Thermo King V250 Bedienungsanleitung

V250

TK 40839-1-MM (Rev. 2, 1/99)

Printed in U.S.A.

The maintenance information in this manual covers unit models:

V250 10 (914500) Condenser 10 Plus (085067)

V250 20 Generic (085007) Condenser 10 Plus UK (085068)

V250 LOTEMP (715394) Kit - low temperature (715394)

Condenser 10 (085001) E1000 Evaporator (085031)

Evaporator - Thin Line (085003) E1000E Evaporator (085034)

V250 115/1/60 Standby (085009) V250/E1000E Evaporator (085041)

Evaporator (085005) V250 Converte (085066)

For further information, refer to…

V250 Parts Manual TK 40834

Diagnosing Thermo King Refrigeration Systems TK 5984

Tool Catalog TK 5955

V250 Operating Manual TK 40836

Installation Manual TK 41156

The information in this manual is provided to assist owners, operators and service people in the proper upkeep

and maintenance of Thermo King units. For detailed descriptions of Thermo King engines, compressors, or

refrigeration systems, see the appropriate Thermo King Overhaul Manual or Refrigeration Systems Maintenance

Manual.

This manual is published for informational purposes only and the information so provided should not be considered

as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be

consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to,

the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.

Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manu-

facturer’s plants as, in the manufacturer’s judgment, to effect its stability.”

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

ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec-

ommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held

liable in contract or in tort (including negligence) for any special, indirect or consequential damages,

including injury or damage caused to vehicles, contents or persons, by reason of the installation of any

Thermo King product or its mechanical failure.

Recover Refrigerant

At Thermo King, we recognize the need to preserve the

environment and limit the potential harm to the ozone

layer that can result from allowing refrigerant to escape

into the atmosphere.

We strictly adhere to a policy that promotes the recovery

and limits the loss of refrigerant into the atmosphere.

In addition, service personnel must be aware of Federal

regulations concerning the use of refrigerants and the

certification of technicians. For additional information on

regulations and technician certification programs, con-

tact your local THERMO KING dealer.

WARNING: Use ONLY Polyol Ester based refrigeration compressor oil (TK P/N 203-413) in

R-404A and R-134a units.

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

DO NOT mix Polyol Ester and standard synthetic compressor oils.

Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes

contaminated with moisture or standard oils, dispose of properly—DO NOT USE!

WARNING: When servicing Thermo King R-404A and R-134a units, use only those service

tools certified for and dedicated to R-404A or R-134a refrigerant and Polyol Ester

compressor oils. Residual non-HFC refrigerants or oils will contaminate R-404A and R-134a

systems.

R-404A R-134a

Table of Contents

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Maintenance Inspection Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Unit Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Bi-monthly Pre-Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Starting the Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Adjusting the Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

After Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Post Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Bi-monthly Post Trip Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Unit Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Selecting the Temperature Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Selecting the Setpoint Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Setpoint Differential Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Testing the Cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Display Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Thermostat Switch Sequence Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Electric Standby Operation (Model 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Defrost Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

V250 Defrost System and P.C. Board Identification and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

P.C. Board Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Troubleshooting the V250 Defrost System with P.C. Board P/N 41-776 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Troubleshooting the V250 Defrost System with P.C. Boards P/N 41-1619 and P/N 41-1812 . . . . . . . . . . . . . .44

Table of Contents (continued)

Electrical Maintenance (continued)

P.C. Board P/N 41-776 Test Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

P.C. Board P/N 41-1812 and P/N 41-1619 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

M10 (V250/V-090) Cab Control Box Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Condenser Fan Pressure Switch (CFPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

AC Components (Model 20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Electric Standby Circuits (Model 20 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

12 Volt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Evaporator Heaters (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Charging the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Checking Compressor Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Low Pressure Cutout Switch (LPCO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Cleanup Procedure for Small Truck Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

High Pressure Cutout and Condenser Fan Pressure Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Hot Gas Solenoid Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Liquid Injection Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Liquid Injection Metering Orifice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Testing the Liquid Injection Solenoid Valve and Metering Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Check Valve Repair (Model 20 Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Low Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Suction Pressure Regulator Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Replacing Refrigerant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Table of Contents—(continued)

V-250 R-404A Conversion Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Structural Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Unit Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Condenser Fan Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Unit Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Compressor and Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Clutch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Clutch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Shaft Seal Cover and Shaft Seal: Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

System Compressor and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Clutch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Belt Tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Engine/Compressor Belt and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Electric Motor/Compressor Belt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Over-the-Road Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Road Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Electric Standby Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Possible Cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Electric Standby Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

V250 Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Wiring Diagrams and Schematic Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Safety Precautions

GENERAL PRACTICES

1. ALWAYS WEAR GOGGLES OR SAFETY

GLASSES. Refrigerant liquid, refrigeration oil, and

battery acid can permanently damage the eyes (see First

Aid under Refrigeration Oil).

2. Never operate the unit with the compressor discharge

valve closed.

3. Keep your hands, clothing and tools clear of the fans

and belts when the unit is running. This should also be

considered when opening and closing the compressor

service valves.

4. Make sure gauge manifold hoses are in good condition.

Never let them come in contact with a belt, fan motor

pulley, or any hot surface.

5. Never apply heat to a sealed refrigeration system or

container.

6. Fluorocarbon refrigerants, in the presence of an open

flame or electrical short, produce toxic gases that are

severe respiratory irritants capable of causing death.

7. Make sure all mounting bolts are tight and are of cor-

rect length for their particular application.

8. Use extreme caution when drilling holes in the unit.

The holes may weaken structural components, and

holes drilled into electrical wiring can cause fire or

explosion.

9. Use caution when working around exposed coil fins.

The fins can cause painful lacerations.

10. Use caution when working with a refrigerant or refrig-

eration system in any closed or confined area with a

limited air supply (for example, a truck box or garage).

Refrigerant tends to displace air and can cause oxygen

depletion resulting in suffocation and possible death.

11. EPA Section 608 Certification is needed to work on

refrigeration systems.

REFRIGERANT

Although fluorocarbon refrigerants are classified as safe

refrigerants, certain precautions must be observed when

handling them or servicing a unit in which they are used.

When exposed to the atmosphere from the liquid state, fluo-

rocarbon refrigerants evaporator rapidly, freezing anything

they contact.

First Aid

In the event of frost bite, the objectives of First Aid are to

protect the frozen area from further injury, to warm the

affected area rapidly and to maintain respiration.

• EYES: For contact with liquid, immediately flush eyes

with large amounts of water and get prompt medical

attention.

• SKIN: Flush area with large amounts of lukewarm

water. Do not apply heat. Remove contaminated cloth-

ing and shoes. Wrap burns with dry, sterile, bulky

dressing to protect from infection/injury. Get medical

attention. Wash contaminated clothing before reuse.

• INHALATION: Move victim to fresh air and use CPR

if necessary. Stay with victim until arrival of emer-

gency medical personnel.

REFRIGERATION OIL

Avoid refrigeration oil contact with the eyes. Avoid pro-

longed or repeated contact of refrigeration oil with skin or

clothing. Wash thoroughly after handling refrigeration oil to

prevent irritation.

First Aid

In case of eye contact, immediately flush with plenty of

water for at least 15 minutes. Wash skin with soap and

water. CALL A PHYSICIAN.

Safety Precautions (Rev 1/99)

ELECTRICAL HAZARDS

High Voltage

When servicing or repairing a refrigeration unit, the possi-

bility of serious or even fatal injury from electrical shock

exists. Extreme care must be used when working with an

operating refrigeration unit. Lethal voltage potentials can

exist on connections in the high voltage tray of the control

box.

Precautions

1. When working on high voltage circuits on the refrigera-

tion unit, do not make any rapid moves. If a tool drops,

do not grab for it. People do not contact high voltage

wires on purpose. It occurs from an unplanned move-

ment.

2. Use tools with insulated handles that are in good condi-

tion. Never hold metal tools in your hand if exposed,

energized conductors are within reach.

3. Treat all wires and connections as high voltage until a

meter and wiring diagram show otherwise.

4. Never work alone on high voltage circuits on the refrig-

eration unit, another person should always be standing

by in the event of an accident to shut off the refrigera-

tion unit and to aid a victim.

5. Have electrically insulated gloves, cable cutters and

safety glasses available in the immediate vicinity in the

event of an accident.

First Aid

IMMEDIATE action must be initiated after a person has

received an electrical shock. Obtain immediate medical

assistance if available.

The source of shock must be immediately removed by

either shutting down the power or removing the victim from

the source. If it is not possible to shut off the power, the wire

should be cut with either an insulated instrument (e.g., a

wooden handled axe or cable cutters with heavy insulated

handles) or by a rescuer wearing electrically insulated

gloves and safety glasses. Whichever method is used do not

look at the wire while it is being cut. The ensuing flash can

cause burns and blindness.

If the victim has to be removed from a live circuit, pull the

victim off with a non-conductive material. Use the victim’s

coat, a rope, wood, or loop your belt around the victim’s leg

or arm and pull the victim off. DO NOT TOUCH the victim.

You can receive a shock from current flowing through the

victim’s body. After separating the victim from power

source, check immediately for the presence of a pulse and

respiration. If a pulse is not present, start CPR (Cardio Pul-

monary Resuscitation) and call for emergency medical

assistance. If a pulse is present, respiration may be restored

by using mouth-to-mouth resuscitation, but call for emer-

gency medical assistance.

Low Voltage

Control circuits used in the refrigeration unit are low volt-

age (12 volts dc). This voltage potential is not considered

dangerous, but the large amount of current available (over

30 amperes) can cause severe burns if shorted or ground.

Do not wear jewelry, watch or rings. These items can short

out electrical circuits and cause severe burns to the wearer.

Specifications

General

Compressor Belt driven, multi cylinder, wobble plate type driven

by the truck engine (Model 10) and by the truck

engine or electric motor. (Model 20)

Engine Compressor Oil Charge 6 oz (177 ml) in compressor

Total system: 12 oz (355 ml)

Electric Standby Compressor Oil Charge 6 oz 177 ml) in each compressor

Total system: 24 oz (710 ml)

Compressor Oil Type Polyol Ester P/N 203-413

Defrost Method:

Truck Engine Operation Model 10 Hot gas

Model 20 Hot gas

Electric Standby Model 20 Hot gas

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

Termination interval 45 minutes

R-134A REFRIGERATION SYSTEM

Refrigerant Charge and Type 5 lb (2.3 kg) R-134a

Defrost Termination Switch: Opens 52 F (11.1 C)

Closes 42 F (5.6 C)

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

Closes 230 ± 5 F (110 ± 3 C)

High Pressure Cutout Switch: Opens 350 + 25/-0 psi (2413 + 172/-0 kPa)

Closes 200 ± 20 psi (1379 ± 138 kPa)

Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum (-17 to -34 kPa)

Closes 4 to 7 psi (28 to 48 kPa)

Condenser Fan Pressure Switch: Opens 130 ± 10 psi (896 ± 69 kPa)

Closes 180 ± 10 psi (1241 ± 69 kPa)

Specifications (Rev 1/99)

R-404A REFRIGERATION SYSTEM

Refrigerant Charge and Type 5 lb (2.3 kg) R-404A

Defrost Termination Switch: Opens 52 F (11.1 C)

Closes 42 F (5.6 C)

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

Closes 230 ± 5 F (110 ± 3 C)

High Pressure Cutout Switch: Opens 470 ± 7 psi (3241 ± 48 kPa)

Closes 375 ± 38 psi (2585 ± 262 kPa)

Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum (-17 to -34 kPa)

Closes 4 to 7 psi (28 to 48 kPa)

Condenser Fan Pressure Switch: Opens 130 ± 10 psi (896 ± 69 kPa)

Closes 180 ± 10 psi (1241 ± 69 kPa)

ELECTRICAL SYSTEM

Fuses

F1 Condenser Fan Fuse 15 amps

F2 Evaporator Fan Fuse 15 amps

F3 Power Fuse 10 amps

F4 Control Circuit Fuse 3 amps

Battery Circuit Breaker 40 amps

Transformer Fuse 4 amps (10 amps in 115/1/60 units)

F5 Defrost Circuit Fuse 1 amp

F7 Transformer Fuse 10 amps

Condenser and Evaporator Fan Motors

Voltage Horsepower Power Rating

in Kilowatts rpm Full Load Current

12 Vdc 0.17 0.12 1750-2000 6-9 amps

Hot Gas Solenoid and Liquid Injection Solenoid Coils

Voltage Current Resistance

12 Vdc 0.6-0.8 amps 15-19 ohms

Inhaltsverzeichnis

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