TK 40839-1-MM (Rev. 2, 1/99) : 1994 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A

V250
TK 40839-1-MM (Rev. 2, 1/99)
Copyright© 1994 Thermo King Corp., Minneapolis, MN, U.S.A.

Printed in U.S.A.
Downloaded from www.Manualslib.com manuals search engine

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.
R-404A R-134a
WARNING: Use ONLY Polyol Ester based refrigeration compressor oil (TK P/N 203-413) in
R-404A and R-134a units.
DO NOT use Polyol Ester based oil in standard Thermo King units.
DO NOT mix Polyol Ester and standard synthetic compressor oils.
Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes
contaminated with moisture or standard oils, dispose of properly—DO NOT USE!
WARNING: When servicing Thermo King R-404A and R-134a units, use only those service
tools certified for and dedicated to R-404A or R-134a refrigerant and Polyol Ester
compressor oils. Residual non-HFC refrigerants or oils will contaminate R-404A and R-134a
systems.

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 REFRIGERANT

1. ALWAYS WEAR GOGGLES OR SAFETY Although fluorocarbon refrigerants are classified as safe
GLASSES. Refrigerant liquid, refrigeration oil, and refrigerants, certain precautions must be observed when
battery acid can permanently damage the eyes (see First handling them or servicing a unit in which they are used.
Aid under Refrigeration Oil). When exposed to the atmosphere from the liquid state, fluo-
rocarbon refrigerants evaporator rapidly, freezing anything
2. Never operate the unit with the compressor discharge
they contact.
valve closed.
3. Keep your hands, clothing and tools clear of the fans First Aid
and belts when the unit is running. This should also be In the event of frost bite, the objectives of First Aid are to
considered when opening and closing the compressor protect the frozen area from further injury, to warm the
service valves. affected area rapidly and to maintain respiration.
4. Make sure gauge manifold hoses are in good condition. • EYES: For contact with liquid, immediately flush eyes
Never let them come in contact with a belt, fan motor with large amounts of water and get prompt medical
pulley, or any hot surface. attention.
5. Never apply heat to a sealed refrigeration system or • SKIN: Flush area with large amounts of lukewarm
container. water. Do not apply heat. Remove contaminated cloth-
6. Fluorocarbon refrigerants, in the presence of an open ing and shoes. Wrap burns with dry, sterile, bulky
flame or electrical short, produce toxic gases that are dressing to protect from infection/injury. Get medical
severe respiratory irritants capable of causing death. attention. Wash contaminated clothing before reuse.
7. Make sure all mounting bolts are tight and are of cor- • INHALATION: Move victim to fresh air and use CPR
rect length for their particular application. if necessary. Stay with victim until arrival of emer-
gency medical personnel.
8. Use extreme caution when drilling holes in the unit.
The holes may weaken structural components, and
REFRIGERATION OIL
holes drilled into electrical wiring can cause fire or
explosion. Avoid refrigeration oil contact with the eyes. Avoid pro-
longed or repeated contact of refrigeration oil with skin or
9. Use caution when working around exposed coil fins.
clothing. Wash thoroughly after handling refrigeration oil to
The fins can cause painful lacerations.
prevent irritation.
10. Use caution when working with a refrigerant or refrig-
eration system in any closed or confined area with a First Aid
limited air supply (for example, a truck box or garage). In case of eye contact, immediately flush with plenty of
Refrigerant tends to displace air and can cause oxygen water for at least 15 minutes. Wash skin with soap and
depletion resulting in suffocation and possible death. water. CALL A PHYSICIAN.
11. EPA Section 608 Certification is needed to work on
refrigeration systems.
i
Safety Precautions (Rev 1/99)
ELECTRICAL HAZARDS First Aid

IMMEDIATE action must be initiated after a person has
High Voltage received an electrical shock. Obtain immediate medical
assistance if available.
When servicing or repairing a refrigeration unit, the possi-
bility of serious or even fatal injury from electrical shock The source of shock must be immediately removed by
exists. Extreme care must be used when working with an either shutting down the power or removing the victim from
operating refrigeration unit. Lethal voltage potentials can the source. If it is not possible to shut off the power, the wire
exist on connections in the high voltage tray of the control should be cut with either an insulated instrument (e.g., a
box. wooden handled axe or cable cutters with heavy insulated
handles) or by a rescuer wearing electrically insulated
Precautions gloves and safety glasses. Whichever method is used do not
1. When working on high voltage circuits on the refrigera- look at the wire while it is being cut. The ensuing flash can
tion unit, do not make any rapid moves. If a tool drops, cause burns and blindness.
do not grab for it. People do not contact high voltage
If the victim has to be removed from a live circuit, pull the
wires on purpose. It occurs from an unplanned move- victim off with a non-conductive material. Use the victim’s
ment.
coat, a rope, wood, or loop your belt around the victim’s leg
2. Use tools with insulated handles that are in good condi- or arm and pull the victim off. DO NOT TOUCH the victim.
tion. Never hold metal tools in your hand if exposed, You can receive a shock from current flowing through the
energized conductors are within reach. victim’s body. After separating the victim from power
source, check immediately for the presence of a pulse and
3. Treat all wires and connections as high voltage until a respiration. If a pulse is not present, start CPR (Cardio Pul-
meter and wiring diagram show otherwise.
monary Resuscitation) and call for emergency medical
4. Never work alone on high voltage circuits on the refrig- assistance. If a pulse is present, respiration may be restored
eration unit, another person should always be standing by using mouth-to-mouth resuscitation, but call for emer-
by in the event of an accident to shut off the refrigera- gency medical assistance.
tion unit and to aid a victim.
Low Voltage
5. Have electrically insulated gloves, cable cutters and
safety glasses available in the immediate vicinity in the Control circuits used in the refrigeration unit are low volt-
event of an accident. 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.
ii
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)
1
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
Power Rating
Voltage Horsepower rpm Full Load Current
in Kilowatts
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
2
Specifications (Rev 1/99)
Electrical Standby Compressor Motors
Full Load Overload

Full Load
Voltage Phase Frequency Horsepower Kilowatts Current Relay Setting
rpm
(amps) (amps)
115 Vac 1 60 Hz 1.5 1.1 1750 15.0 16.0
230 Vac 1 60 Hz 2.0 1.5 1755 8.6 9.5
220 Vac 1 50 Hz 1.7 1.3 1460 10.0 11.0
230 Vac* 3 60 Hz 2.0 1.5 1695 6.8 3.5 **
220 Vac* 3 50 Hz 1.6 1.2 1430 6.0 3.5 **
400 Vac* 3 50 Hz 1.6 1.2 1405 3.2 3.5
* Motor can be wired for all three voltages.

** Overload relay monitors 1/2 motor windings on 220 and 230.
Optional Electric Heaters
Voltage Power Rating Watts Current Resistance

230 Vac 1500 6.5 amps 35.3 ohms
400 Vac 1134 2.8 amps 141.1 ohms
BELT TENSION (Using Tool P/N 204-427)

Field Reset
Engine/Compressor 35
Electric Motor/Compressor 57
3
4
Maintenance Inspection Schedule
First Week Inspection and Maintenance

AFTER FIRST WEEK OF OPERATION:
• Check the belt tension
• Tighten the unit mounting bolts
• Check the refrigerant level
Bi-monthly Annually Inspect/Service These Items

ELECTRICAL
• • Check defrost initiation and termination.
• • Check thermostat cycle sequence.
• • Check operation of protection shutdown circuits.
• Check thermostat and thermometer calibration in 32 F (0 C) ice-water bath.
• Inspect wire harness for damaged wires or connections.
• Inspect/replace DC fan motor brushes.
REFRIGERATION
• • Check refrigerant level.
• Replace dehydrator.
STRUCTURAL
• • Visually inspect unit and refrigerant hoses for fluid leaks.
• • Visually inspect unit for damaged, loose or broken parts.
• • Clean defrost drains.
• • Inspect belts for condition and proper tension (belt tension tool P/N 204-427).
• • Clean entire unit including evaporator coil and condenser coil.
• • Check all unit mounting bolts, brackets, lines, hoses, etc.
5
6
Unit Description
The Thermo King V250 is a truck refrigeration system that The electric standby compressor is connected in parallel
is designed for low and medium temperature applications with the engine-driven compressor. The engine compressor
on medium-sized trucks. There are two basic models: is driven by a belt from the engine. The standby compressor
is driven by a belt from the electric motor. Both compres-
• Model 10: Cool and defrost on engine-driven compres-
sors use the same refrigeration system circuit. Check valves
sor operation.
isolate one compressor from the other during operation.
• Model 20: Cool and defrost on both truck engine- Compressor operation is controlled by the thermostat,
driven and electric standby compressor operation. which energizes the compressor clutch during engine opera-
tion or starts the electric motor and energizes the compres-
The system consist of three separate assemblies: the con-
sor clutch on electric standby operation. The refrigeration
denser, the evaporator, and the compressor.
system is protected by a high pressure cutout switch and a
The condenser has a unique design that allows it to be low pressure cutout switch.
mounted horizontally or vertically, on the roof or on the
The control circuits operate on 12 volts dc supplied by the
front of the truck box.
truck battery for over-the-road operation. On standby oper-
The evaporator is mounted inside the truck box. Funnel and ation, the power is rectified from an ac transformer.
thin-line evaporators are available. The funnel evaporator
The cab control box is mounted in the truck cab. It contains
mounts on the ceiling or the front wall. The thin-line evapo-
the On-Off key, Manual Defrost key, thermometer, thermo-
rator mounts on the front wall.
stat, and indicator lights.
Liquid Injection System

If the discharge gas leaving the engine driven compressor
reaches a temperature of 230 ± 5 F (110 ± 3 C), the liquid
injection switch closes, providing voltage to the liquid injec-
tion solenoid. The solenoid opens a valve, allowing liquid
refrigerant to flow from the liquid line near the receiver out-
let valve to the metering orifice attached to the suction fit-
ting at the compressor. As the refrigerant passes through the
metering orifice it expands and evaporates, cooling the suc-
tion gas entering the compressor. This cooling effect is
Condenser and Evaporator Configurations transferred to the discharge gas leaving the compressor from
the adjacent cavity in the compressor head. When the dis-
The compressor is mounted on and driven by the truck charge gas is cooled to 200 ± 5 F (93 ± 3 C), the liquid injec-
engine. Refrigeration hoses or lines are used to connect the tion switch opens, the liquid injection solenoid valve closes
condenser, the evaporator and the compressor. Model 20 and refrigerant no longer flows through the liquid injection
units have another compressor and an electric motor system.
mounted in the condenser section for electric standby
operation.
7
Unit Description (Rev 1/99)
Oil Separator Electric Standby Operation
An oil separator is a standard feature. It separates compres- During electric standby operation, the thermostat controls
sor oil from refrigerant vapor and returns the oil to the com- the operation of the unit by energizing and de-energizing the
pressor through the oil fill hole by using a special adapter. power relay, the electric relays, and the heat contactor. The
The oil separator helps provide positive oil return at high thermostat places the unit in cool by energizing the power
compressor speeds and low operating temperatures. This relay and the electric relays.
feature enhances compressor lubrication and extends com- The thermostat places the unit in null by de-energizing all
pressor life. Units built after November 1996 will be located the relays and contactors. The thermostat places the unit in
in the condenser section. Refer to photo on page 12 and heat by energizing the heat contactor.
drawing on page 61.
When the power relay and the electric relays are energized,
they close contacts that energize the fan relay, the motor
UNIT OPERATION
contactor, and the electric standby compressor clutch.
These units shift between cool, null, and heat (optional) to
When the heat contactor is energized, it energizes the elec-
maintain the box temperature at the thermostat setpoint.
tric evaporator heaters and the fan relay.
The operating modes are: cool, null, heat (optional), and
defrost.
Cool
Engine Operation The thermostat shifts the unit to cool at temperatures more
than 5.4 F (3 C) above the thermostat setpoint. The thermo-
The thermostat controls the operation of the unit by energiz-
stat keeps the unit running in cool until the temperature falls
ing and de-energizing the power relay and the heat relay.
to the thermostat setpoint.
The thermostat places the unit in cool by energizing the
power relay. The thermostat places the unit in null by de- During engine operation the engine compressor and the
energizing all the relays. The thermostat places the unit in evaporator fans operate while the unit is in cool. During
heat by energizing the heat relay. electric operation, the electric motor, the electric standby
compressor, and the evaporator fans operate while the unit
When the power relay is energized, power flows to energize
is in cool.
the fan relay and the compressor clutch through normally
closed contacts in ER2.
Null
When the heat relay is energized, it closes contacts that The thermostat shifts the unit from cool to null at the ther-
energize the fan relay, the water pump, and the water valve.
mostat setpoint. The thermostat shifts the unit from null to
When the fan relay is energized, it closes contacts that ener- heat at 3 F (1.7 C) below the thermostat setpoint. The ther-
gize the condenser and evaporator fans. The condenser fan mostat shifts the unit from heat to null at 2.4 F (1.3 C) above
is also controlled by the condenser fan pressure switch. the thermostat setpoint. The thermostat shifts the unit from
This normally open switch monitors the compressor dis- null to cool at 5.4 F (3 C) above the thermostat setpoint.
charge pressure. When the discharge pressure rises to 180 ±
10 psi (1241 ± 69 kPa), the switch closes and energizes the
condenser fan. When the discharge pressure drops to 130 ±
10 psi (896 ± 69 kPa), the switch opens and de-energizes the
condenser fan.
8
Heat (Optional)
The thermostat shifts the unit to heat at temperatures more
than 3 F (1.7 C) below the thermostat setpoint. The thermo-
stat keeps the unit running in heat until the temperature rises
to 2.4 F (1.3 C) above the thermostat setpoint. During
engine operation, the water pump and the evaporator fans
operate while the unit is in heat.
During electric operation, the evaporator heaters and the

evaporator fans operate while the unit is in heat.
Defrost
The defrost cycle can be initiated any time the evaporator
coil temperature is below 42 F (5.6 C). Defrost is initiated
automatically by the defrost timer, or manually by pressing
the Manual Defrost switch. AGA329
Initiating defrost energizes the defrost relay. This energizes

the hot gas solenoid to route hot gas to the evaporator, and 0 Setpoint
de-energizes the fan relay to stop the evaporator and con- 1 Temperature Drop
denser fans. 2 Temperature Rise
The unit runs in defrost until the evaporator coil tempera- 3 Cool
ture rises to 52 F (11.1 C), causing the defrost termination 4 Null
switch to open. This de-energizes the defrost relay and ter- 5 Heat (Optional)
minates defrost. If the defrost termination switch does not
open in less than 45 minutes, the defrost timer will termi- (1) Shifts from Null to Cool if not previously in Heat
nate the defrost cycle 45 minutes after is was started. (2) Shifts from Null to Heat if not previously in Cool
Thermostat Algorithm
UNIT FEATURES
• Digital Thermometer
• Electronic Thermostat
• Defrost Timer
• Hot Gas Defrost
• Defrost Termination Switch
• Liquid Injection System
9
• Manual Defrost Key • Heat, Truck Engine and Electric Standby Heater Strips
(Model 20)
• Suction Pressure Regulator
• Paint, Special Color
• Oil Separator
• 24 V dc Converter
• Six Cylinder Compressor
• R-404A Dealer Installed
• R-134a
Unit Features (continued) SERIAL NUMBER LOCATIONS

• Standby Electric Motor and Six Cylinder Standby Condenser: Roadside.
Compressor (Model 20 only)
Evaporator: Roadside panel.
• Refrigerant Flow Controlled Between Compressors by
Compressor: Nameplate on compressor body.
Discharge Check Valve (Model 20 only)
Standby Motor: Nameplate on motor.
PROTECTION FEATURES
• Control Circuit Fuses
• Refrigerant High Pressure Cutout
• Refrigerant Low Pressure Cutout
• Refrigerant High Pressure Relief Valve
• Power Cord Warning Light (in Cab Control Box)
• Overload Relay Protection for Electric Standby Motor

(Model 20 only)
• Transformer Fuses (Model 20 only)
OPTIONAL FEATURES
• Electric Motors (Model 20 only)
115 Volt/1 Phase/60 Hz
• Heat, Truck Engine (Model 10)
10
AGA339
Vertical Mounted Condenser (Early Model)
AGA673
Vertical Mounted Condenser (Later Model)
11
1 2 3 4 5 6
AEA825
14 13 12 11 10 9
1. High Voltage Box 8. Oil Separator

2. Compressor 9. Liquid Injection Solenoid
3. Hot Gas Solenoid (Behind Fan Blade) 10. Drier
4. Hourmeters Location (Optional) 11. Condenser Coil
5. Low Voltage Box 12. Check Valve Assembly
6. Condenser Fan 13. Motor (Model 20 only)
7. Receiver Tank 14. 24 Volt Converter
Condenser Components—Front/Top View (Starting 1997)
12
1. Expansion Valve 3. Fan Motor

2. Thermostat Sensor 4. Suction Pressure Regulator
Funnel Evaporator
13
1. Thermostat Sensor 4. Expansion Valve

2. Heat Exchanger 5. Evaporator Coil
3. Suction Pressure Regulator
Thin-Line Evaporator
14
AEA667
1. Relays 2. PC Board
Low Voltage Box—Pre-1996
15
2
6
AEA660
1. Transformer 6. Transformer Fuse

2. Motor Start Capacitors 7. Overload Relay
3. Motor Start Relay 8. Motor Contactor
4. DC Power Filter Capacitor 9. Heat Contactor (Optional)
5. Motor Run Capacitor
High Voltage Box—Pre-1997
16
AEA826
5 4 3 2
1. Transformer 6. Transformer Fuse

2. Motor Start Capacitors 7. Overload Relay
3. DC Power Filter Capacitor 8. Motor Contactor
4. Motor Run Capacitor 9. Heat Contactor (Optional)
5. Motor Start Relay
High Voltage Box—Starting 1997
17
2
1
AGA340
1. D.C. Power Filter Capacitor 5. Transformer

2. Motor Starting Capacitor 6. Motor Contactor
3. Motor Start Relay 7. Fuse and Fuseholder
4. Motor Run Capacitor 8. Motor Protector
High Voltage Box - Typical for Single Phase P97
18
AGA345
1. D.C. Power Filter Capacitor 4. Motor Contactor

2. Transformer 5. Fuse and Fuse Holder
3. Overload Relay
High Voltage Box - Typical for 3 Phase P97
19
1 2 3 4 5 6 7
AEA661
14 13 12 11 10 9
1. Power Cord Indicator 8. Thermostat Dial

2. Running Indicator 9. Setpoint Key
3. Defrost Indicator 10. AC Overload Indicator
4. Heat Indicator 11. Digital Display
5. Cool Indicator 12. Manual Defrost Key
6. Celsius Indicator 13. On-Off Key
7. Fahrenheit Indicator 14. On Indicator
Cab Control Box—M10 Pre-1997
20
NOTE: The M13 and M10 cab boxes are identified by the position of the defrost indicator light. On the M13 cab box the
defrost indicator light is positioned on the defrost key. On the M10 cab box the defrost indicator light is positioned left of
the digital display. Refer to the following illustrations. Refer to Service Bulletin 177.
AEA835
1. Defrost Indicator Light
M13 Cab Box—TK No. 45-1780
AEA836
1. Defrost Indicator Light
M10 Cab Box—TK No. 45-1705
21
22
Operating Instructions
UNIT CONTROLS 12. AC OVERLOAD INDICATOR. When this light is on,

it indicates that the overload relay has opened. This
Cab Control Box indicator must be reset by pressing the On-Off Key
1. ON-OFF KEY. Press this key to turn the unit ON and after allowing time for the overload relay to cool.
OFF. 13. SETPOINT KEY. Press this key to make the thermo-
2. ON INDICATOR. When this light is on, it indicates stat setpoint appear on the digital display. The thermo-
that the unit is turned ON. When this light is off, it stat setpoint will remain on the display for 10 to 15
indicates that the unit is turned OFF. seconds after the key is released. This gives the opera-
tor time to adjust the thermostat setpoint.
3. POWER CORD INDICATOR. When this light is on, it
indicates that the unit is connected to an electric 14. THERMOSTAT DIAL. Turn this dial to adjust the
standby power source. thermostat setpoint.
4. RUNNING INDICATOR. When this light is on, it NOTE: The Thermostat Dial will change the thermo-
indicates that the unit is running. stat setpoint without pressing the Setpoint Key.
5. MANUAL DEFROST KEY. Press this key to start a Low Voltage Box
defrost cycle. The unit will not defrost unless the
1. DEFROST TIMER. The defrost timer is built-in to the
defrost termination switch is closed (evaporator coil
PC board. It can automatically initiate or terminate a
temperature below 42 F [5.6 C]).
defrost cycle if necessary. The initiation interval is
6. DEFROST INDICATOR. When this light is on, it indi- adjustable from 1 hour to 10 hours. The termination
cates that the unit is in defrost. interval is set at 45 minutes. Refer to the Electrical
Maintenance section for more information about the
7. DIGITAL DISPLAY. This display is active only when
defrost timer.
the unit is turned on. The thermometer reading (return
air sensor temperature) normally appears on the dis- 2. CONTROL RELAYS. Six control relays are located
play. Pressing the setpoint key causes the thermostat on the PC board. These relays are used to control the
setpoint to appear on the display for 10 to 15 seconds. operation of the unit.
8. HEAT INDICATOR. When this light is on, it indicates 3. ENGINE HOURMETER (Optional). This hourmeter
that the unit is running in heat. records the amount of time the unit runs on engine
operation.
9. COOL INDICATOR. When this light is on, it indicates
that the unit is running in cool. 4. ELECTRIC HOURMETER (Model 20) (Optional).
This hourmeter records the amount of time the unit runs
10. CELSIUS INDICATOR. When this light is on, it indi-
on electric standby operation.
cates that the temperature is being displayed in degrees
Celsius. High Voltage Box (Model 20)
11. FAHRENHEIT INDICATOR. When this light is on, it 1. MOTOR CONTACTOR. The motor contactor is used
indicates that the temperature is being displayed in to control the operation of the electric motor that drives
degrees Fahrenheit. the electric standby compressor.
23
Operating Instructions (Rev 1/99)
2. HEATER CONTACTOR (Optional). The heater con- F2 This 15 amp fuse protects the circuit to the evapo-
tactor is used to control the operation of the optional rator fan motor.
electric evaporator heaters.
F3 This 10 amp fuse protects the circuit to the power
relay and the heat relay.
Other Controls
1. DEFROST TERMINATION SWITCH. This tempera- F4 This 3 amp fuse protects the circuit from the trans-
ture sensitive switch is located on the evaporator coil. former output to the cab control box.
It closes to enable defrost when the evaporator coil F5 Defrost Circuit Fuse. 1 Amp
temperature falls below 42 F (5.6 C).
F6 A 40 amp fuse protects the battery circuit.
The switch opens to terminate, or disable, defrost when
the evaporator coil temperature rises to 52 F (11.1 C). F7 A 10 amp fuse protects transformer motor circuit
for 115V/1 Ph/60 Hz, 230V,1 Ph/60 Hz, and 230V/
2. CONDENSER FAN PRESSURE SWITCH. This pres-
1 Ph/50 Hz. A 4 amp fuse protects the transformer
sure sensitive switch is located on the receiver tank.
motor circuit for 230V and 400V at 3 Ph, 50 units
When the pressure in the receiver tank rises above 180
and 230V, 3 Ph, 60 Hz units.
psi (1241 kPa), the switch closes to energized the con-
denser fan. When the pressure in the receiver tank falls 2. CIRCUIT BREAKER. A 40 amp circuit breaker or 40
below 130 psi (896 kPa), the switch opens to de-ener- amp fuse protects the circuit from the vehicle battery to
gize the condenser fan. the unit.
3. LIQUID INJECTION SWITCH. This temperature sen- 3. HIGH PRESSURE CUTOUT SWITCH. This pressure
sitive switch is located on the discharge fitting of the sensitive switch is located on the receiver tank. If the
truck engine compressor. When the discharge tempera- pressure in the receiver tank rises above 350 psi (2413
ture rises above 230 F (110 C), the switch closes to kPa) for R-134a systems or 470 psi (3241 kPa) for R-
open the liquid injection solenoid. When the discharge 404A systems, the switch opens the circuit to the
temperature falls below 200 F (93 C), the switch opens power relay, which stops the unit.
to close the liquid injection solenoid.
NOTE: This operation is for units with printed circuit
4. SUCTION PRESSURE REGULATOR VALVE. This board manufactured prior to 3-25-96 (see “P.C. Board
valve is located in the suction line in the evaporator. It P/N 41-776 (First Version)” on page 38).
limits the suction pressure at the compressor. The nor-
When the HPCO opens on models using printed ciruit
mal pressure setting for this valve is 18 to 20 psi (124 to
board manufactured between 3-26-96 and 5-21-96,
138 kPa).
see “P.C. Board P/N 41-1619 (Second Version)” on
page 39 or after 5-21-96 (see “P.C. Board P/N 41-
UNIT PROTECTION DEVICES 1812 (Third Version)” on page 40) the HPCO will
1. PC BOARD FUSES. Five fuses are located on the PC cycle the compressor clutch only.
board in the low voltage box. 4. LOW PRESSURE CUTOUT SWITCH. This pressure
F1 This 15 amp fuse protects the circuit to the con- sensitive switch is located on the suction line in the
denser fan motor. evaporator. If the pressure in the suction line falls
24
below 5 to 11 in. Hg of vacuum (-17 to -37 kPa), the inspection is not a substitute for regularly scheduled mainte-
switch opens the circuit to the power relay, which stops nance inspections, it is an important part of the preventive
the unit. maintenance program designed to head off operating prob-
lems before they happen.
NOTE: This operation is for units with printed circuit
board manufactured prior to 3-25-96 (see “P.C. Board 1. LEAKS. Inspect for refrigerant leaks and worn refrig-
P/N 41-776 (First Version)” on page 38). erant lines.
When the LPCO opens on models using printed ciru- 2. BELTS. Inspect for cracks, wear and proper tensions.
cit board manufactured between 3-26-96 and 5-21-96,
3. ELECTRICAL INSPECTION. The electrical connec-
see “P.C. Board P/N 41-1619 (Second Version)” on
tions should be securely fastened. Wires and terminals
page 39 or after 5-21-96 (see “P.C. Board P/N 41-
should be free of corrosion, cracks or moisture.
1812 (Third Version)” on page 40) the HPCO will
cycle the compressor clutch only. 4. DEFROST DRAINS. Check the defrost drain hoses
and fittings to make sure that they are open so conden-
5. FUSE PLUG. The fuse plug is located on the receiver
sate can run out during defrost. Check the bottom end
tank. It opens to relieve the pressure in the refrigera-
of each drain hose to make sure that it is not plugged or
tion system if the pressure becomes excessive. If the
crushed.
fuse plug has opened, it must be replaced. It cannot be
reused. 5. STRUCTURAL INSPECTION. Visually check for
physical damage.
6. OVERLOAD RELAY (Model 20). This auto reset
relay protects the electric motor that drives the electric 6. REFRIGERANT CHARGE. Check the receiver tank
standby compressor. The overload relay opens the cir- sight glass for the proper charge level.
cuit to the cab control box, which de-energizes the
motor contactor and the electric motor if the motor Starting the Unit
overloads for any reason (e.g., low line voltage or
improper power supply) during electric standby opera- Model 10 Units
tion. When the overload relay opens, it illuminates the 1. Start the truck engine.
AC overload indicator.
2. Press the On-Off key in the cab control box to turn the
7. TRANSFORMER FUSE (Model 20). This fuse is unit ON.
located in the high voltage box. The 115 volt, single
phase, 60 Hz unit has a 10 amp fuse. All other units use 3. Adjust the thermostat to the proper setting.
a 4 amp fuse.
Model 20 Units
UNIT OPERATION Engine Operation

1. Start the truck engine.
Bi-monthly Pre-Trip Checks
2. Press the On-Off Key in the cab control box to turn the
The following bi-monthly pre-trip inspection should be
unit ON.
completed before loading the truck. While the bi-monthly
25
3. Adjust the thermostat to the proper setting. 2. PRECOOLING. With the thermostat set at the correct
temperature, allow the unit to run for one-half to one
NOTE: The power cord indicator will come on if the
hour (longer if possible) before loading the truck. Pre-
unit is connected to an electric standby power supply.
cooling will remove residual body heat and moisture
from the box interior and provide a good test of the
Electric Standby Operation
refrigeration system.
1. Connect the electric standby power supply to the unit’s
power receptacle. Make sure that the power supply has 3. DEFROST. When the unit has finished pre-cooling the
the proper voltage and phasing. truck interior (the evaporator temperature has dropped
below 42 F (5.6 C), initiate a defrost cycle with the
2. Press the On-Off Key in the cab control box to turn the Manual Defrost switch. The defrost cycle should end
unit ON. automatically.
3. Adjust the thermostat to the proper setting.
Loading Procedure
NOTE: The power cord indicator will come on while
the unit is connected to an electric standby power 1. Make sure that the unit is OFF before opening the doors
supply. to minimize frost accumulation on the evaporator coil
and heat gain in the truck. (The unit may be running
Adjusting the Thermostat when the truck is being loaded from a warehouse with
door seals.)
The thermometer reading (return air sensor temperature)
normally appears on the digital display while the unit is 2. Spot check and record the load temperature while load-
turned ON. Pressing the Setpoint Key causes the thermostat ing. Especially note any off-temperature product.
setpoint to appear on the display for 10 to 15 seconds. 3. Load the product so there is adequate space for air cir-
1. Press the Setpoint Key to display the setpoint. The set- culation completely around the load. DO NOT block
point will appear on the display for 10 to 15 seconds. the evaporator inlet or outlet.
2. Turn the Thermostat Dial to adjust the setpoint to the 4. Products should be precooled before loading. Thermo
proper setting while the setpoint is being displayed. King units are designed to maintain loads at the temper-
ature at which they are loaded. Transport refrigeration
3. After the thermometer reading appears on the display, units are not designed to pull hot loads down to temper-
press the Setpoint Key to check the setpoint. ature.
NOTE: The Thermostat Dial will change the setpoint
without pressing the Setpoint Key. Do not turn the Post Loading Procedure
Thermostat Dial without checking the setpoint.
1. Make sure that all the doors are closed and locked.
After Start Inspection 2. Adjust the thermostat to the desired temperature set-
point.
1. THERMOSTAT. Adjust the thermostat setting above
and below the box temperature to check the thermostat 3. Start the unit.
operation (see Operating Modes).
26
4. One-half hour after loading, defrost the unit by momen-

tarily pressing the Manual Defrost switch. If the coil
temperature has dropped below 42 F (5.6 C), the unit
will defrost. The defrost cycle should stop automati-
cally.
Bi-monthly Post Trip Checks

1. Wash the unit.
2. Check for leaks.
3. Check for loose or missing hardware.
4. Check for physical damage to the unit.
27
28
Electrical Maintenance
UNIT WIRING 2. Place dip switch 3 in the proper position.

ON for Celsius
Periodically inspect the unit wiring and the wire harnesses
for loose, chafed or broken wires to protect against unit mal- OFF for Fahrenheit
functions due to open or short circuits.
3. Replace the cover.
CAB CONTROL BOX Selecting the Setpoint Range
Selecting the Temperature Scale The setpoint range can be set at either -26 to 86 F (-32 to 30
C) or -8 to 86 F (-22 to 30 C). Dip switches 1 and 2, located
The temperature readings can be displayed in either the Cel- inside the cab control box, are used to select the setpoint
sius scale or the Fahrenheit scale. Dip switch 3, located range. Place dip switches 1 and 2 in the ON position for a
inside the cab control box, is used to select which scale is setpoint range of -26 to 86 F (-32 to 30 C). Place dip
displayed. Indicator lights next to the digital display show switches 1 and 2 in the OFF position for a setpoint range of
which scale has been selected. Place dip switch 3 in the ON -8 to 86 F (-22 to 30 C). To change the setpoint range selec-
position to display temperatures in degrees Celsius. tion:
Place dip switch 3 in the OFF position to display tempera- 1. Remove the cover from the back of the cab control box.
tures in degrees Fahrenheit. To change the temperature
scale selection: 2. Place dip switches 1 and 2 in the proper position.
1. Remove the cover from the back of the cab control box. ON for a setpoint range of -26 to 86 F (-32 to 30 C).
OFF for a setpoint range of -8 to 86 F (-22 to 30 C).
3. Replace the cover.
1. Dip Switches
Back of Cab Control Box with Cover Removed
29
Electrical Maintenance (Rev 1/99)
NOTE: Do not run a R-134a unit to -26 F (-32 C). R-404A 3. Turn the adjusting potentiometer to the 12 o’clock posi-
units may be operated at -24 F (-32 C). tion.
4. Replace the cover and place the cab control box back in
Setpoint Differential Adjustment its bracket.
Adjust the thermostat setpoint differential to 4 F (2 C).
1. Remove the cab control box from its bracket.
2. Remove the cover from the back of the cab control box.
1. 1 Amp Fuse
2. 12/24 Volt Jumper
3. Main Harness Plug
4. Dip Switches
5. Sensor Plug
6. Setpoint Differential Potentiometer Set to 12 o’clock position
Adjust Setpoint Differential
30
Testing the Cab Control Box Initial Digital Display Test
The cab control box contains the thermometer and the ther- 1. Turn the unit ON. Note what appears on the digital dis-
mostat. The thermometer and the thermostat share the same play. This is the temperature display.
digital display and use the same sensor. The thermometer a. Normal Display (-40 to 199 F [-40 to 38 C])
displays the sensor temperature. The thermostat compares
the sensor temperature with the setpoint to determine the b. Blank Display
unit’s operating mode. The sensor is normally located in the c. Erratic Display
evaporator return airflow.
2. Press the Setpoint key and note what appears on the
Thermometer digital display. This is the setpoint display.
The range for the thermometer is -40 to 99 F (-40 to 38 C). a. Normal Display (-26 to 86 F [-32 to 30 C])
Normally the thermometer reading appears on the digital
b. Blank Display
display. Pressing the Setpoint key causes the thermostat
setpoint to appear on the digital display for 10 to 15 c. Erratic Display
seconds.
d. No Change
Thermostat 3. Refer to the Display Diagnosis Chart to see what to
The setpoint range for the thermostat is -26 to 86 F (-32 to check next.
30 C) or -8 to 86 F (-22 to 30 C). The thermostat setpoint
appears on the digital display when the Setpoint key is Check Power—Engine Operation
pressed. Turning the thermostat dial changes the setpoint. 1. Make sure that the condenser cover is on the unit.
The thermostat controls the operation of the unit by control-
ling the power relay, the heat relay, and the electric relays. 2. Remove the cover from the back of the cab control box.
3. Start the truck engine and turn the unit ON.
Display Diagnosis Chart

Setpoint Display
Normal Display Blank Display Erratic Display No Change
No Problem Faulty Cab Faulty Cab Faulty Cab
Normal Display
Temperature Control Box Control Box Control Box
Display Blank Display Check Sensor Check Power Check Power Check Power
Erratic Display Check Sensor Check Power Check Power Check Power
31
Steps 4 and 5 refer to Wiring Diagram 5D44456 and Sche- proper output voltages (X3-X4) and make sure that the
matic Diagram 5D44455. electric standby power supply is turned ON.
4. Check the voltage between the 2R3 circuit (pin 3) and Steps 6 and 7 refer to Wiring Diagram 5D46190 and Sche-
the CH circuit (pin 9) in the connector on the back of matic Diagram 5D46179.
the cab control box. Battery voltage (12 volts).
6. Check the voltage between 2R1 (pin 2) and the CH cir-
5. If battery voltage is not present, check the wiring and cuit (pin 9) in the connector on the back of the cab con-
connectors in the circuit to the vehicle accessory termi- trol box. Transformer output voltage (12 volts) should
nal 2R3 and SW2 on the PC board. Make sure that the be present.
vehicle accessory terminal has power.
7. If voltage is not present, check the wiring, connectors
Steps 6 and 7 refer to Wiring Diagram 5D46190 and Sche- and components to the transformer (L1, L3; 2R2, 2R2;
matic Diagram 5D46179. and F7) fuse. Check the transformer for the proper out-
put voltages (X3-X4) and make sure that the electric
6. Check the voltage between the ACD circuit (pin 3) and
power standby is ON.
the CH circuit (pin 9) in the connector on the back or
the cab control box. Battery voltage (12 volts).
Check Sensor
7. If the battery voltage is not present, check the wiring A good sensor should have a resistance of 805 to 825 ohms
and connectors in the circuit to the vehicle accessory at a temperature of 32 F (0 C). To check a sensor:
terminal, ACD. Make sure that the vehicle accessory
has power. 1. Disconnect the sensor wires form the back of the cab
control box and connect the sensor wires to an accurate
Check Power—Electric Standby Operation ohmmeter.
1. Make sure that the condenser cover is on the unit. 2. Remove the sensor from the evaporator and place the
sensor in an ice water bath at 32 F (0 C). Use a reliable
2. Remove the cover from the back of the cab control box.
thermometer to confirm the temperature of the ice
3. Connect the unit to an appropriate electric standby water bath. Make sure that the sensor is in the ice water
power supply and turn the unit ON. bath long enough (a few minutes) for the temperature to
saturate the sensor.
Steps 4 and 5 refer to Wiring Diagram 5D44456 and Sche-
matic Diagram 5D44455 3. Check the resistance of the sensor. It should be 805 to
825 ohms. If not, check the sensor wires to make sure
4. Check the voltage between the 2R2 circuit (pin 2) and
that they are not damaged. If the sensor wires are not
the CH circuit (pin 9) in the connector on the back of
damaged, the sensor is defective.
the cab control box. Transformer output voltage (12
volts) should be present. 4. If the sensor is not defective, reconnect the sensor wires
to the back of the cab control box and check the ther-
5. If voltage is not present, check the wiring, connectors,
mometer display. If the thermometer display is not nor-
and components in the circuit to the transformer (L1,
mal, attach a new sensor to the cab control box and
L3; 2R2, 2R1; F5 fuse). Check the transformer for the
recheck the thermometer display. If thermometer dis-
play is still not normal, the cab control box is defective.
32
Faulty Cab Control Box 3. Continue to slowly turn the thermostat dial up to raise
the thermostat setpoint about 2 F (1 C) every 5
Before replacing the cab control box make sure that another
seconds. When the thermostat setpoint is approxi-
problem, such as a loose wire connection or a bad ground, is
mately 3.6 F (2 C) above the thermometer reading, the
not causing the cab control box to malfunction.
Heat Indicator and the Running Indicator should both
Thermometer Calibration Test come on, the heat relay should energize, and the unit
should shift to heat.
1. Place the sensor in an ice-water bath for a few minutes
and allow the sensor temperature to stabilize. 4. Slowly turn the thermostat dial down to lower the ther-
mostat setpoint about 2 F (1 C) every 5 seconds. When
2. Check the thermometer reading. It should be 32 ± 2 F
the thermostat setpoint is equal to the thermometer
(0 ± 1 C).
reading, the Heat Indicator and the Running Indicator
3. If the thermometer reading is out of calibration, replace should both go off, the heat relay should de-energize,
the sensor and repeat the test. and the unit should shift to null.
4. If the thermometer reading is still out of calibration, the 5. Continue to slowly turn the thermostat dial down to
cab control box is defective. lower the thermostat setpoint about 2 F (1 C) every 5
seconds. When the thermostat setpoint is approximately
Thermostat Switch Sequence Test 3.6 F (2 C) below the thermometer reading, the Cool
Indicator and the Running Indicator should both come
This test should be performed during scheduled preventive on, the power relay should energize, and the unit should
maintenance operations. Make sure that the thermometer is shift to cool.
calibrated before performing this test.
If the indicator lights do not come on and go off properly,
NOTE: Press the Setpoint key to display the thermostat and if the unit does not shift operating modes properly, the
setpoint. cab control box is probably defective.
Engine Operation Test If the indicator lights come on and go off properly, but the
unit does not shift operating modes properly, make sure that
1. Start the unit on engine operation and set the thermostat
the power relay, the heat relay, the associated wiring and the
at least 6.3 F (3.5 C) below the thermometer reading.
wire connections are not defective before assuming that the
The Cool Indicator and the Running Indicator should
cab control box is defective. Specifically:
be on, the Heat Indicator should be off, the power relay
should be energized, the heat relay should be de-ener- 1. The thermostat energizes the power relay by energizing
gized, and the unit should be running in cool. pin 6 in the connector on the back of the cab control
box.
2. Slowly turn the thermostat dial up to raise the thermo-
stat setpoint about 2 F (1 C) every 5 seconds. When the 2. The thermostat energizes the heat relay by grounding
thermostat setpoint is approximately equal to the ther- pin 10 in the connector on the back of the cab control
mometer reading, the Cool Indicator and the Running box.
Indicator should both go off, the power relay should de-
Therefore, the cab control box is not defective if it energizes
energize, and the unit should shift to null.
pin 6 and grounds pin 10 properly.
33
Electric Standby Operation Test If the indicator lights come on and go off properly, but the
unit does not shift operating modes properly, make sure that
1. Start the unit on standby operation and set the thermo-
the electric relays, the heat contactor, the associated wiring
stat at least 6.3 F (3.5 C) below the thermometer read-
and the wire connections are not defective before assuming
ing. The Cool Indicator and the Running Indicator
that the cab control box is defective. Specifically:
should both be on, the Heat Indicator should be off, the
electric relays should be energized, the heat contactor 1. The thermostat energizes the electric relays by energiz-
should be de-energized, and the unit should be running ing pin 1 in the connector on the back of the cab control
in cool. box.
2. Slowly turn the thermostat dial up to raise the thermo- 2. The thermostat energizes the heat contactor by ground-
stat setpoint about 2 F (1 C) every 5 seconds. When ing pin 10 in the connector on the back of the cab con-
the thermostat setpoint is approximately equal to the trol box.
thermometer reading, the Cool Indicator and the Run-
Therefore, the cab control box is not defective if it energizes
ning Indicator should both go off, the electric relays
the pin 1 and grounds pin 10 properly.
should de-energize, and the unit should shift to null.
3. Continue to slowly turn the thermostat dial up to raise DEFROST SYSTEM

the thermostat setpoint about 2 F (1 C) every 5 sec-
onds. When the thermostat setpoint is approximately
Engine Operation
3.6 F (2 C) above the thermometer reading, the Heat
Indicator and the Running Indicator should both come A defrost cycle can be initiated by pressing the manual
on, the heat contactor should energize, and the unit defrost key or by the defrost timer when the defrost termina-
should shift to heat (optional). tion switch is closed. Starting a defrost cycle energizes the
defrost relay which energizes the hot gas solenoid and de-
4. Slowly turn the thermostat dial down to lower the ther-
energizes the fan relays. Energizing the hot gas solenoid
mostat setpoint about 2 F (1 C) every 5 seconds. When
diverts hot gas into the evaporator coil to melt the frost and
the thermostat setpoint is equal to the thermometer
ice. De-energizing the fan relay stops the evaporator and
reading, the Heat Indicator and the Running Indicator
condenser fans.
should both go off, the heat contactor should de-ener-
gize, and the unit should shift to null. The defrost termination switch de-energizes the defrost
relay when the evaporator temperature rises above 52 F
5. Continue to slowly turn the thermostat dial down to
(11.1 C).
lower the thermostat setpoint about 2 F (1 C) every 5
seconds. When the thermostat setpoint is approximately To check the defrost cycle, run the unit in cool to drop the
3.6 F (2 C) below the thermometer reading, the Cool evaporator coil to a temperature below 42 F (5.6 C). Press
Indictor and the Running Indicator should both come the manual defrost key. The unit should shift from the cool
on, the electric relays should energize, and the unit to defrost. If the unit continues to cool, double check the
should shift to cool. evaporator coil temperature, and refer to Testing the Defrost
System.
If the indicator lights do not come on and go off properly,
and if the unit does not shift operating modes properly, the
cab control box is probably defective.
34
NOTE: It takes more time to complete a defrost cycle in (5.6 C), completing the defrost circuit to ground (CH) and
low ambient temperatures (below 35 F [2 C]) than it does preparing the electrical system for the defrost cycle.
in high ambient temperatures (above 70 F [21 C]). There-
When the unit does shift into a defrost cycle, the evaporator
fore, consider the ambient temperature before deciding
fan stops, and heat from the hot refrigerant gas melts the
that a unit is not defrosting properly.
frost from the evaporator coil. The switch opens and termi-
nates the defrost cycle when the evaporator coil temperature
Electric Standby Operation (Model 20) rises to 52 F (11.1 C).
Defrost operates essentially the same on electric standby as
it does on engine operation. Installation
The proper polarity must be observed when installing the
Defrost Components defrost termination switch. The wire from the switch is neg-
ative and must be attached to the chassis ground of the unit.
Defrost Timer This chassis ground wire cannot be attached to either of the
The defrost timer is built-in to the PC board in the low volt- switch mounting screws or an improper ground may result.
age box. It initiates and, if necessary, terminates the defrost The 12 wire from the unit attaches to the screw terminal that
cycle. is mounted solidly on the switch. If the polarity is reversed
on the device, it will conduct continuously and act like a
The initiation interval for the defrost timer is adjustable. It switch that is stuck closed.
can be set at intervals ranging from 1 hour to 10 hours. The
initiation interval begins when the defrost termination
switch closes. Every time the defrost termination switch
opens, the timer resets to zero.
At the initiation of the defrost cycle, a 45 minute timer is

activated. If the defrost termination switch does not open
and terminate the defrost cycle, the timer will terminate the
defrost cycle 45 minutes after it started.
Manual Defrost Key

A Manual Defrost key is located in the cab control box.
Pressing the Manual Defrost key initiates the defrost cycle
if the defrost termination switch is closed.
Defrost Termination Switch 1. Defrost Termination Switch 3. Screw Terminal

The electronic defrost termination switch uses solid state 2. 12 Wire 4. Ground Wire
components to control the defrost circuit. The switch is Defrost Termination Switch
mounted in the evaporator and controls the defrost cycle in
response to the evaporator coil temperature. The switch is
closed when the evaporator coil temperature is below 42 F
35
Defrost Termination Switch Bench Test V250 Defrost System and P.C. Board
1. Connect a test light between the screw terminal on the Identification and Testing
switch and the positive battery terminal. The V250 defrost system energizes a hot gas defrost sole-
NOTE: Attempting to test the electronic defrost ter- noid valve (HGV) to route hot gas through the evaporator
mination switch with an ohmmeter is generally not coil. This method of defrosting the evaporator coil is used
satisfactory because of the low voltage available at the for over the road operation, and for electric operation on
meter leads. units equipped with electric standby.
2. Connect the ground wire of the switch to the negative The electrical controls in the defrost system consist of the
battery terminal. following items:
3. Raise the temperature of the defrost termination switch 1. The manual defrost switch and defrost LED located in
above 52 F (11.1 C). The light should be off, indicating cab control box.
an open switch. 2. The defrost termination switch (ETS) mounted on the
4. Cool the defrost termination switch below 42 F (5.6 C). evaporator coil.
The light should come on, indicating the switch has 3. The printed circuit (P.C.) board located in the low volt-
closed. age box in the condenser.
NOTE: Allow adequate time for the temperature 4. The associated wiring.
change to saturate the defrost termination switch
before performing the test. Pressing the manual defrost switch in the cab control box
applies 12 volts to the 11 circuit, which is connected to the
Defrost Relay P.C. board in the low voltage box. The defrost LED is ener-
gized through the 11 circuit and grounded through the 12
The defrost relay controls the operation of the defrost cycle.
circuit.
When the defrost timer or the Manual Defrost key com-
pletes the circuit through the defrost termination switch to The defrost termination switch grounds the 12 circuit to a
ground, the defrost relay is energized. This energizes the chassis ground when it closes. The defrost termination
hot gas solenoid and de-energizes the fan relay. The defrost switch closes when the temperature drops below 42 F. It
relay stays energized until the defrost cycle is terminated by opens when the temperature rises above 52 F.
the defrost termination switch or the defrost timer.
The P.C. board contains the following items that are part of
the defrost system:
Hot Gas Solenoid
The hot gas solenoid is a normally closed solenoid valve 1. The defrost relay (DR).
that controls the flow of refrigerant through the refrigeration 2. The defrost relay LED (PL7).
system. The hot gas solenoid opens when it is energized by
the defrost relay. This causes most of the hot gas refrigerant 3. The timing chip for the timed defrost interval (defrost
to bypass the condenser and flow directly to the evaporator, initiation timer).
where it heats the evaporator coil. 4. The adjustable potentiometer (R16/R17) used to adjust
the timed defrost interval.
5. The fast clock jumper (W2) used to speed up the timed

defrost interval for testing.
36
6. The timing chip for the maximum defrost time limit closed. The timer retains the accumulated time when the
(defrost termination timer), which is set at 45 minutes. unit shifts to null or when the unit is turned off. When the
timer accumulates 4 hours, it applies 12 volts to the 11/
7. The fast clock jumper (W1) used to speed up the maxi-
DRF-DR circuit. This energizes the defrost relay to start
mum defrost time limit for testing.
defrost. The timer resets to zero and starts over whenever 12
Manual defrost is selected by pressing the manual defrost volts are present on the 11 circuit. Jumper W2 is used to fast
switch. This applies 12 volts to the 11 circuit, which is con- clock this timer to approximately 1 minute for testing.
nected to the 85 pin of the defrost relay coil. The 86 pin of
the defrost relay coil is connected to the 12A circuit. The P.C. Board Identification
12A circuit is connected to the 12 circuit through the timer
for the maximum defrost time limit. If the 12 circuit is Currently, three different P.C. boards have been used on the
grounded through a closed defrost termination switch, the V250.
defrost relay will energize and pull in. • The first version, P/N 41-776, has four fuses.
When the defrost relay is energized, it closes a set of con- • The second version, P/N 41-1619, has five fuses.
tacts that connect the 8B (power) circuit to the 26 circuit.
This energizes the hot gas valve. When the defrost relay is • The third version, P/N 41-1812, also has five fuses, but
energized, it also opens a set of contacts that connect the 8B uses a different arrangement for jumpers W1 and W2.
(power) circuit to the 26D circuit. This de-energizes the fan The fast clock jumper pins for W1 and W2 are located
relay to stop the condenser and evaporator fans. Once ener- in the same positions, but the standard (parked) posi-
gized, the defrost relay coil is held in by a latching circuit tions for these jumpers are identified as W3 and W4
that consists of a diode (D20) connecting the 26 circuit to and are located below potentiometer R17.
the 11 circuit. A significant electrical change was made between the first
The unit will remain in defrost until one of the following version and second version. Opening the high pressure cut-
events occurs: out (HPCO) or the low pressure cutout (LPCO) de-ener-
gizes the power relay PR on the first version. Opening the
1. The defrost termination switch opens and removes the HPCO or the LPCO de-energizes the circuit to the compres-
ground from the 12 circuit. This de-energizes the sor clutch on the second and third versions.
defrost relay.
A P.C. board is identified by its Service Part Number (P/N
2. The unit is turned off. or SP#), which is located to the left of the potentiometer
3. The 45 minute maximum defrost time limit is reached R16/R17. The P.C. board must be correctly identified to
and the timer opens the connection between the 12 and determine which wiring schematics and diagrams to use
12A circuits. This removes the ground from the 12A when troubleshooting the electrical system.
circuit to de-energize the defrost relay. • For the first version, P/N 41-776, use 5D44455 and
The timer for the maximum defrost time limit controls a 5D44456.
transistor that acts like a set of relay contacts connecting the • For the second version, P/N 41-1619, and the third ver-
12 circuit to the 12A circuit. Jumper W1 is used to fast sion, P/N 41-1812, use 5D46179 and 5D46190.
clock this timer to approximately 1.5 minutes for testing.
NOTE: The nameplate on the cover of the low voltage box
The timed defrost interval timer can be adjusted from 1 to does not necessarily identify the P.C. board correctly. The
10 hours by placing the dial on the potentiometer (R16/R17) P.C. board must be identified by looking at its part number.
in the desired position. The factory setting is 4 hours. The
timer is powered by the 2 circuit, but it does not start to time
until the unit is running and the defrost termination switch is
37
1 2
6
AGA406
1. Defrost Relay 4. Jumper W2 Defrost Initiation Timer

2. Defrost LED PL7 5. Potentiometer R17
3. Jumper W1 Defrost Termination Timer 6. Service Part Number
P.C. Board P/N 41-776 (First Version)
38
1 2
3
4
7
AGA407

3. Jumper W1 Defrost Termination Timer 7. Service Part Number
4. Defrost Fuse F5
P.C. Board P/N 41-1619 (Second Version)
39
1 2
3
4
6
7
8
AGA408

3. Jumper W1 Defrost Termination Timer 7. Standard (Parked) Jumper Position
4. Defrost Fuse F5 8. Service Part Number
P.C. Board P/N 41-1812 (Third Version)
40
Troubleshooting the V250 Defrost System nected and the 11 circuit energized, check the fol-
with P.C. Board P/N 41-776 lowing:
a. Remove the defrost relay from its socket.

Unit will not defrost when the manual defrost
Check for voltage on the 11 circuit at the 85
switch is pressed.
pin of the defrost relay socket while the press-
A. Check the defrost termination switch. ing the manual defrost switch.
1. The defrost termination switch should be closed at b. If no voltage is present on the 11 circuit, go to
temperatures below 42 F. Make sure the evaporator step B.3.
temperature is below 42 F.
c. If voltage is present on the 11 circuit, install a
2. Disconnect the 12 wire from the defrost termina- new relay in the defrost relay socket. Recheck
tion switch and place a jumper between the 12 wire the voltage on the 12 circuit while pressing the
and ground. Press the manual defrost switch. manual defrost switch.
a. If the unit goes into defrost, the defrost termi- If voltage is still not present on the 12 circuit,
nation switch is probably defective and should the P.C. board is probably defective and
be replaced. (NOTE: If this step is being per- should be replaced.
formed as instructed by later steps in this pro-
cedure, the defrost termination switch may not If voltage is now present on the 12 circuit, go
be defective.) to the next step.
b. If the unit does not defrost, go to the next step. 2. If voltage is present between J4-5 (12 circuit) and
J4-2 (CH circuit) with the 12 wire disconnected
3. Check for voltage between J4-5 (12 circuit) and J4- from the defrost termination switch and the 11 cir-
2 (CH circuit) at the P.C. board while pressing the cuit energized, check the following:
manual defrost switch (to energize the 11 circuit).
a. Ground the 12 circuit and press the manual
a. If voltage (approximately 12 volts) is present, defrost switch.
check the 12 wire from the P.C. board to the
defrost termination switch for an open or short b. The unit should go into defrost and the defrost
circuit and repair it. relay LED (PL7) should light. The defrost
relay was defective.
b. If no voltage is present, remove the jumper
from the 12 wire at the defrost termination 3. If no voltage is present on the 11 circuit at the 85
switch and repeat step A.3. If voltage is now pin of the defrost relay socket while pressing the
present, repeat step A.2. If voltage is still not manual defrost switch, check the following: Check
present, go to the next step. for voltage between J1-11 (11 circuit - gray wire)
and a chassis ground (CH circuit) at the P.C. board
B. Check the P.C. Board. while pressing the manual defrost switch.
1. If no voltage is present between J4-5 (12 circuit) a. If voltage is present, the P.C. board is probably
and J4-2 (CH circuit) with the 12 wire discon- defective and should be replaced.
41
b. If no voltage is present, check the wire harness circuits X1 (J5-4) and X4 (J5-1), and the rest of the
from the cab control box to the P.C. board. If electric standby power supply.
the wire harness is not defective, check the cab
4. Check for voltage between pin 8 (11 circuit -gray
control box (step c.).
wire) and pin 9 (CH circuit - black wire) in the
c. Check the cab control box. Before checking connector in the back of the cab control box while
the cab control box, place a good relay in the pressing the manual defrost switch. Voltage should
defrost relay socket and ground the 12 wire at be present and the defrost LED (on the cab control
the defrost termination switch. box) should be lit.
1. Check for continuity to a good chassis ground at a. If no voltage is present, the cab control box is
pin 9 (CH circuit - black wire) in the connector in probably defective and should be replaced.
the back of the cab control box. This is the ground
b. If voltage is present, go to the next step.
circuit for the cab control box. If this circuit does
not have continuity to ground, check the following: 5. Check for voltage between pin 8 (11 circuit -gray
the black (CH) wire in the wire harness to the P.C. wire) and pin 4 (12 circuit - yellow wire) in the
board J1-8, the CH circuit on the P.C. board, and connector in the back of the cab control box while
the other associated CH circuits. pressing the manual defrost switch. Voltage should
be present and the defrost LED should be lit.
2. Check for voltage (approximately 12 volts)
between pin 3 (2R3 circuit - orange wire) and pin 9 a. If voltage is present but the defrost LED is not
(CH circuit - black wire) at the connector in the lit, the cab control box is probably defective
back of the cab control box. The 2R3 circuit is the and should be replaced.
over the road power circuit. If voltage is not
b. If no voltage is present, check the 12 circuit to
present on the 2R3 circuit, check the following: the
make sure it has continuity to ground and
orange (2R3) wire in the wire harness to the P.C.
repeat steps C.4. and C.5.
board J1-3, the 2R3 circuit on the P.C. board, the
ACC circuit on the P.C. board, and the ACC wire
Unit will defrost only when the manual defrost
from the P.C. board J6-1 to the accessory terminal switch is pressed and held in.
in the truck.
Check for voltage (approximately 12 volts) between J3-4
3. (Only for units equipped with electric standby) (26 circuit) and a chassis ground (CH circuit) at the P.C.
Check for voltage (approximately 12 volts) board while pressing the manual defrost switch.
between pin 2 (2R2 circuit - red wire) and pin 9
(CH circuit - black wire) at the connector in the 1. If no voltage is present, replace the defrost relay with a
back of the cab control box. The 2R2 circuit is the new one and recheck the voltage on the 26 circuit while
electric standby power circuit. If voltage is not pressing the manual defrost switch.
present on the 2R2 circuit, check the following: the a. If voltage is now present, the defrost relay was
red (2R2) wire in the wire harness to the P.C. board defective.
J1-4, the 2R2 circuit on the P.C. board, the 2R1 cir-
cuit on the P.C. board, fuse F4 on the P.C. board, b. If voltage is still not present, the P.C. board is prob-
ably defective and should be replaced.
42
2. If voltage is present on the 26 circuit but the unit will b. If the resistance is in this range, the hot gas valve is
not stay (latch) in defrost, diode D20 or its circuit is probably defective and should be replaced.
probably defective. Replace the P.C. board or diode
D20. Unit stays in defrost for only one to two minutes.
Check the position of jumper W1. If it is in the fast clock
Hot gas valve does not energize when unit is in
position (see the appropriate drawing), defrost will termi-
defrost.
nate approximately 1 to 2 minutes after it starts.
Check for voltage (approximately 12 volts) at the 8A - 8B
circuit also, between J3-4 (26 circuit) and J3-2 (CH circuit) Defrost will not terminate on maximum time limit
at the P.C. board while the unit is in defrost. of approximately 45 minutes.
1. If no voltage is present check the F-3 Fuse, replace if Use the following procedure to check the defrost termina-
necessary. tion timer. This procedure assumes the rest of the defrost
system functions properly.
a. If voltage is still not present, replace the defrost
relay with a new one and recheck the voltage on 1. Place jumper W1 in the fast clock position (see the
the 26 circuit while the unit is in defrost. appropriate drawing).
b. If voltage is still not present, replace the power 2. Ground the 12 circuit.
relay. 3. Press the manual defrost switch to initiate defrost.
c. If voltage is now present, the power relay was 4. Defrost should terminate approximately 1 to 2 minutes
defective. after it starts.
d. If voltage is still not present, the P.C. board is prob- 5. If defrost does not terminate on the maximum defrost
ably defective and should be replaced. time limit, the timer is defective. The P.C. board should
be replaced.
2. If voltage is present on the 26 circuit, check the 26 cir-
cuit from the P.C. board to the hot gas valve for an open Defrost will not initiate automatically.
or short circuit.
Use the following procedure to check the defrost initiation
3. If the 26 circuit from the P.C. board to the hot gas valve timer. This procedure assumes the rest of the defrost system
is intact, check the CH circuit from the hot gas valve to functions properly.
the P.C. board for an open or short circuit.
1. Place jumper W2 in the fast clock position (see the
4. If the CH circuit from the hot gas valve to the P.C. appropriate drawing).
board is intact, check the coil on the hot gas valve. To
2. Ground the 12 circuit.
check the coil disconnect it from the 26 and CH circuits
and check its resistance with a good ohmmeter. The hot 3. Defrost should initiate in approximately 1 to 2 minutes.
gas valve coil should have a resistance of 15 to 19
4. If defrost does initiate on the timed defrost interval, the
ohms.
timer is defective. The P.C. board should be replaced.
a. If the resistance is significantly out of this range,
the coil is probably defective and should be
replaced.
43
Troubleshooting the V250 Defrost System B. Check the P.C. Board.

with P.C. Boards P/N 41-1619 and P/N 41- 1. Check defrost fuse F5 (1 amp).
1812
a. If fuse F5 is burnt out, replace it and perform
Unit will not defrost when the manual defrost step A.2.
switch is pressed.
b. If fuse F5 is not burnt out, go to the next step.
A. Check the defrost termination switch.
2. If no voltage is present between P4-5 (12 circuit)
1. The defrost termination switch should be closed at and P4-2 (CH circuit) with the 12 wire discon-
temperatures below 42 F. Make sure the evaporator nected and the 11 circuit energized, check the fol-
temperature is below 42 F. lowing:
2. Disconnect the 12 wire from the defrost termina- a. Remove the defrost relay from its socket.
tion switch and place a jumper between the 12 wire Check for voltage on the 11 circuit at the 85
and ground. Press the manual defrost switch. pin of the defrost relay socket while the press-
a. If the unit goes into defrost, the defrost termi- ing the manual defrost switch.
nation switch is probably defective and should b. If no voltage is present on the 11 circuit, go to
be replaced. (NOTE: If this step is being per- step B.4.
formed as instructed by later steps in this pro-
cedure, the defrost termination switch may not c. If voltage is present on the 11 circuit, install a
be defective.) new relay in the defrost relay socket. Recheck
the voltage on the 12 circuit while pressing the
b. If the unit does not defrost, go to the next step. manual defrost switch.
3. Check for voltage between P4-5 (12 circuit) and If voltage is still not present on the 12 circuit,
P4-2 (CH circuit) at the P.C. board while pressing the P.C. board is probably defective and
the manual defrost switch (to energize the 11 cir- should be replaced.
cuit).
If voltage is now present on the 12 circuit, go
a. If voltage (approximately 12 volts) is present, to the next step.
check the 12 wire from the P.C. board to the
defrost termination switch for an open or short 3. If voltage is present between P4-5 (12 circuit) and
circuit and repair it. P4-2 (CH circuit) with the 12 wire disconnected
from the defrost termination switch and the 11 cir-
b. If no voltage is present, remove the jumper cuit energized, check the following:
from the 12 wire at the defrost termination
switch and repeat step A.3. a. Ground the 12 circuit and press the manual
defrost switch.
If voltage is now present, repeat step A.2.
b. The unit should go into defrost and the defrost
If voltage is still not present, go to the next relay LED (PL7) should light. The defrost
step. relay was defective.
44
4. If no voltage is present on the 11 circuit at the 85 3. Only for units equipped with electric standby)
pin of the defrost relay socket while pressing the Check for voltage (approximately 12 volts)
manual defrost switch, check the following: Check between pin 2 (2R1 circuit - red wire) and pin 9
for voltage between P1-11 (11 circuit - gray wire) (CH circuit - black wire) at the connector in the
and a chassis ground (DRF circuit) at the P.C. back of the cab control box. The 2R1 circuit is the
board while pressing the manual defrost switch. electric standby power circuit. If voltage is not
present on the 2R1 circuit, check the following: the
a. If voltage is present, the P.C. board is probably
red (2R1) wire in the wire harness to the P.C. board
defective and should be replaced.
P1-4, the 2R1 circuit on the P.C. board, fuse F4 on
b. If no voltage is present, check the wire harness the P.C. board, circuits X1 (P5-4) and X2 (P5-5),
from the cab control box to the P.C. board. If and the rest of the electric standby power supply.
the wire harness is not defective, check the cab
4. Check for voltage between pin 8 (DRF circuit -
control box (step C.).
gray wire) and pin 9 (CH circuit - black wire) in
C. Check the cab control box. Before checking the cab the connector in the back of the cab control box
control box, place a good relay in the defrost relay while pressing the manual defrost switch. Voltage
socket and ground the 12 wire at the defrost termination should be present and the defrost LED (on the cab
switch. control box) should be lit.
1. Check for continuity to a good chassis ground at a. If no voltage is present, the cab control box is
pin 9 (CH circuit - black wire) in the connector in probably defective and should be replaced.
the back of the cab control box. This is the ground
b. If voltage is present, go to the next step.
circuit for the cab control box. If this circuit does
not have continuity to ground, check the following: 5. Check for voltage between pin 8 (11 circuit -gray
the black (CH) wire in the wire harness to the P.C. wire) and pin 4 (12 circuit - yellow wire) in the
board P1-8, the CH circuit on the P.C. board, and connector in the back of the cab control box while
the other associated CH circuits. pressing the manual defrost switch. Voltage should
be present and the defrost LED should be lit.
2. Check for voltage (approximately 12 volts)
between pin 3 (ACD circuit - orange wire) and pin a. If voltage is present but the defrost LED is not
9 (CH circuit - black wire) at the connector in the lit, the cab control box is probably defective
back of the cab control box. The ACD circuit is the and should be replaced.
over the road power circuit. If voltage is not
b. If no voltage is present, check the 12 circuit to
present on the ACD circuit, check the following:
make sure it has continuity to ground and
the orange (ACD) wire in the wire harness to the
repeat steps C.4. and C.5.
P.C. board P1-3, the ACD circuit on the P.C. board,
the ACD circuit on the P.C. board, and the ACD
and ACC wires from the P.C. board P6-1 to the
accessory terminal in the truck.
45
Unit will defrost only when the manual defrost 3. If the 26 circuit from the P.C. board to the hot gas valve
switch is pressed and held in. is intact, check the CH circuit from the hot gas valve to
Check for voltage (approximately 12 volts) between P3-4 the P.C. board for an open or short circuit.
(26 circuit) and a chassis ground (CH circuit) at the P.C. 4. If the CH circuit from the hot gas valve to the P.C.
board while pressing the manual defrost switch. board is intact, check the coil on the hot gas valve. To
1. If no voltage is present check the F-3 Fuse, replace if check the coil disconnect it from the 26 and CH circuits
necessary and check its resistance with a good ohmmeter. The hot
gas valve coil should have a resistance of 15 to 19
2. If no voltage is present, replace the defrost relay with a ohms.
new one and recheck the voltage on the 26 circuit while
pressing the manual defrost switch. a. If the resistance is significantly out of this range,
the coil is probably defective and should be
a. If voltage is now present, the defrost relay was replaced.
defective.
b. If the resistance is in this range, the hot gas valve is
b. If voltage is still not present, the P.C. board is prob- probably defective and should be replaced.
Unit stays in defrost for only one to two minutes.
3. If voltage is present on the 26 circuit but the unit will
not stay (latch) in defrost, diode D20 or its circuit is Check the position of jumper W1. If it is in the fast clock
probably defective. Replace the P.C. board or diode position (see the appropriate drawing), defrost will termi-
D20. nate approximately 1 to 2 minutes after it starts.
Hot gas valve does not energize when unit is in Defrost will not terminate on maximum time limit
defrost. of approximately 45 minutes.
Check for voltage (approximately 12 volts) between P3-4 Use the following procedure to check the defrost termina-
(26 circuit) and P3-2 (CH circuit) at the P.C. board while the tion timer. This procedure assumes the rest of the defrost
unit is in defrost. system functions properly.
1. If no voltage is present, replace the defrost relay with a 1. Place jumper W1 in the fast clock position (see the
new one and recheck the voltage on the 26 circuit while appropriate drawing).
the unit is in defrost.
a. If voltage is now present, the defrost relay was
3. Press the manual defrost switch to initiate defrost.
defective.
4. Defrost should terminate approximately 1 to 2 minutes
b. If voltage is still not present, the P.C. board is prob-
after it starts.
5. If defrost does not terminate on the maximum defrost
2. If voltage is present on the 26 circuit, check the 26 cir-
time limit, the timer is defective. The P.C. board should
cuit from the P.C. board to the hot gas valve for an open
be replaced.
or short circuit.
46
Defrost will not initiate automatically. 11. Turn the variable resistance until the cab box shows
“05” degrees.
Use the following procedure to check the defrost initiation
timer. This procedure assumes the rest of the defrost system 12. LEDs PL1, 2, 3, 5, 8, and 11 should light as well as the
functions properly. LED in the cab box display between the digits at the top
of the display and the snowflake LED.
1. Place jumper W2 in the fast clock position (see the
appropriate drawing). 13. Turn variable resistance until the cab box shows “00”
degrees.
14. All LEDs except PL3 should go off.
3. Defrost should initiate in approximately 1 to 2 minutes.
15. Turn the variable resistance until the cab box shows
4. If defrost does initiate on the timed defrost interval, the
“-05” degrees.
timer is defective. The P.C. board should be replaced.
16. LEDs PL1, 2, 3, 5, and 9 should light as well as the
P.C. Board P/N 41-776 Test Procedure LED in the cab box display to the top left of the digits.
1. Connect a 12 volt DC power supply, positive to GS1 17. Jumper on W2 away from J1, and turn R16 fully
stud hole (2 circuit) and negative to GS3 stud hole (CH counter clockwise.
circuit).
2. Connect 12 volt positive to pin 1 of connector J6 (ACC “05” degrees.
circuit).
19. In about 1 minute the circuit should go into the defrost
3. Connect pin 3 and pin 5 of connector J4 together (this mode. In this mode LEDs PL3, 7, 8, and 11 should light
connects 12 to CH). as well as the defrost indicator on Move the jumper on
W1 toward connector J1, the cab box.
4. Connect pin 1 of connector J2 and pin 1 of connector J4
together (this connects 7 to 7B). 20. In another minute and 15 seconds the circuit should
come out of the defrost mode. LEDs PL1, 2, 3, 5, 8, and
5. Plug the cab box into the P.C. board with the cab box
11 should light.
harness.
21. Turn cab box and power supply off.
6. Connect a variable resistance (620 to 1200 ohms) to the
two pin connector on the cab box harness (this simu- 22. Disconnect pin 1 of connector J6 from the positive side
lates the thermostat sensor). of the power supply. Connect pin 4 (or 5) of connector
J5 and stud hole GS2 to positive.
7. Plug in the six relays as specified on the board.
23. Turn power supply and cab box on.
8. Replace any fuses that are missing or blown.
24. With cab box display showing “05” degrees LEDs P11,
9. With the power supply turned on and the cab box
2, 3, 5, 6, 8, and 10 should light as well as the power
turned off, PL3 only should light.
cord indicator on the cab box.
10. Turn cab box on and turn the setpoint to “00” degrees.
25. When circuit goes into the defrost mode LEDs PL3, 6,
7, 8, and 10 should light.
47
26. Turn variable resistance until the cab box shows “00” 7. Plug in the six relays as specified on the board.
degrees.
8. Replace any fuses that are missing or blown.
27. LEDs PL3 and 6 should light.
9. With the power supply turned on and the cab box
28. Turn the variable resistance until the cab box shows turned off, PL3 only should light.
“-05” degrees.
10. Turn cab box on and turn the setpoint to “00” degrees.
29. LEDs PL3, 4, and 6 should light as well as the top left
LED in the cab box display.
“05” degrees.
30. Turn off the cab box and power supply. Move jumpers
12. LEDs PL1, 2, 3, 5, 8, and 11 should light as well as the
on W1 and W2 to the opposite positions. Turn R16 to
LED in the cab box display between the digits at the top
position #3.
of the display and the snowflake LED.
This test will checkout most circuits on the board. It will not
13. Turn variable resistance until the cab box shows “00”
test a circuit that may be broken or burned out between the
degrees.
relays and all the connector pins that were not connected to
in this test. To test these, a volt meter or external lights 14. All LEDs except PL3 should go off.
would have to be connected to each pin and observed for the
proper results.
“-05” degrees.
P.C. Board P/N 41-1812 and P/N 41-1619 16. LEDs PL1, 2, 3, 5, and 9 should light as well as the
LED in the cab box display to the top left of the digits.
Test Procedure
17. Move the jumpers from W3 and W4 to W1 and W2
1. Connect a 12 volt DC power supply, positive to GS1 positions and turn R17 fully counter clockwise.
stud hole (2 circuit) and negative to GS3 stud hole (CH
circuit).
“05” degrees.
2. Connect 12 volt positive to pin 1 of connector P6 (ACD
19. In about 1 minute the circuit should go into the defrost
circuit).
mode. In this mode LEDs PL3, 7, 8, and 11 should light
3. Connect pin 3 and pin 5 of connector P4 together (this as well as the defrost indicator on the cab box.
connects 12 to CH).
20. In another minute and 15 seconds the circuit should
4. Connect pin 1 of connector P2 and pin 1 of connector come out of the defrost mode. LEDs PL1, 2, 3, 5, 8, and
P4 together (this connects 8B to 8HA). 11 should light.
5. Plug the cab box into the P.C. board with the cab box 21. Turn cab box and power supply off.
harness.
22. Disconnect pin 1 of connector P6 from the positive side
6. Connect a variable resistance (620 to 1200 ohms) to the of the power supply. Connect pin 4 (or 5) of connector
two pin connector on the cab box harness (this simu- P5 and stud hole GS2 to positive.
lates the thermostat sensor).
23. Turn power supply and cab box on.
48
24. With cab box display showing “05” degrees LEDs P11, 6. With all switches off, apply power to the circuit.
2, 3, 5, 6, 8, and 10 should light as well as the power
7. With the cab box On/Off switch off, no lights should
cord indicator on the cab box.
come on.
25. When circuit goes into the defrost mode LEDs PL3, 6,
8. Turn on the cab box On/Off switch. The temperature
7, 8, and 10 should light.
display should come on.
26. Turn variable resistance until the cab box shows “00”
9. Press the setpoint key once and adjust the setpoint to
degrees.
“00” degrees.
27. LEDs PL3 and 6 should light.
10. Turn the variable resistance so that temperature read
28. Turn the variable resistance until the cab box shows “- out is “00” degrees.
05” degrees.
11. Only the display, the C or F LED, and the LED in the
29. LEDs PL3, 4, and 6 should light as well as the top left ON/OFF switch should be on at this time.
LED in the cab box display.
12. Close switch S1 to pin 2. The power cord LED should
30. Turn off the cab box and power supply. Move jumpers come on and PL1 connected to pin 1.
from W1 and W2 to W3 and W4. Turn R17 to position
13. Turn variable resistance to indicate 5 degrees on dis-
#3.
play.
This test will checkout most circuits on the board. It will not
14. PL2 connected to pin 6 and the LED at the top of the
test a circuit that may be broken or burned out between the
display between the digits on the cab box should come
relays and all the connector pins that were not connected to
on.
in this test. To test these, a volt meter or external lights
would have to be connected to each pin and observed for the 15. Close switch S4 to pin 7. The snowflake LED on the
proper results. cab box should come on.
16. Close switch S2 to pin 4 and switch S4 to pin 7.

M10 (V250/V-090) Cab Control Box Test
Procedure 17. Press the defrost key on the cab box. PL3 connected to
pin 8 and the defrost LED on the cab box should come
1. Connect +12 Vdc Power to pin 3 and negative ground on but only while this key is being held.
to pin 9.
18. Turn the variable resistance to indicate -5 degrees on
2. Connect light bulbs or LEDs between ground and pins the display and open switch S4 to pin 7.
1, 6, and 8.
19. PL2 should go off and PL4 connected to pin 10 should
3. Connect a light bulb or LED between +12 Vdc and pin come on. The snowflake LED and the LED at the top of
10. display between the digits should go off, and the LED
4. Connect switches between +12 Vdc and pins 2, 4, 5, at the top of the display to the left of the digits should
and 7. come on.
5. Connect a variable resistance (620 to 1120 ohms) to the 20. Close switch S3 to pin 5. This should cause the cab box
2 pin sensor connector. to shut off and the alarm symbol LED to come on.
49
AGA409
M10 Cab Control Box Test Circuit
50
CONDENSER FAN PRESSURE SWITCH AC COMPONENTS (Model 20)

(CFPS)
CAUTION: The unit uses high voltage alternating
The CFPS is located in the discharge line. Electrically it is current (ac) during electric operation. Lethal volt-
located between F1 and the condenser fan motor. It closes to age potentials can exist on connections in the high voltage
energize the condenser fan when the heat pressure rises to box. Take appropriate precautions and use extreme care
180 ± 10 psi (1241 ± 69 kPa). It opens to de-energize the when testing the unit.
condenser fan when the head pressure drops to 130 ± 10 psi
(896 ± 69 kPa). To check the CFPS: Contactors
1. Install a manifold gauge set. Test the contact points of the contactor by checking the volt-
age drop across each set of points when the contactor is
2. Connect a voltmeter between F3 and the condenser fan
energized and the system is operating. If the voltage drop
where the CFPS wires are connected to the main wire
across a set of points is more than 15 volts ac, replace the
harness.
contactor.
3. Run the unit on cool, check the voltmeter reading, and
Test the contactor coil by checking the voltage across the
watch the condenser fan.
coil. The contactor coil should be energized by a minimum
a. When the head pressure is below 180 ± 10 psi of 10 volts dc.
(1241 ± 69 kPa), the CFPS should be open, the
voltmeter should indicate battery voltage, and the Overload Relay
condenser fan should not be running.
The overload relay should open if the motor circuit current
If the voltage is low and the condenser fan is run- draw is more than overload relay setting listed in the Speci-
ning, the CFPS is defective. fications chapter.
If the voltage is low and the condenser fan is not
running, check the power circuit back through the ELECTRIC STANDBY CIRCUITS
fan relay to the battery. Also check the ground cir- (Model 20 Only)
cuit (CH) back to the battery.
Make sure the unit is connected to the proper power source.
b. When the head pressure rises above 180 ± 10 psi The current draw through the compressor motor should not
(1241 ± 69 kPa), the CFPS should close, the volt- exceed the full load current listed in the Specifications.
meter should indicate no voltage, and the con-
The dc current draw through the 2 wire should not exceed
denser fan should be running.
30 amps in 12 volt systems and 20 amps in 24 volt systems.
c. When the head pressure drops below 130 ± 10 psi
If the DC current is excessive, check the current draw
(896 ± 69 kPa), the CFPS should open, the voltme-
through each fan motor. The current draw through an indi-
ter should indicate battery voltage, and the con-
vidual fan motor should not exceed the full load current
denser fan should not be running.
listed in the Specifications.
If the CFPS does not open or close at the proper
If the fan motor currents are satisfactory, check the control
pressures, it is defective and must be replaced. relays and switches for shorts.
51
When the unit is inoperative, follow a systematic checking

sequence. This will save time and eliminate guesswork.
Check the power cable receptacle for power. If power is

present, check for power at the unit terminal board.
Check for control circuit power at the circuit breaker. If the

contactor is pulled down but the compressor motor fails to
start, the trouble is probably in the compressor motor
assembly.
12 Volt System
The dc voltage should be 12.5 to 13 volts and the current
through the 2R wire should be less than 25 amps. If the cur-
rent is less than 25 amps and the voltage is less than 12
volts:
1. Check the ac line voltage the transformer fuse. The line

voltage must be at least 90% of the voltage specified
for the unit. if the ac line voltage is acceptable and the
transformer fuse is intact, go to step 2.
2. Measure the transformer output voltage (ac) at the rec-

tifier between wires X1 and X4. If the transformer out-
put voltage is between 12 to 13 volts ac no load, it is ok.
If the transformer output voltage is acceptable, go to
step 3.
3. Check the rectifier output voltage (dc) on the 2R wires

at the terminal board.
If the rectifier output voltage is less than 13 Vdc and

the load is not excessive (not more than 25 amps), the
rectifier is defective.
EVAPORATOR HEATERS (Optional)

Test the resistance of each evaporator heater by disconnect-
ing it from the circuit and checking it with an ohmmeter.
The resistance of each heater should be approximately 70
ohms.
52
Refrigeration Maintenance
NOTE: The following procedures involve servicing the refrigeration system. Some of these service procedures are regu-
lated by Federal, and in some cases, by State and Local laws.
All regulated refrigeration service procedures must be performed by an EPA certified technician, using approved equip-
ment and complying with all Federal, State and Local laws.
REFRIGERANT CHARGE
Charging the Refrigeration System

The receiver tank sight glass allows the operator to deter-
mine the amount of charge under established operating con-
ditions. These units can be damaged by an over-charge of
refrigerant. The amount of refrigerant the system can hold
depends on circuit volume which is affected by hose length.
The most satisfactory method of charging the engine-driven
compressor circuit and the electric standby driven compres-
sor circuit is:
1. Connect a gauge manifold to the engine-driven com-

pressor and receiver tank.
2. Connect the center hose of the gauge manifold to the

manifold of an evacuation station.
3. Connect the hose from a drum of refrigerant to the

manifold of the evacuation station. Make sure the
valve on the refrigerant drum is closed.
Evacuate System
4. Open the valves on the gauge manifold and the valves
6. After the additional hour of evacuation, close the valve
on the evacuation station.
at the evacuation pump, stop the vacuum pump, and
5. Start the vacuum pump and evacuate the system to 500 observe the reading on the vacuum gauge for 5 min-
microns. After the system reaches 500 microns, evacu- utes. The pressure should not exceed 2000 microns.
ate the system for an additional hour.
NOTE: If it does, repeat steps 4 and 5. This time if
NOTE: If the system will not come down to 500 the pressure exceeds 2000 microns within 5 minutes,
microns, there is probably a leak in the system or in look for a leak in the system or in the evacuation and
the evacuation and charging equipment hoses. Find charging equipment hoses. Find and repair the leak.
and repair the leak.
7. Open the vacuum valve at the vacuum pump, start the
vacuum pump, and evacuate the system to 500 microns.
8. When the system reaches 500 microns, close the vac-

uum valve at the evacuation station manifold. The sys-
tem is now ready to charge.
53
Refrigeration Maintenance (Rev 1/99)
9. Close the low side valve on the gauge manifold, leave 13. With these conditions established, open the low side
the high side valve on the gauge manifold open, and valve on the gauge manifold and open the valve on the
open the valve on the refrigerant drum to deliver liquid. refrigerant drum to deliver liquid.
10. Allow 5 lb (2.3 kg) of refrigerant to enter the system.

Then close the valve on the refrigerant drum and the
high side valve on the gauge manifold.
Finish Charging With Liquid
14. Observe the receiver tank sight glass. When the ball in
Add Liquid Refrigerant the receiver tank sight glass reaches the top of the sight
glass, close the valve on the refrigerant drum.
11. Start the unit on engine operation, set the thermostat at
0 F (-20 C), and run the unit in cool until the box tem- 15. Close the low side valve on the gauge manifold and
perature approaches 0 F (-20 C). operate the unit for 15 minutes.
12. Make sure that the unit is running in cool, the compres- 16. Model 20 only.
sor is running at approximately 1000 rpm, the suction
a. Turn the unit OFF and shut off the truck engine.
pressure is 2 to 8 psi (14 to 55 kPa), and the head pres-
sure is at least 180 psi (1241 kPa) for R-134a systems b. Connect the electric power receptacle to an appro-
and 275 psi (1896 kPa) for R-404A. If necessary, raise priate electric power supply. Start and run the unit
the head pressure by covering the condenser. in cool on electric operation for a minimum of 15
minutes.
54
18. Stop the unit, shut OFF the truck engine and remove the
gauge manifold set.
19. The above conditions MUST be established each time

the refrigerant level is checked or if refrigerant needs to
be added for any reason.
NOTE: To prevent oil migration from one compressor to

another, and for proper oil return when a compressor is
operating, operate a compressor for a minimum of 15 min-
utes. Do not operate the compressor for shorter intervals.
Checking the Refrigerant Charge

If the unit has an insufficient charge of refrigerant, the evap-
orator 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 may be determined by inspec-
tion of the refrigerant through the receiver tank sight glass
with the following conditions established:
Testing the Refrigerant Charge with an Empty Box

Run On Electric Operation 1. Place a test box over the evaporator.
c. Turn the unit OFF and disconnect the electric
2. Install a gauge manifold set.
power supply. Start the truck and run the unit in
cool on engine operation for a minimum of 15 3. Run the unit in cool on engine operation until the ther-
minutes. mometer reads 0 F (-18 C). By allowing the box to leak
a small amount, you will be able to maintain 0 F (-18 C).
17. Check the receiver tank sight glass with the unit running
in cool, the box temperature at 0 F (-20 C), and a head 4. The discharge or head pressure gauge should be at least
pressure of at least 180 psi (1241 kPa) for R-134a sys- 180 psi (1241 kPa) on the gauge manifold for R-134a
tems and 275 psi (1896 kPa) for R-404A systems. The systems and 275 psi (1896 kPa) for R-404A systems.
ball should be at the top of the sight glass. If the pressure is below this, it can be raised by cover-
If not, open the valve on the refrigerant drum to deliv- ing a portion of the condenser grille with a piece of
ery liquid and open the low side valve on the gauge cardboard.
manifold. Add refrigerant liquid until the ball in the
5. Under these conditions the ball should be at the top of
receiver tank sight glass reaches the top of the sight
the sight glass to indicate a full charge.
glass, then close the valve on the refrigerant drum and
close the low side valve on the gauge manifold.
55
Testing the Refrigerant Charge with a Loaded Box 4. Operate at a low speed (600 to 800 rpm) for 2 hours, or
until the compressor oil level reaches a minimum
1. Install a gauge manifold.
allowable level, whichever occurs first. Drain the col-
2. Run the unit in cool on engine operation. lected oil from the oil separator as it fills, taking care to
not allow any collected oil to recirculate.
3. Cover the condenser to drive any excess refrigerant
from the condenser into the receiver tank. 5. Prepare the original compressor that was removed from
the unit (or a replacement) by draining out any existing
4. As the head pressure rises, check the receiver tank sight
oil and replacing the oil with the amount of oil shown
glass. If there is no indication of refrigerant in the
in the Specifications chapter.
receiver tank sight glass, indicated by the float ball
being down in the bottom sight glass, the unit contains 6. Install the original compressor (or its replacement), and
less than a full charge and more refrigerant MUST be proceed with the manual evacuation and refrigerant
added. Refer to Charging the Refrigeration System to charging procedure. Charge to normal amount of refrig-
add refrigerant. erant 5 lb (2.3 kg).
CHECKING COMPRESSOR OIL CHARGE HIGH PRESSURE CUTOUT SWITCH

The compressors are furnished with the amount of oil (HPCO)
shown in the Specifications chapter. The oil level in the The HPCO is located on the receiver tank. If the discharge
compressor will change after the compressor is initially run, pressure rises above 350 psi (2413 kPa) for R-134a systems
making any level measurements inaccurate. or 470 psi (3241kPa) for R-404A systems, the HPCO de-
To ensure an adequate oil supply, the following procedure energizes the power relay.
must be followed whenever the refrigerant charge is lost or NOTE: This operation is for units with printed circuit
removed from a unit: board manufactured prior to 3-25-96 (see “P.C. Board P/N
1. Install a compressor on the system having a residual oil 41-776 (First Version)” on page 38).
supply and self-lubricating system such as a TK 214 When the HPCO opens on models using printed circuit
model. Connect an oil separator on the discharge or board manufactured between 3-26-96 and 5-21-96, see
suction line to collect and drain out circulated oil. “P.C. Board P/N 41-1619 (Second Version)” on page 39 or
NOTE: A suction line oil separator can be improvised after 5-21-96 (see “P.C. Board P/N 41-1812 (Third Ver-
by installing a suction filter upside down in the suc- sion)” on page 40) the HPCO will cycle the compressor
tion line near the compressor. Cap off both access clutch only.
ports, and use the lower one to drain off the accumu- To test the HPCO, rework a gauge manifold per the High
lated oil. Pressure Cutout Manifold illustration.
2. Place a normal amount of oil in the cleanup compressor
before operating.
3. Charge with 6.0 to 7.0 lb (2.7 to 3.2 kg) of refrigerant.
56
4. Failure of the high pressure cutout system to stop com-

pressor operation should be investigated first by check-
ing the control circuit operation and second by
replacing the HPCO.
LOW PRESSURE CUTOUT SWITCH

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

of vacuum (-17 to -37 kPa), the LPCO should open and
the unit should stop.
1. Relief Valve (66-7392) NOTE: This operation is for units with printed circuit
board manufactured prior to 3-25-96 (see “P.C. Board P/N
2. O-Ring (33-1015)
41-776 (First Version)” on page 38).
3. Adapter Tee Weather Head (No. 552X3)
When the LPCO opens on models using printed circuit
High Pressure Cutout Manifold
board manufactured between 3-26-96 and 5-21-96, see
1. Connect the gauge manifold to the compressor dis- “P.C. Board P/N 41-1619 (Second Version)” on page 39 or
charge service valve. after 5-21-96 (see “P.C. Board P/N 41-1812 (Third Ver-
sion)” on page 40) and the LPCO will cycle the compres-
NOTE: Service manifold hoses must have Schrader
sor clutch only.
valve (tire valve) depressors.
2. Set the thermostat well below the box temperature so

that the unit will be in cool.
3. Raise the discharge pressure of the compressor first by

blocking the condenser coil air flow.
NOTE: The discharge pressure should never be

allowed to exceed a pressure of 400 psi (2758 kPa)
when using R-134a and 475 psi when using R-404A.
57
CLEANUP PROCEDURE FOR SMALL Tools Required:

TRUCK UNITS • Motor-driven TK 214 “Flushing Compressor”
• Suction Line Filter (P/N 204-498 with Filter P/N 66-

2988)
• Pipes (In Place of Oil Separator, Check Valve, Oil Sep-

arator 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 contaminated refrigerant from system.
4. Remove lines from compressors roadside and standby).
5. Flush each compressor using the flushing compressor

and an HFC refrigerant. (Always recover the refrigerant
before disconnecting flushing compressor.)
6. Remove check valve (or check valve seats) from sys-

tem to ensure flow in all directions.
7. Remove oil separator and install a connecting pipe.

1. Remove Internal Parts From Expansion
Valve 8. Remove internals from expansion valve.
2. Disconnect and Cap (If So Equipped)
9. Open suction pressure regulator (CPR) valve to highest
3. Replace Drier With Tube setting.
4. Discharge Line
10. Install temporary suction line filter (P/N 204-498 and
5. Flushing Compressor
P/N 66-2988) in suction line.
6. Suction Line
7. Suction Oil 11. Install connecting pipe in place of standby compressor.
8. Recovered Oil 12. Connect flushing system to roadside discharge and

suction line (see illustration).
Connecting Flushing Compressor to Unit
NOTE: If a Van Steenburgh reclaimer is available, do not 13. Evacuate the system and check for leaks. Continue to
evacuate to remove moisture and air.
use this procedure. Follow procedure described in Service
Bulletin T&T 134. 14. Install HFC refrigerant and flush the system. (Energize
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
58
will drain out of the suction line filter. (Add compressor

oil as required.) Refrigerant oil in the flushing com-
pressor will absorb acids from the system.
15. Test compressor oil for acid contamination.
16. Continue flushing until compressor oil is clean.
Putting the Unit Back Into Operation

1. Replace check valve (or check valve seats).
2. Install new oil separator.
3. Install new liquid injection orifice.
4. Install new drier.
5. Install new expansion valve.
6. Install compressors and lines.
7. Use dry nitrogen to pressurize system to 150 psi

(1034 kPa).
8. Use bubble solution to check for leaks.
9. Install correct amount of oil.
10. If no leaks, evacuate unit. A leak-free and dry unit will

maintain a 1000 micron vacuum for five minutes or
longer.
11. Charge unit with proper amount of the correct refriger-

ant.
12. Operate and check for proper operation. (Adjust suction

pressure regulator.)
13. After two weeks of operation, change the drier.
59
60
Refrigeration Service Operations
NOTE: 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.
COMPRESSOR 2. Loosen the drive belt adjuster and remove the compres-
sor drive belt.
Removal
3. Disconnect the discharge, suction and liquid injection
1. Remove the refrigerant charge from the system. hoses.
1. Electric Standby Compressor (Model 20 Only) 7. Condenser Pressure Switch

2. Hot Gas Solenoid 8. Liquid Injection Solenoid
3. Drier 9. Oil Separator
4. Fuse Plug and Oil Fill Hole 10. Condenser Coil
5. Receiver Tank 11. Check Valve Assembly (Model 20 Only)
6. High Pressure Cutout Switch
Condenser Components
61
Refrigeration Service Operations (Rev 1/99)
4. Keep the compressor ports and the suction and dis- Installation
charge lines for the compressor covered to prevent con-
1. Clean the tubes for soldering.
tamination of system components.
2. Place the coil in the unit and install the mounting hard-
5. Remove the compressor mounting screws. Remove the
ware.
compressor.
3. Solder the inlet and liquid line connections.
Installation
4. Pressurize the system and test for leaks.
NOTE: Any compressor installed in this system must
5. Evacuate the system.
contain the proper amount of compressor oil (see the
Specifications section). Always check to make sure that 6. Recharge the unit.
the compressor contains the proper amount of oil. Follow
7. Reinstall the cover.
the system cleanup procedures to remove old oil from the
system.
DRIER
1. Place the compressor in position and install the mount-
ing screws and the belt. Removal
2. Use belt tension tool P/N 204-427 to adjust belt ten- 1. Pump down the refrigeration system and equalize the
sion. The engine/compressor belt tension should be pressure to slightly positive.
adjusted to 58 on the gauge; the electric motor/com-
2. Disconnect the ORS nuts at the ends of the drier.
pressor belt should be adjusted to 57.
3. Loosen the mounting hardware and remove the drier.
3. Connect the refrigeration hoses. Pour 2 oz (59 ml) of
compressor oil into the suction hose before installation.
Installation
4. Pressurize the system and test for leaks. 1. Place new O-rings in the ORS fittings on the ends of
5. Evacuate the system and recharge. the drier.
2. Install the new drier and tighten the mounting screws

CONDENSER COIL and nuts.
Removal 3. Install and tighten the inlet ORS nut. Hold the drier
with a back-up wrench on the hex behind the ORS fit-
1. Remove the refrigerant charge.
ting.
2. Remove the condenser cover.
4. Release a small amount of refrigerant to purge the air
3. Unsolder the inlet and liquid lines. through the drier, and then tighten the outlet ORS nut.
4. Remove the mounting hardware. 5. Pressurize the system and inspect for leaks. If no leaks
are found, open the refrigeration valves and place the
5. Remove the condenser coil.
unit in operation.
62
RECEIVER TANK Removal

Removal
2. Remove the coil and disassemble the valve.
3. Unsolder the hot gas lines from the valve, and remove
2. Disconnect the refrigerant lines from the receiver tank.
the valve from the unit.
3. Remove the mounting clamp.
CAUTION: Use a heat sink to prevent
4. Remove the receiver tank. damaging the valve.
Installation Installation
1. Position the receiver tank in the unit and install the 1. Clean the tubes for soldering.
mounting clamp.
2. Remove the coil, disassemble the valve, and place the
2. Connect the refrigerant lines to the receiver tank. valve in position.
3. Pressurize the refrigeration system and check for leaks. 3. Solder the inlet and outlet connections. After the valve
cools, assemble the valve and install the coil.
4. If no leaks are found, evacuate the system.
CAUTION: Use a heat sink to prevent
5. Recharge the unit.
damaging the valve.
HIGH PRESSURE CUTOUT AND 4. Pressurize the refrigeration system and test for leaks.
CONDENSER FAN PRESSURE SWITCHES 5. If no leaks are found, evacuate the system.
Removal 6. Recharge the unit with the proper refrigerant.

LIQUID INJECTION SOLENOID VALVE
2. Disconnect the wires and remove the switch.
Removal
Installation
1. Pump down the low side and equalize the pressure to
1. Apply a refrigerant locktite to the threads of the switch. slightly positive.
2. Install and tighten the switch and reconnect the wires. 2. Remove the coil from the solenoid valve.
3. Pressurize the refrigeration system and test for leaks. 3. Remove the solenoid valve from the receiver tank.
4. If no leaks are found, charge the system.
Installation
HOT GAS SOLENOID VALVE 1. Remove the coil from the solenoid valve.
NOTE: Valves that have nylon seats must be disassembled 2. Install the solenoid valve on the receiver tank.
before soldering. 3. Connect the refrigerant line to the solenoid valve.
63
4. Install the coil on the solenoid valve and connect the 6. Recharge the unit.
wires.
5. Open the refrigeration valves.
OIL SEPARATOR
Removal
2. Disconnect the ORS nuts at the end of the oil separator.
3. Loosen the mounting hardware and remove the oil sep-

arator.
Installation
1. Soak new o-rings in refrigerant oil (same type that is
1. 1/4 Flare (w/Permanent Depressor)
used in the system) and place the new rings in the ORS
2. 1/4 Flare SAE 45° Flare (TYP)
fittings on the ends of the oil separator.
NOTE: Used when oil separator is routed to evapora-
2. Install and tighten the inlet and outlet ORS nut.
tor section for testing. Use as a tool only. do not leave
3. Hold the oil separator with a backup wrench on the hex in unit.
behind the ORS fitting.
Tee-Fitting for V250 Suction Line Access
4. Pressurize the refrigerant system and check for leaks.
5. If no leaks are found, evacuate the system. LIQUID INJECTION METERING ORIFICE
Removal
slightly positive.
2. Disconnect the refrigeration hose from the metering

orifice and remove the metering orifice from the suc-
tion hose fitting.
NOTE: Take caution to avoid the danger of liquid

refrigerant escaping when the line is disconnected.
64
NOTE: This orifice may become plugged with dirt 3. Set the thermostat on the lowest setting.
unless the refrigeration hose and solenoid valve are
4. Start the truck and run the unit on the engine-driven
kept clean.
compressor until the suction pressure stabilizes.
5. Place a jumper wire between CH and the LIS terminal

on the liquid injection solenoid.
6. With the jumper wire in place the suction pressure

should rise.
7. With the jumper wire removed the suction pressure

should return to the stabilized pressure in step 4.
8. If the suction pressure does not change, check the CLU

wire for voltage, the liquid injection solenoid valve, or
the metering orifice.
9. Shut off the unit and the truck, remove the gauge mani-
fold set and replace the LIS wire.
CHECK VALVE REPAIR (Model 20 Only)
Testing the Check Valve

1. Liquid Injection Metering Orifice The check valve is a very important part of the Model 20
Engine Compressor system. The check valve isolates the engine-driven com-
pressor from the electric standby compressor, ensuring the
Installation compressor oil and refrigerant do not migrate between com-
pressors. The check valve should be tested when the system
1. Install the metering orifice on the suction hose fitting.
is initially charged and operating and anytime the system
2. Connect the refrigeration hose to the metering orifice has been opened for service or repair. Testing the check
fitting. valve requires two gauge manifold sets.
3. Open the refrigeration valves. 1. Disconnect the liquid injection solenoid valve wires.
Testing the Liquid Injection Solenoid

Valve and Metering Orifice
1. Disconnect the LIS wire from the liquid injection sole-
noid.
2. Install a gauge manifold set on the engine-driven com-

pressor.
65
1. Cap Nut 5. Piston Seat

2. Sealing Washer 6. Washer
3. Spring 7. Screw
4. Piston 8. Valve Body
Check Valve Assembly
NOTE: Illustration only, no service parts available.
66
2. With the unit off, install a gauge manifold set on each and low sides were equalized. If the high side pressure
compressor. is increasing or has increased noticeably, the discharge
check valve is leaking internally. Stop the unit.
3. Observe the gauge manifold readings of the electric
standby compressor. If the high side and low side read- 12. Remove the gauge manifold sets and the electric
ings are not the same, open the gauge manifold valves standby power source. Connect the wires to the liquid
and equalize the pressures. Close the gauge manifold injection solenoid valve.
valves.
If the check valve is leaking internally, refer to the
4. Adjust the thermostat so the unit will run in cool. Start repair procedures.
the truck and run the unit with the engine-driven com-
pressor. Check Valve Repair
5. Observe the gauge manifold readings of the engine- Disassembly

driven compressor. The head pressure should increase
and the suction pressure should decrease.
2. Loosen the cap nut and remove the cap nut, sealing
6. Observe the gauge manifold readings of the electric
washer, spring, and piston assembly.
standby compressor. The high side pressure should
remain the same as the pressure in step 3 after the high 3. Check the spring. The free length should be 0.57 in.
and low sides were equalized. If the high side pressure (14.4 mm). Replace the spring if the free length is less
is increasing or has increased noticeably, the discharge than 0.51 in. (13.0 mm).
check valve is leaking internally.
4. Inspect the pistons and the piston seats. Replace the
7. Turn the unit off and shut off the truck engine. Connect pistons or the piston seats if they are worn or damaged.
the remote control box to an appropriate electric power
5. Inspect the valve body. The piston bores and the valve
source.
body seats should be clean and undamaged. The pis-
8. Observe the gauge manifold reading of the engine- tons should move freely in the piston bores. Clean or
driven compressor. If the high side and low side read- replace if necessary.
ings are not the same, open the gauge manifold valves
and equalize the pressures. Close the gauge manifold Assembly
valves.
NOTE: Coat all parts with compressor oil before
9. Adjust the thermostat so the unit will run in cool. Start assembly.
the unit and run on electric standby. 1. Place the sealing washer on the cap nut.
10. Observe the gauge manifold readings of the electric 2. Place the spring on the piston assembly.
standby compressor. The head pressure should increase
and the suction pressure should decrease. 3. Place the piston and spring in the cap nut.
11. Observe the gauge manifold readings of the engine- 4. Carefully place the piston and cap nut in the valve
driven compressor. The high side pressure should body.
remain the same as the pressure in step 8 after the high
5. Tighten the cap nut.
67
Check Valve Replacement 5. Remove the defrost termination switch wire.
Removal 6. Unsolder the suction line from the evaporator coil.
1. Remove the refrigerant charge. 7. Remove the mounting bolts and slide the coil from the
unit.
2. Disconnect the refrigeration line connections.
3. Remove the mounting hardware and remove the check Installation

valve. 1. Place the coil in the housing.
Installation 2. Install the mounting bolts and tighten them.
1. Place the check valve in position and install the mount- 3. Clean the tubes for soldering.
ing hardware. 4. Solder the suction line to the evaporator coil.
2. Connect the refrigeration lines. 5. Connect the hot gas line to the distributor.
3. Pressurize the refrigeration system and test for leaks. 6. Connect the expansion valve to the distributor.
4. If no leaks are found, evacuate the system. 7. Connect the defrost termination switch wire.
5. Recharge the unit with refrigerant and check compres- 8. Install the expansion valve on the mounting bracket.
sor oil.
9. Pressurize the system and test for leaks. If no leaks are
found, evacuate the system.
EVAPORATOR COIL
10. Connect the evaporator fan motor wires. Install the
Removal evaporator panel.
slightly positive.
2. Remove the evaporator panel. Disconnect the evapora-

tor fan motor wires.
3. Disconnect the expansion valve from the distributor.
4. Disconnect the hot gas line from the distributor.
68
11. Open the refrigeration valves and place the unit in oper- 3. Disconnect the equalizer line from the expansion valve.
ation. Check the refrigerant charge and the compressor
4. Disconnect the liquid line and the distributor from the
oil and add as required.
expansion valve.
5. Remove the expansion valve from the unit.
Installation
1. Install the expansion valve assembly in the unit.
2. Connect the liquid line and the distributor to the expan-

sion 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.
1. Heat Exchanger
Location of Expansion Valve Bulb
2. Suction Pressure Regulator Valve
3. Expansion Valve
4. Evaporator Coil
Evaporator Components
(Thinline Shown Standard Is Similar)
EXPANSION VALVE ASSEMBLY
Removal
slightly positive.
2. Remove the feeler bulb from the suction line clamps.

Note the position of the feeler bulb on the suction line.
Completely Wrap Bulb with Tape
69
5. Pressurize the low side and test for leaks. If no leaks 5. Open the refrigeration valves, and place the unit in
are found, evacuate the low side. operation. Check refrigerant charge and add refrigerant
as required.
LOW PRESSURE CUTOUT SWITCH
REPLACING REFRIGERANT HOSES
Removal
Disassembly
1. Pump down the low side and stop the unit.
1. Remove the refrigerant charge or pump down the low
2. Disconnect the wires and remove the switch.
side.
Installation 2. Use two wrenches to loosen the fittings.
1. Apply a refrigerant locktite to the threads of the switch. 3. Remove the hose and remove the fittings from the hose.
2. Install and tighten the switch and reconnect the wires.
Assembly
3. Pressurize the refrigeration system and test for leaks.
1. Measure the hose, and using a sharp knife or suitable
4. If no leaks are found, evacuate the low side. plastic tube and hose cutter tool, cut to length. Make
sure the cut is clean and square. Wipe the inside of the
5. Open the receiver tank outlet valve, start the unit and
hose clean.
check the refrigerant charge.
NOTE: DO NOT use a saw to cut the hose.
SUCTION PRESSURE REGULATOR
VALVE
Removal
slightly positive.
2. Release the remaining pressure and unsolder the suc-

tion pressure regulator valve from the suction tubes.
Cut Hose
Installation
1. Clean the tubes for soldering.
2. Place the valve in position and solder the connections.
3. Pressurize the low side and check for leaks.
4. If no leaks are found, evacuate the low side.
70
2. Place the socket on the hose and turn it counterclock- 4. Screw the nipple into the socket.
wise until the hose bottoms out. Then back it out 1/4 of
a turn.
AGA383
AGA341
Install Socket Flare Fittings
3. Lubricate the nipple threads and the inside of the hose The flare fittings on the liquid injection line should first be
with oil. tightened finger tight, then they should be turned 3/4 of a
turn.
ORS Fittings
Lubricate the ORS fittings with refrigeration oil (same type
of oil that is used in the system) and tighten them until they
bottom out.
AGA342
Lubricate With Oil
ORS Fitting
71
72
V-250 R-404A Conversion Instructions
This option should be only used with units containing a low

voltage board. (2C20447G01). Service parts # 41-1812 with
cycle clutch on high/low pressure cutout operation.
1. Install new expansion valve.
2. Install new high pressure cutout switch.
3. Apply R-404A decals over the R-134a decals.
4. Change switches in back of cab control box. Move

switches 1 and 2 to the ON position. This will allow the
thermostat to be set to -24 F (-31 C).
1 2
ON X X
OFF
5. Run drain tube heaters into drain hoses until about 6

inches of wire remains out. Keep wires to top side of
drain hoses and slip hoses over the drain tubes coming
out of the evaporator.
1. Drain Hose
2. Drain Pan
3. Heater
6. Unplug the defrost solenoid from the low voltage con-

trol. Plug drain tube heater harness into control box
plug and defrost solenoid into heater harness. Run
heater harness to evaporator and plug drain tube heaters
into harness.
73
74
Structural Maintenance
UNIT INSPECTION
Inspect the unit during the pre-trip inspection and during
scheduled maintenance inspections for loose or broken
wires or hardware, compressor oil leaks, or other physical
damage which might affect the unit performance and
require the repair or replacement of parts.
EVAPORATOR COIL
Clean the evaporator coil during scheduled maintenance
inspection by blowing compressed air down through the
coil out into the box (direction opposite the normal air Roofmount Unit
flow). Inspect the coil and fins for damage and repair if
necessary (requires removing the evaporator fan and front
cover).
CAUTION: Air pressure should not be high enough

to damage the coil fins.
CONDENSER COIL
Clean the condenser coil during scheduled maintenance
inspections by blowing compressed air from the back side
of the coil out toward the front of the unit (the direction
opposite normal air flow). Inspect the coil and fins for dam-
age and repair if necessary.
CONDENSER FAN LOCATION

Mount the condenser fan so the hub is flush with the end of
the shaft.
UNIT MOUNTING BOLTS

Periodically check and torque the unit mounting bolts to 60
ft-lb (81 N•m).
Nosemount Unit
75
76
Compressor and Clutch Maintenance
Operation Removal
A stationary field coil is mounted on the compressor body 1. Remove the center bolt using the puller arbor
concentric with the shaft. A pulley assembly, consisting of (TK 204-804) to prevent drive plate rotation.
a pulley, a disc and a hub is mounted on the shaft of the
compressor. The hub and disc are flexibly connected with
flat springs that in the disengaged position, hold the disc
slightly away from the pulley web (friction surface).
When an electric current flows through the field coil, a mag-

netic field is created. The magnetic field pulls the disk
against the pulley web and compresses the flat springs. This
causes the hub and disk to rotate with the pulley.
1. Holder
Remove Center Bolt

2. Remove the drive plate using the shaft seal kit (TK
204-805). Then remove the shims from either the drive
shaft or the drive plate.
1. Hub 4. Disk
2. Stationary Field Coil 5. Flat Springs
3. Pulley
Compressor Clutch Assembly
CLUTCH REMOVAL
NOTE: Make sure the proper tools are available before
performing maintenance procedures. Refer to the tool list-
ing at the end of this chapter for tools required. Contact
your local Thermo King dealer for further information.
Remove Drive Plate
77
Compressor and Clutch Maintenance (Rev 1/99)
3. Remove the snap ring using external snap ring pliers NOTE: To avoid damaging the pulley groove, the
(TK 204-808). pulley claws should be hooked into (NOT UNDER)
the pulley groove.
4. Remove the cover.
1. Snap Ring
2. Cover Remove Pulley
Remove Snap Ring and Cover 6. Remove the coil’s lead wire from the holder on the top
of the compressor.
5. Remove the pulley assembly using the clutch remover
(TK No. 204-806) and the spacer positioned on the 7. Remove the three screws that attach the coil to the com-
cylinder head hub. pressor and remove the coil.
78
NOTE: DO NOT hold the coil by the lead wire. 3. Coil
Inspect the coil for a loose connector or cracked insula-

tion. If the insulation is cracked, replace the coil.
Repair or replace the wire or the connector if either is
loose or damaged.
1. Drive Plate
2. Pulley Assembly
Remove Coil
3. Coil
Inspection Inspect Components

1. Drive Plate
Clutch Installation
If the contact surface is scorched, the drive plate and
pulley should be replaced. NOTE: Before installation refer to the “Inspection”
procedures previously described.
2. Pulley Assembly
1. Confirm that the felt is installed on the front of the cyl-
Inspect the appearance of the pulley assembly. If the inder head.
pulley’s contact surface is excessively grooved due to
slippage, both the pulley and drive plate must be 2. Install the coil on the compressor (with the lead wire on
replaced. There should also be no foreign matter, such top). At this time, confirm that the coil’s concave por-
as oil or grit, lodged between the clutch plate and tion is aligned with the felt and then tighten the mount-
pulley. Thoroughly clean these contact surfaces and the ing screws to the specified torque.
drive plate. NOTE: Specified torque: 2.9 to 4.3 ft-lbs (0.4 to 0.6
kgm).
3. Install the lead wire in the wire holder on the

compressor.
79
5. Install the cover and the snap ring using external ring
pliers.
NOTE: When installing the snap ring, the chamferred

inner edge of the snap ring should face upward.
1. Felt
Install Coil
4. Install the pulley assembly using the compressor holder

(TK No. 204-807) and a hand press.
1. Snap Ring
2. Cover
Install Cover and Snap Ring
6. Install the driver plate on the drive shaft, together with

the original shim(s). Press the drive plate down by
hand.
7. Tighten the bolt to the specified torque using the puller

arbor (TK No. 204-804) to prevent drive-plate rotation.
NOTE: Specified torque: 8.7 to 10.1 ft-lbs (1.2 to

1.4 kgm).
Install Pulley
80
After tightening the bolt, ensure that the pulley rotates NOTE: Specified clearance: 0.01 to 0.02 in. (0.3 to
smoothly. 0.6 mm).
Check Clearance
1. Shims
Electrical Connection
Install Shims and Drive Plate
1. Connect the lead wire to the electrical circuit.
8. Ensure that the clutch clearance is as specified. If nec-
essary, adjust the clearance using shims. NOTE: The stationary field is grounded at the fac-
tory; therefore, it is necessary only to connect the hot
Adjusting shims are available in the following thick- (lead) wire.
nesses:
2. Engage and disengage the clutch several times to check
Shim TK P/N Thickness in. (mm) the clutch engagement. The disc should snap firmly
TK 11-8031 0.0039 in. (0.1 mm) against the pulley.
TK 11-8032 0.0118 in. (0.3 mm)
TK 11-8033 0.0197 in. (0.5 mm) SHAFT SEAL COVER AND SHAFT SEAL:
REMOVAL AND INSTALLATION
Removal
1. Remove the magnetic clutch assembly, as outlined in
“Magnetic Clutch Removal” section of this manual.
2. Remove the felt pad.
3. Use the seal remover (from the shaft seal kit P/N 204-
805) to remove the shaft seal cover. Turn the seal
remover to engage the hook on the seal remover with
81
the hook on the shaft seal cover, then slowly pull the
shaft seal cover out of the cylinder head.
NOTE: The shaft seal cover SHOULD NOT be

reused. Always use a new shaft seal cover when reas-
sembling a compressor.
1. Shaft Seal
Remove Shaft Seal
Inspection
The shaft seal should not be reused. Always use a new shaft
1. Shaft Seal Cover seal when reassembling a compressor. Be extremely careful
2. Felt Pad to make sure the lip of the shaft seal that is being installed is
not scratched or damaged in any way. Make sure the shaft
Remove Shaft Seal Cover seal is free from lint and dirt that could damage the shaft
4. Use the seal remover (from the shaft seal kit P/N 204- seal surface.
805) to remove the shaft seal. Turn the seal remover to
engage the hook on the seal remover with the hook on
the shaft seal, then slowly pull the shaft seal out of the
cylinder head.
Inspect Shaft Seal
82
Shaft Seal Installation 4. Place the shaft seal on the seal guide and slide the
seal into the cylinder head.
Before installing a shaft seal inspect it carefully (see Inspec-
tion).
1. Clean the section of the front cylinder head that holds

shaft seal.
2. Apply clean compressor oil to the new shaft seal and to

the front cylinder head. If the slip surfaces are dirty,
clean them with thinners, dry the clean surfaces and
apply clean compressor oil.
3. Place the seal guide (from the shaft seal kit P/N
204-805) on the end of the shaft.
1. Seal Guide
2. Shaft Seal
Place Shaft Seal on Guide
5. Use the seal installer (from the shaft seal kit P/N
204-805) to press the shaft seal into the cylinder
head as far as possible.
6. Remove the seal guide from the shaft.
1. Seal Guide
Place Guide on Shaft
Press Seal Into Cylinder Head
83
7. Place the seal guide (from the shaft seal kit P/N Special Tools
204-805) on the end of the shaft.
8. Place the shaft seal cover on the seal guide and slide
the shaft seal cover into the cylinder head.
8932a
Clutch Remover P/N 204-806

Install Shaft Seal Cover
9. Use the seal installer (from the shaft seal kit P/N
204-805) to press the shaft seal cover into the
cylinder.
10. Remove the seal guide from the shaft.
NOTE: Position the shaft seal cover as shown in the illus-

tration. The felt pad should also be replaced with a new
8932b
one when the shaft seal is replaced.
Compressor Holder P/N 204-807
Proper Shaft Seal Cover Position
84
8932c 8932e
Clutch Installation Kit P/N 204-890 Shaft Seal Kit P/N 204-805
8932d
Snap Ring Pliers P/N 204-808
85
Each compressor comes with a standard charge of Polyol

Ester (POE) oil inside. This quantity of oil is enough to sup-
ply the compressor lubrication when it is installed into an
already “oil wet” system. New systems require an extra
quantity of oil be added to “wet” all the interior surfaces of
the system.
During normal operation there is always a quantity of oil

that travels around inside the system. This oil lubricates all
the components, returns to the compressor for a while, and
again travels around the system.
Adding Extra Oil to the System

The initial oil charge into a new system is based on the size
of the system and the amount of oil, which remains in the
compressor during operation.
The correct oil to use in the V250 using R-134a and R-

404A is Polyol Ester (POE) oil (TK No. 203-413). Any
extra or replacement oil should be placed into the sys-
tem at the receiver tank port.
CAUTION: Keep all oil containers tightly sealed

from the air. Oil tends to absorbed moisture from
the air and can become contaminated if left open. If
contaminated oil is put into a system, it may damage the
components of the system.
Major Loss of Refrigerant

8932f
In case of a major loss of refrigerant, it must be assumed
Pulley Arbor P/N 204-804 that some system oil is lost also. The oil level should be
verified by the “Checking the Oil Level” method in this
manual.
SYSTEM COMPRESSOR AND OIL
Installation of the Compressor

The compressor is mounted in the condenser section. The
side to side mounting angle of the compressor must remain
± 45 from the horizontal. The forward to backward angle
must be within ± 10 of horizontal. Access to the air condi-
tioning system service ports is from the top of the unit.
86
Checking the Oil Level Oil contamination.

1. Dirt in the oil.
Drain the Oil
2. Color changed to a varnish color.
3. Presence of foreign substances, metal shavings, etc. in

the oil.
NOTE: Always replace oil with new fresh oil taken from a
sealed container only.
NOTE: Always replace the system filter-drier anytime the

system has been opened for service.
When a System Becomes Contaminated

A severely contaminated system may be indicated by black
oil in the compressor. If severe contamination occurs, it will
be necessary to flush the complete system. If flushing is
required, use industry approved materials.
Draining the Oil
In all cases when this occurs you must determine the extent
Remove the compressor from the unit and drain the oil from
of contamination. Do this by removing the filter-drier and
the compressor drain plug and all other ports. Turn the
determine if the darker colored oil is present at that point of
clutch (rotating the internal compressor parts) by hand and
the system too. If it is, flushing the system is recommended.
drain oil again. Repeat until all oil is removed from the
compressor. Measure the oil in liquid ounces. Also, inspect If the oil appears clean at the filter-drier, install a new filter-
the oil for signs of contamination. drier and replace the compressor with clean new oil. Refer
to checking and draining the compressor oil section for
details.
CAUTION: Any extra or replacement oil should be

placed into the system at the receiver tank port.
Electrical Connection
1. Connect the lead wire to the electrical circuit.
NOTE: The stationary field is grounded at the

factory; therefore, it is necessary only to connect the
hot (lead) wire.
2. Engage and disengage the clutch several times to check

the clutch engagement. The disc should snap firmly
against the pulley.
87
Clutch Test BELT TENSIONS

1. If the field coil lead wire is broken, replace the field
coil.
Engine/Compressor Belt and Pulleys
Correct pulley alignment and proper belt tension are very
2. Check the amperage and voltage. The amperage range
should be 3.6 to 4.2 amps at 12 volts or 1.8 to 2.1 amps important factors in compressor installation. The compres-
sor clutch must be perfectly aligned with the engine pulley
at 24 volts. Note the following symptoms and
and any auxiliary idler or belt adjustment pulley compo-
conditions.
nents. When installing the clutch, be sure the shaft drive
a. A very high amperage reading—a short within the key is in place and the shaft bolt is properly tightened.
field coil. Check the pulley alignment by holding a 24 to 35 in. (60 to
90 cm) long rod, 0.5 in. (13 mm) in diameter firmly into the
b. No amperage reading—an open circuit in the
V-groove of the clutch pulley and make sure the rod aligns
winding.
squarely with the engine drive pulley groove. Double check
c. An intermittent or poor system ground results in by making sure the belt goes from pulley to pulley in perfect
lower voltage at the clutch. Check for tight fit of alignment with no indication of a sideward bend.
the coil retaining snap ring or coil retaining screws
Adjust the belt tension to 58 to 60 on TK Gauge P/N 204-
for good ground.
427. Check the belt tension again after 36 to 48 hours of
d. Replace field coil if it has an open or short circuit. initial operation of the unit because the belt may stretch
slightly during the first hours of use. Remember, good
3. Air Gap—An incorrect air gap could cause erratic
alignment and proper belt tension ensure long belt life.
engagement or disengagement and/or clutch rattle.
Check the air gap with a feeler gauge (0.01 to 0.02 in.
[0.3 to 0.6 mm]). Adjust per the Clutch Installation
chapter.
88
Electric Motor/Compressor Belt

Loosen the bolts that fasten the compressor mounting
bracket to the frame and turn the adjusting nut to tension the
belt. Tighten the bolts that fasten the compressor mounting
bracket to the frame when the belt tension reads 58 to 60 to
TK Gauge P/N 204-427.
NOTE: Do not overtighten the belts. Proper belt tension

should allow the belt to be deflected 0.5 in. (13 mm) at the
center of the span with no motor movement. A belt that is
too tight causes severe overload on the compressor and
motor bearings. Use only approved Thermo King Service
Parts replacement belts. They are specially designed for
these units.
1. Compressor Mounting Bracket Bolt

2. Adjuster
Electric Motor/Compressor Belt
89
90
Over-the-Road Mechanical Diagnosis
If the desired box temperature cannot be obtained, any of a hand or hot towels to see if the valve opens. Evacuate
the following may be indicated: the system in the same manner used during installation.
Install a new drier.
1. EXCESSIVE HEAT LOAD. An excessive heat load
on the system will be caused by too many, or exces- 8. EXPANSION VALVE LOSES ITS CHARGE. If the
sively long, stops with the doors open. Excessive heat expansion valve loses its charge, the valve will close
loads will also be caused by loose doors, loose body causing the system to go into vacuum. Replace the
panels, warm loads and poor insulation. valve.
2. DIRT ON COILS. Dirt on the condenser or evaporator 9. AIR IN THE SYSTEM. Air is not condensable. Its
coils acts as an insulator reducing the capacity of the presence in the system increases head pressure. When
unit. the compressor is stopped, air will gather at the high
point of the high side. Evacuate the system.
3. INCORRECT BELT TENSION. If the drive belt is not
correctly tensioned, the compressor will not be driven 10. TEMPERATURE OF THE LIQUID LINE. During
at the proper speed, and unit efficiency will be reduced. normal operation, the liquid line will be slightly
By contrast, too much tension will place an additional warmer than the surrounding air. An extremely hot line
load on the bearings causing rapid wear. indicates either a shortage of refrigerant or a lack of a
liquid seal at the receiver outlet. A cold line indicates a
4. SHORTAGE OF REFRIGERANT. Shortage of refrig-
restriction, and some flashing takes place in the liquid
erant reduces the capacity of the unit. Find and remedy
line sight glass.
the cause of the shortage and recharge the system. DO
NOT operate the unit if there is an indication of low 11. DIRTY OR WET DRIER. If the outlet line of the drier
charge. DO NOT operate below 30 F (-1 C) box tem- is colder than the inlet line, the drier is either saturated
perature if the refrigerant level is below the sight glass with moisture or is dirty and must be replaced.
on the receiver tank.
12. DIRT IN THE EXPANSION VALVE SCREEN.
5. FAULTY EXPANSION VALVE ADJUSTMENT. High Recover the refrigerant charge, remove the screen and
superheat settings will starve the evaporator causing clean. If the moisture is in the refrigeration system, it
low suction pressure. Low superheat settings will flood will collect at the expansion valve and freeze. This is
the coil causing high suction pressure. The superheat indicated by abnormally low suction pressure. Clean
setting should be adjusted ONLY by a trained refrigera- the system, replace the drier, evacuate the system pres-
tion service technician. surize and check for leaks. If no leaks are found, charge
the system.
The superheat setting is 8 F (4.4 C) at 0 F (-18 C) box
temperature. 13. ICE ON THE EVAPORATOR COIL. Run the unit
through a defrost cycle to remove the ice.
6. EXCESSIVE OIL. Too much compressor oil in the
system may result in lower than normal suction pres- 14. AIR FLOW. Do not load product directly in front of the
sure as well as lowered capacity. air return or discharge. Ensure that the fan is correctly
positioned in the orifice to achieve maximum air flow.
7. MOISTURE IN THE SYSTEM. Symptom: Expansion
valve freeze-up—will not refrigerate. Usually this can
be checked by warming the expansion valve with either
91
Over-the-Road Mechanical Diagnosis (Rev 1/99)
15. COMPRESSOR LIFE. The following will shorten the • Insufficient oil charge
life of a compressor:
• Wrong oil or mixed oil
• Operating a contaminated system
• Lack of compressor lubrication on installation-startup
• No oil trap
• Excess compressor speed (refer to the chart below)
• Clogged oil separator (JetLube™)
• Clogged liquid injection orifice (JetCool™)
• Defective temperature switch (JetCool™)
Road Compressors
Specifications Relative Performance
Model Displ. Dimensions Compressor RPM Formula

MAX RPM (Metrics) A B C* D
Drive Clutch High Maximum
TM 16HD 10.5 cid 3.28in. 4.41 in. 8.77 in. 4.09 in.
Pulley ÷ Pulley X Engine = Compressor
3000 rpm (163 cc) (83.3 mm) (112 mm) (222.8 mm) (104 mm) Dia. Dia. RPM RPM
TM 15 HD 9.0 cid 3.28 in. 4.41 in. 8.55 in. 4.09 in.
6.5 ÷ 5.25 X 2500 = 3095
4000 rpm (147 cc) (83.3 mm) (112 mm) (217.3 mm) (104 mm)
6000 rpm (131 cc) (83.3 mm) (112 mm) (217.3 mm) (104 mm)
6000 rpm (131 cc) (73.3 mm) (98 mm) (209 mm) (104 mm)
6000 rpm (82 cc) (515 mm) (80 mm) (174 mm) (112 mm)
*Add 1 in. (2.5 cm) to dimensions

for bolt-on manifold.
Bolt-on manifold for TM 16 HD,
TM 15 HD, and TM 13 HD only.
92
Electric Standby Mechanical Diagnosis
CONDITION POSSIBLE CAUSE REMEDY

Compressor does not run Improperly wired Check wiring against diagram
Low line voltage Check line voltage—determine
location of voltage drop
Relay contacts not closing Check and replace relay if defective
Open circuit in motor winding Check motor leads. If leads OK,
replace motor
High pressure cutout switch open Eliminate cause of excessive
pressure
Thermostat faulty Repair or replace
Compressor piston stuck Replace compressor
Frozen compressor or motor Repair or replace
bearings
Shortage of refrigerant Check for leaks, repair as required,
and recharge
Low pressure cutout switch open Check and replace if necessary.
Overload relay open Turn On-Off switch OFF and back
ON
Unit short cycles Shortage of refrigerant (low pressure Repair leak and recharge
cutout)
Restricted expansion valve (low Replace expansion valve
pressure cutout)
Refrigerant overcharge (high Remove excess charge
pressure cutout)
Cycling on high pressure cutout Check air flow and fan
Clogged condenser coil Clean coil
Motor contactor burnout Low line voltage Increase voltage (must be ± 10% of
compressor motor rating)
Excessive line voltage Reduce voltage (must be ± 10% of
compressor motor rating)
93
Electric Standby Mechanical Diagnosis (Rev 1/99)

Unit operates long or Shortage of refrigerant Repair leak and recharge
continuously
Discharge valve leaking Replace compressor
Thermostat faulty Replace cab box
Dirty condenser Clean condenser
Air in system Purge
Compressor inefficient Replace compressor
Plugged expansion valve Clean or replace
Iced or plugged coil Defrost or clean
Defective truck body insulation Correct or replace
Too many door openings Keep doors closed
Load too warm Precool hot product
Excessive superheat at expansion Adjust
valve
Door seals worn Repair/replace
Box temperature too high Refrigerant shortage Repair leak and recharge
Thermostat set too high Reset control
Expansion valve or strainer plugged Clean or replace
Restricted lines Clean restriction. Tubing pinched
shut
Hot load Precool hot product
Expansion valve superheat too high Adjust
or too low
Head pressure too high Refrigerant overcharge Remove excess
Air in system Evacuate system
Dirty condenser Clean
Restricted condenser Clean condenser
Condenser fan not running Check fan motor
Condenser fan rotating backwards Check wiring
94

Head pressure too low Refrigerant shortage Repair leak and recharge
Compressor suction or discharge Replace compressor
valve inefficient
Noisy unit Insufficient compressor oil Add oil to proper level
Mounting bolts loose Tighten
Oil slugging or refrigerant flooding Adjust oil level or refrigerant charge.
back Check expansion valve for proper
superheat
Compressor loses oil Refrigerant leak Repair leak and recharge
Plugged expansion valve or strainer Clean or replace
Wrong oil viscosity Use proper oil
Short cycling Refer to Unit Short Cycles
Superheat too high Adjust expansion valve
Frosted or sweating suction line Expansion valve set too low, Adjust expansion valve
admitting excess refrigerant
Heat exchanger internal leak Replace
Hot liquid line Shortage of refrigerant Repair leak and recharge
Frosted liquid line Restricted dehydrator or strainer Replace restricted part
Condenser coils cool when unit is Refrigerant undercharge Repair leak and recharge
in cool
Compressor inefficient Replace compressor
Unit in vacuum. Frost on Ice plugging expansion valve orifice Apply hot wet cloth to expansion
expansion valve only valve. Moisture indicated by
increase in suction pressure.
Replace drier
Plugged expansion valve strainer Clean strainer or replace expansion
valve
Sensor bulb lost charge Replace expansion valve
95
ELECTRIC STANDBY SERVICE CHECKS

1. Motor does not run 1. Check for power at source
2. Check for power at plug
3. Check for power at compressor contactor
4. Check for power at overload terminals (contactor
closed)
5. Check for power at motor terminals
2. Power at motor terminals but motor does not run 1. Replace motor
3. Motor hums but does not run 1. Check for locked rotor
2. Check for worn bearings. Replace if necessary
3. Check for locked compressor and repair
4. Power source for single phasing (on 3 phase units)
5. Check capacitors (on single phase units)
4. Check transformer 1. Check for power output 12-13 Vdc, 12 volt system
5. Check rectifier 1. Check for rectifier output 12-13 Vdc, 12 volt system
96
10 7
12
4
8 6

9
2
97
5
Model 10 Cool
AGA666
13 11
1. Compressor 8. Expansion Valve

2. Oil Separator 9. Evaporator Coil 1
3. Condenser Coil 10. Suction Pressure Regulator
4. Receiver Tank 11. Liquid Injection Orifice
5. Liquid Injection Solenoid 12. Hot Gas Solenoid
6. Drier 13. Pan Heater
7. Heat Exchanger
10 7
12
AGA667
8 6 4

9 2
98
Model 10 in Defrost
1. Compressor 11
2. Oil Separator 13
3. Condenser Coil
4. Receiver Tank
5. Liquid Injection Solenoid 1 3
6. Drier
7. Heat Exchanger
8. Expansion Valve
9. Evaporator Coil
10. Suction Pressure Regulator
11. Liquid Injection Orifice
12. Hot Gas Solenoid
13. Pan Heater
10 7
12
4
8 6
14

9
99
15
AGA668
13 11
3
1. Compressor 9. Evaporator Coil
2. Oil Separator 10. Suction Pressure Regulator 1
3. Condenser Coil 11. Liquid Injection Orifice
4. Receiver Tank 12. Hot Gas Solenoid
5. Liquid Injection Solenoid 13. Pan Heater
6. Drier 14. Standby Compressor
7. Heat Exchanger 15. Check Valve
8. Expansion Valve
10 7
12
8 6 4
14

9
15
100
AGA669
13 11
Model 20 in Defrost—Electric Standby Operation

1 3
2. Oil Separator 10. Suction Pressure Regulator
8. Expansion Valve
10 7
12
8 6 4
14

9
15
101
AGA670
11
13
Model 20 in Cool—Vehicle Engine Operation

3
8. Expansion Valve
10 7
12
8 4
6
14

9
2
5
102
15
AGA671
13 11
Model 20 in Defrost—Vehicle Engine Operation

1. Compressor 9. Evaporator Coil 3
8. Expansion Valve
V250 Installation Checklist
Prior to Installation Final Inspection

Do you have the correct compressor bracket kit? Twelve ounces of polyester oil, per compressor, is
installed.
Does the compressor fit the designated location on this
engine? Liquid injection occurs when discharge temperature
exceeds approximately 230° F (110 C).
Are you sure that the calculated maximum compressor
speed does not exceed the recommendation? Condenser fan operates at discharge pressures above
approximately 130 psi (896 kPa).
Will you route hoses through the box floor or use an
external hose kit? Compressor clutch disengages at discharge pressures
above approximately 300 psi (2069 kPa).
If the external hose kit is used, is there adequate space
between the cab and box? Compressor clutch disengages at suction pressures
below approximately 5 inches Hg. vacuum.
How will the condenser be mounted—vertical, horizon-
tal shelf kit, roof-mount? Temperature drop across the evaporator coil is adequate
and box temperature pulls down normally.
What evaporator type “thin line” or “funnel”?
Manual defrost operates and terminates normally.
Where will you mount the cab control?
Defrost drains are unrestricted.
What other options are to be installed? (Engine heat,
electric heat, low temperature kit, etc.) Suction pressure regulator set at 20 psi (138 kPa).
Compressor belt tension is correct.

During Installation
Thermo King logo installed on condenser.
Are hoses and harnesses routed to avoid sharp bends,
abrasion, heat, brake lines, and sharp edges? Optional electric standby and electric heaters work
properly.
Is the liquid injection orifice installed?
Engine heat option (if installed) operates correctly.
Is there an oil trap in the suction line?
Can the unit maintain a 2000 micron vacuum level for

at least five minutes?
103
104
Wiring Diagrams and Schematic Index
Dwg No. Drawing Title Rev. Page
5D46179 V250 Schematic Diagram C 107-108
5D46190 V250 Wiring Diagram F 109-110
5D44455 V250 Schematic Diagram C 111-112
5D44456 V250 Wiring Diagram C 113-114
5D49374 115V 1PH 60Hz Wiring Diagram C 115
5D49275 V250 Wiring Diagram A 116
5D49360 V250 with P97 Power Pack Schematic Diagram A 117-118
5D49368 230V 1PH 50/60 Hz Wiring Diagram C 119
105
106
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TK 40839-1-MM (Rev. 2, 1/99) : 1994 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A

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Copyright:

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TK 40839-1-MM (Rev. 2, 1/99) : 1994 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A

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Copyright:

Available Formats

V250

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

Copyright© 1994 Thermo King Corp., Minneapolis, MN, U.S.A.

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DO NOT mix Polyol Ester and standard synthetic compressor oils.

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Electrical Maintenance (continued)

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

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GENERAL PRACTICES REFRIGERANT

ELECTRICAL HAZARDS First Aid

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

R-404A REFRIGERATION SYSTEM

Condenser and Evaporator Fan Motors

Hot Gas Solenoid and Liquid Injection Solenoid Coils

Voltage Current Resistance

Electrical Standby Compressor Motors

Full Load Overload

* Motor can be wired for all three voltages.

Optional Electric Heaters

Voltage Power Rating Watts Current Resistance

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

First Week Inspection and Maintenance

Bi-monthly Annually Inspect/Service These Items

Liquid Injection System

Oil Separator Electric Standby Operation

During electric operation, the evaporator heaters and the

Initiating defrost energizes the defrost relay. This energizes

• Hot Gas Defrost

• Defrost Termination Switch

• Liquid Injection System

Unit Features (continued) SERIAL NUMBER LOCATIONS

• Refrigerant High Pressure Cutout

• Refrigerant Low Pressure Cutout

• Refrigerant High Pressure Relief Valve

• Power Cord Warning Light (in Cab Control Box)

• Overload Relay Protection for Electric Standby Motor

• Transformer Fuses (Model 20 only)

Vertical Mounted Condenser (Early Model)

Vertical Mounted Condenser (Later Model)

1. High Voltage Box 8. Oil Separator

Condenser Components—Front/Top View (Starting 1997)

1. Expansion Valve 3. Fan Motor

1. Thermostat Sensor 4. Expansion Valve

Low Voltage Box—Pre-1996

1. Transformer 6. Transformer Fuse

High Voltage Box—Pre-1997

1. Transformer 6. Transformer Fuse

High Voltage Box—Starting 1997

1. D.C. Power Filter Capacitor 5. Transformer

1. D.C. Power Filter Capacitor 4. Motor Contactor

1. Power Cord Indicator 8. Thermostat Dial

Cab Control Box—M10 Pre-1997

1. Defrost Indicator Light

M13 Cab Box—TK No. 45-1780

1. Defrost Indicator Light

M10 Cab Box—TK No. 45-1705

UNIT CONTROLS 12. AC OVERLOAD INDICATOR. When this light is on,

UNIT OPERATION Engine Operation

4. One-half hour after loading, defrost the unit by momen-