Compressor FRASCOLD D211Y

    System Oil Capacity Main: 5.1 oz (150 cc)

    Standby Operation: 40.1 oz (1200 cc)

    Compressor Oil Type Polyol Ester P/N 203-515

    Refrigerant 8.1 lbs (3.7 kg) R-404A

    8.0 lbs (3.6 kg) R-134a

    Defrost Method: Hot gas

    Defrost Timer: Initiation Interval Adjustable, 1 hour to 10 hours

    Termination Interval Termination is not timed.Defrost is terminated by Klixon

    switch.

    Specifications

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    46

    ELECTRICAL SYSTEM

    Fuses

    Fuse 1: Evaporator Fan Motor (EF1) 15 amps

    Fuse 2: Evaporator Fan Motor (EF2) 15 ampsFuse 3: Engine-driven Compressor Clutch Coil, Condenser SolenoidValve Coil (heating option), Hot Gas Solenoid Valve Coil

    15 amps

    Fuse 5: Condenser Fan Motor (CFM1) 15 amps

    Fuse 6: Condenser Fan Motor (CFM2) 15 amps

    Fuse 7: Evaporator Fan Motor (EF3) 15 amps

    Fuse 4: Electric Standby 3 amps

    Fuse 4/1: Cab Control Box 3 amps

    Condenser Fan Motors (2)

    Voltage Full Load rpm Full Load Current

    13 Vdc 3000 9.2 Amps

    Specifications

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    Evaporator Fan Motors (3)

    Voltage Full Load rpm Full Load Current

    13 Vdc 2700 6.2 Amps

    Coils for Hot Gas Solenoids

    Voltage Current Resistance

    12 Vdc 2.3 Amps 5.2 Ohms

    AC Electric Motor

    Voltage Phase Frequency Full Load Current

    208/230 3 60 Hz 14.1 Amps

    208/230 1 60 Hz 16.0 Amps

    BELT TENSION Check vehicle manufacturer specifications

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    Maintenance Inspection ScheduleA closely followed maintenance program will help to keep

    your Thermo King unit in top operating condition. The

    following general schedule is provided to assist in monitoringthat maintenance.

    For more specific detail, see the maintenance manual for your

    unit and to the PreTrip Inspection chapter in this manual.

    After first week of operation:

    Check belt tension.

    Tighten unit mounting bolts.

    Check refrigerant level.

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    Maintenance Inspection Schedule

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    Check all unit mounting bolts, brackets, lines, hoses, etc.

    Weekly Monthly Semi-

    Annual

    Annual Inspect/Service These Items

    Maintenance Inspection Schedule

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    WarrantyTerms of the Thermo King Warranty are available on request.

    Please reference document TK 51350 for the Thermo King

    Vehicle-Powered Truck Unit Warranty.

    Warranty

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    Gl

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    001

    GlossaryThis glossary is published for informational purposes only and

    the information being furnished herein should not be

    considered as all-inclusive or meant to cover all contingencies.NOTE: Additional terms not found in the glossary may be

    located in the index section of this manual.

    accumulator: A device located in the suction line to collectliquid refrigerant and meter it safety back to the compressor as

    gas.

    ambient air temperature: Temperature of the airsurrounding an object.

    amp: Abbreviation for ampere. The basic measuring unit ofelectrical current.

    bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.

    Battery Sentry: Part of the CYCLE-SENTRYsystem. The

    Battery Sentry module monitors alternator charge rate and will

    keep the unit running until the battery is adequately charged.

    box temperature: The temperature within atemperature-controlled compartment.

    Btu (british thermal unit): The quantity of heat requiredraise the temperature of one pound of water by one degree

    Fahrenheit. 1 Btu = 252 calories.

    bulkhead: 1)return air bulkhead. A metal or plastic wal

    placed at the front of the box to prevent loading of product

    tightly against the Thermo King unit. (Loading too close to

    unit restricts air flow and system efficiency.) 2) bulkhead

    divider. A thick, insulated wall used to separate

    compartments of a multi-temperature truck or trailer.calorie: The amount of heat required to raise temperature one gram of water one degree Celsius. 1 calorie = 0.004 Btu

    Celsius: The metric unit of temperature measurement. Thpreferred alternate to the term centigrade. Abbreviated C.

    centigrade. See Celsius.

    Glossary

    CFC Chl fl b A hl i b d f i d A f bi i hi h h

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    CFC: Chlorofluorocarbon. A chlorine-based refrigerant

    consisting of chlorine, fluorine and carbon. Example: R12. In

    many countries it is illegal to release this type of refrigerant to

    the atmosphere because chlorine damages the earths

    atmosphere. CFC refrigerants are not used in modern Thermo

    King units.circuit breaker: A thermal device that automaticallyinterrupts an electrical circuit when the current in the circuit

    exceeds the predetermined amperage rating of the breaker. See

    amp.

    coil: A cooling or heating element made of pipe or tube,formed into a helical or serpentine shape, that may be equipped

    with thin metal fins to aid heat transfer.

    cold curtains: Flexible vinyl curtains used to reduce airexchange between the refrigerated compartment and the

    outside during door openings.

    compound gauge: A gauge calibrated in psig (or kPa) tomeasure pressure, and in inches of mercury (Kg/cm2) to

    measure vacuum.

    compressor: The refrigeration component that compresses

    refrigerant vapor and creates refrigerant flow.

    condenser: An arrangement of tubing in which the

    vaporized and compressed refrigerant is liquefied as heat is

    removed.

    cycles per second: SeeHertz.

    damper door: A door on the evaporator section that closesduring defrost to prevent hot air from entering the refrigeratedcargo compartment.

    data logger: An electronic device that monitors and storesunit operating and temperature data for later review. Examples:

    DMS, DAS, DRS and AccuTrac.

    DE: Dual Evaporator. A multi-temp host unit with two

    evaporators capable of refrigerating two separate, longitudinal

    compartments.defrost: The removal of accumulated ice from an evaporatorcoil. Periodic defrost is necessary when the evaporator coil is

    operating below freezing. Defrost is required more frequently

    when the air passing through the evaporator has a high

    moisture content.

    defrost termination switch: A component that terminates

    defrost operation at a specific temperature.

    Glossary

    d f t ti A lid t t d l th t i iti t d f t t t Th t f th f i ti t th t b

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    defrost timer: A solid state module that initiates defrost at

    selected intervals. Also establishes a maximum defrost

    duration if normal circuits malfunction.

    dehydrator: A device used to remove moisture fromrefrigerant. Also called a drier.

    discharge air temperature: The temperature of air leavingthe evaporator.

    drier: See dehydrator.

    ECT: A ceiling-mounted Thermo King remote evaporator. SeeEWand TLE.

    ERC: Extended Remote Unit Control. (Door switches) Anoption on Thermo King multi-temperature units to improve

    temperature control when doors are opened during delivery.When a compartment door is opened, the refrigeration unit for

    that compartment may be forced to NULL, defrost, or some

    other mode. Opening a compartment door may also affect the

    operating mode of other compartments. ERC systems are

    connected in a variety of ways to meet customer needs.

    ETV (Electronic Throttling Valve) : A device used with a

    microprocessor to precisely control the refrigeration system.

    evaporator: The part of the refrigeration system that abso

    heat during the cooling cycle.

    EW: A wall-mounted Thermo King remote evaporator. See

    ECTand TLE.

    F: See Fahrenheit.Fahrenheit: A unit of temperature measurement used in thUnited States. Abbreviated F.

    freeze up: 1) Failure of a refrigeration system to operatenormally due to moisture in the refrigerant and the formatio

    of ice at the expansion valve. The expansion valve may be

    frozen shut or open, causing improper unit operation in eith

    case. 2) The formation of a solid ice mass over the evapora

    coil reducing air flow.fuse: An electrical safety device (typically a cartridge)inserted into an electrical circuit. It contains material that w

    melt or break when the current is increased beyond a specif

    value. When this occurs, the circuit is opened and electrical

    current flow is stopped.

    Glossary

    fusible link: An electrical safet de ice (t picall a short hp (horsepower): A nit of po er eq i alent to 746 atts

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    fusible link: An electrical safety device (typically a short

    piece of wire) inserted into an electrical circuit. The wire melts

    or breaks when the current is increased beyond a specific

    value. When this occurs, the circuit is opened and electrical

    current flow is stopped.

    HCFC: Hydrochlorofluorocarbon. A chlorine-basedrefrigerant containing hydrogen, chlorine, fluorine and carbon.

    Example: R22. Because chlorine damages the earths

    atmosphere, in many countries, it is illegal to release this type

    of refrigerant to the atmosphere. HCFC refrigerants are not

    used in modern Thermo King units.

    Hertz: A unit of frequency equal to one cycle per second.

    Abbreviated Hz.

    HFC: A refrigerant consisting of hydrogen, fluorine andcarbon. Examples: R134a and 404A. HFC refrigerants contain

    no chlorine and are, therefore, considered safe for the

    environment.

    high pressure relief valve: A safety valve on the

    refrigeration system that allows refrigerant to escape from the

    system if pressure exceeds a predetermined value.

    hp (horsepower): A unit of power equivalent to 746 watts

    or 550 foot-pounds per second.

    HPCO (High Pressure Cut Out Switch): A

    pressure-operated switch that opens to stop unit operation

    when discharge pressure reaches a predetermined maximum.

    invertible: A multi-temperature truck or trailer unit designedto allow the placement of deep-frozen cargo in any

    compartment. SeeMulti-Temp.

    kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =

    0.145 psi.

    load: 1) The product being refrigerated and transported.

    2) The amount of heat being removed by the refrigeration

    system. (For example, a compressor is under a heavy heat loadwhen expected to cool a very warm box.)

    LPCO (Low Pressure Cut Out Switch): A

    pressure-operated switch that opens to stop unit operation

    when suction pressure reaches a predetermined minimum.

    modulation: An optional system that reduces load (product)dehydration and avoids top freeze.

    Glossary

    movable bulkhead: A thick insulated portable wall like psi: Pounds per square inch A unit of pressure

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    movable bulkhead: A thick, insulated, portable wall-like

    device used to compartmentalize a temperature-controlled

    truck or trailer. See bulkhead.

    Multi-Temp: A Thermo King truck or trailer unit capable ofmaintaining different set-points in multiple compartments.

    no. 1 diesel fuel: A grade of diesel fuel formulated toprevent jelling in low ambient temperatures.

    no. 2 diesel fuel: A grade of diesel fuel formulated formoderate to warm ambient temperatures.

    ohm: An electrical unit measuring the amount of resistance(opposition to the current flow) in an electrical circuit.

    pre-cooling: 1) To cool down an empty box

    (temperature-controlled area) to the desired load temperatureprior to loading. 2) To cool cargo to a desired temperature

    before loading.

    pre-heat: The heating of diesel engine glow plugs prior tostart-up. Some engines use an intake manifold heater rather

    than glow plugs.

    pre-trip inspection: Checking the operation of a

    refrigeration system before loading.

    psi: Pounds per square inch. A unit of pressure.

    1 psi = 0.069 bar = 6.89 kPa.

    psig: Pounds per Square Inch Gauge. Pressure in pounds p

    square inch as displayed by a gauge calibrated to zero when

    open to the atmosphere.

    receiver tank: A refrigerant storage device included innearly all Thermo King units.

    refrigerant: The medium of heat transfer in a refrigerationsystem which absorbs heat by evaporating at a low temperat

    and releases heat by condensing at a higher temperature.

    refrigerant oil: A special oil used to lubricate compressor

    refrigeration systems.

    remote evaporator: A separate evaporator unit located isecond or third compartment of a multi-temperature truck o

    trailer unit.

    return air bulkhead: A structure (metal or plastic) mounin the front of a trailer and designed to prevent restriction o

    return air flow to the Thermo King unit due to improper

    loading. See bulkhead.

    Glossary

    return air temperature: The temperature of the air Vac (volts alternating current): An electric current that

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    return air temperature: The temperature of the air

    returning to the evaporator. See box temperature.

    rpm: Revolutions per minute.

    setpoint: The temperature selected on a thermostat ormicroprocessor controller. This is normally the desired box

    temperature.

    short cycling: When a refrigeration unit cycles between the

    heat and cool modes more often than normal.

    sight glass: A system component that permits visualinspection of oil or refrigerant level and condition.

    thermostat: A device that controls unit modes of operation tomaintain a selected box temperature.

    TLE: Thin-line evaporator. A Thermo King remote evaporatordesigned to be compact (thin) while supplying superior air

    flow. SeeECTandEW.

    top freeze: When the top portion of perishable cargo is

    damaged by freezing temperatures discharged from the

    refrigeration unit. This may occur near the front of the box

    when product is placed too close to the cold, discharge air flow.

    Vac (volts alternating current): An electric current that

    reverses direction at regularly recurring intervals.

    Vdc (volts direct current): An electric current that flows in

    one direction only and is constant in value.

    volts: The basic measuring unit of electrical potential.

    watt: The basic measuring unit of electrical power.

    Index

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    Index

    AAfter Start Inspection37

    CCab Control Box Operating Instructions (M-13, M-16,

    M-17)32Compressor15Control Circuits16

    D

    Defrost Mode Operation (M-13, and M-16 only).33

    Display26Display Setpoint Temperature32Displaying Return Air Temperature32

    E

    Electric Standby Operation17Electrical Hazard10ELECTRICAL SYSTEM46Emergency Cold Line65

    enroute inspections39, 42Enter Setpoint Temperature.33

    Evaporator16Evaporator Drain Tube Heaters17

    FFirst Aid-Refrigerant11First Aid-Refrigerant Oil11Fuses20

    G

    GENERAL45General Display Information26

    IIn-Cab Control Box16In-Cab Control Box Description25inspecting load41Introduction13introduction7

    Index

    K Refrigerant Oil 11

    http://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdf
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    K

    keypadTK logo27

    LLiquid Injection System17loading inspections39loading procedures

    pre-loading inspection39

    M

    Maintenance49Maintenance Inspection Schedule49

    O

    Oil Separator18Operating Instructions31

    Ppre-loading inspection39Protection Features19

    RRefrigerant

    10

    ,17

    Refrigerant Oil11

    SSafety Decals12Safety Precautions9standard display27

    T

    TK logo key27

    U

    Unit Description13Unit Features14Unit Operation37

    Wwarranty53Weekly Pretrip Inspection34

    Serial Number Locations

    Serial Number Locations

    http://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdfhttp://../Module%20Masters/1_Incab%20Control%20Box%20Desc_M13%20only.pdf
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    Serial Number LocationsCONDENSER: Nameplate located on the back inside wall ofcondenser frame.

    ENGINE DRIVEN COMPRESSOR: Nameplate located oncompressor body. The engine driven compressor is located in

    the truck engine compartment.

    STANDBY COMPRESSOR: Nameplate located on

    compressor body. The Standby compressor is located inside the

    Condenser assembly.

    1. Condenser Serial Number Location2. Stand By Compressor Serial

    Number Location

    Figure 25: Condenser and Standby CompressoSerial Number Locations

    AMA51

    21

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    Emergency Cold Line

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    Emergency Cold Line

    If you cant get your rig rolling, and you have tried the Thermo

    King North American Service Directory (available from any

    Thermo King dealer) to reach a dealer without success, then

    call the Toll Free Emergency Cold Line Number

    (888) 887-2202.

    The answering service at the factory will assist you in reach

    a dealer to get the help you need. The Cold Line is answered

    hours a day by personnel who will do their best to get you

    quick service at an authorized Thermo King Dealer.

    AKB12

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    Recover Refrigerant

    At Thermo King, we recognize the need to preserve the environmentand limit the potential harm to the ozone layer that can result from

    allowing refrigerant to escape into the atmosphere.

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

    the loss of refrigerant into the atmosphere.

    In addition, service personnel must be aware of Federal regulationsconcerning the use of refrigerants and the certification of technicians.

    For additional information on regulations and technician certification

    programs, contact your local THERMO KING dealer.