Ingersoll-Rand Thermo King V-520 Series User manual

Distributed by:
Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy effi cient heating, ventilating and air
conditioning systems, building and contracting services, parts support and advanced controls
for commercial buildings and homes.
SB-210+
Additional text information
to be placed here
TK 5XXXX-X-PL
TK 54343-1-MM
©2009 Ingersoll Rand Company
Printed in U.S.A.
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
Distributed by:
SB-210+
Additional text information
to be placed here
TK 5XXXX-X-PL
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
SB-210+
Additional text information
to be placed here
TK 5XXXX-X-PL
Distributed by:
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
Distributed by:
V-520
V-520 MAX
TK 54343-1-MM (Rev 3, 03/15)
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
Maintenance Manual

V-520
V-520 MAX
TK 54343-1-MM (Rev 3, 03/15)
Copyright© 2009 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.

2
Revision History
Rev. 0 – TK 54343-1-MM (Rev. 0, 12/09) Original release.
Rev. 1 – TK 54343-1-MM (Rev. 1, 04/14) Update Compressor Maintenance and overall
general updates.
Rev. 2 – TK 54343-1-MM (Rev. 2, 04/14) Correct Fuse 11 on page 24.
Rev. 3 – TK 54343-1-MM (Rev. 3, 03/15) Add compressor ground wire information to page
61.
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
The maintenance information in this manual covers unit models:
V-520 10 (900829) V-520 MAX 30 (902053)
V-520 20 (900830) V-520 MAX 50 (902054)
V-520 30 (902041) V-520 SPECTRUM 10 (900834)
V-520 50 (902049) V-520 SPECTRUM 20 (900835)
V-520 MAX 10 (900831) V-520 SPECTRUM 50 (902235)
V-520 MAX 20 (900833)
For further information, refer to:
V-520 Series Operating Manual TK 54342
V-520 Series Parts Manual TK 53990
V-520 SPECTRUM Parts Manual TK 54016
V-520 Series Installation Manual TK 54014
Direct Smart Reefer Microprocessor Control System Diagnostic Manual TK 52573
Diagnosing Thermo King Refrigeration Systems TK 5984
Evacuation Station Operation and Field Application TK 40612
Tool Catalog TK 5955
The information in this manual is provided to assist owners, operators and service people in the
proper upkeep and maintenance of Thermo King units. The above manuals may be purchased from
your local Thermo King dealer.

3
No warranties, express or implied, including warranties of fitness for a particular
purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits
the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations
concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local Thermo King dealer.
R-134a/R-404A
WARNING: Use only Polyol Ester-based refrigeration compressor oil in
R-134a/R-404A units. See Thermo King Parts Manual for part number.
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.
When servicing Thermo King R-134a or R-404A units, use only those service
tools certified for and dedicated to R134a/R-404A refrigerant and Polyol Ester
compressor oils. Residual non-HFC refrigerants or oils willcontaminate R-134a
and R-404A systems.

4
CHANGES, COMMENTS and SUGGESTIONS
You are invited to comment on this manual so it can be updated and improved to better meet you
needs. Any corrections, comments or suggestions are welcome. Please complete the following
information:
Manual Form Number _____________________________________________________
Section and Page # _______________________________________________________
Your Name ______________________________________________________________
Company Name __________________________________________________________
Phone Number ___________________________________________________________
Corrections, Comments and Suggestions _____________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
Return to:
NORTH AMERICA
THERMO KING CORPORATION
314 West 90th Street
Mail Stop 38
Minneapolis, MN 55420
Attn: Service Department
EUROPEAN SERVED AREA
THERMO KING CORPORATION
Ingersoll Rand Climate Control Technologies
Monivea Road
Mervue, Galway, Ireland
Attn: Service Department

5
About This Manual
Purpose
The purpose of this manual is to provide general maintenance information necessary to maintain the
climate control unit at peak operating standards. This includes system and bill of material numbers, safety
information, general unit information, maintenance procedures and related information (such as wiring
and schematic diagrams), and some diagnostic and troubleshooting information.
This manual may cover more than one unit. Therefore, it may contain information not applicable to your
unit.
Contents
This manual is organized into the following chapters:
Before you Call Thermo King Service!
Who to call: Your Thermo King Service Representative.
Before you call Thermo King Service, have the following information on hand:
• Bill of Material (usually located on the unit serial plate)
• Model Number - found on side of the unit
Blank Pages
This manual may contain blank pages at the end of chapters. This is normal. There is no information
missing from the manual.
Chapter Purpose
Safety Precautions Provides detailed safety information. You should be familiar with the
safety precautions before working on any unit.
Model Systems (Systems
Designations) Table This table lists the bills of material and kit options that apply to the Thermo King units covered in this manual. Use this information to:
1. Determine if you have the right manual for your unit: the bill of material
(B/M) number on your unit serial plate should match one of the bill of
material numbers listed in this section. If you cannot find your unit in the
table, call TK Service for more information.
2. Communicate with TK Service Department: If you need to call TK
Service, you must know your model number so that the service
representative can help you.
Specifications Lists unit specifications.
General Description Gives an overview description of the unit including standard and optional
features, general information, and unit photographs or illustrations.
Operating Instructions Provides unit operating instructions.
Maintenance Inspection Schedule Table of routine maintenance procedures.
Maintenance Chapters Provides detailed maintenance procedures required for your unit.
(Electrical, Refrigeration, Compressor, Clutch, Structural)
Diagnosis Chapters Provides troubleshooting information for diagnosing problems.
Diagrams Includes diagrams such as refrigeration, schematic, and wiring diagrams
applicable to units covered in this manual.

About This Manual
6
Roadside/Curbside Terminology
Roadside/Curbside terminology: These terms can be confusing because of differences between North
America and Europe. Please note:
Curbside: The side to the driver’s right when the driver is in his seat and facing forward.
Roadside: The side to the driver’s left when the driver is in his seat and facing forward.

7
Table of Contents
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auto Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigeration Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Microprocessor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Welding of Units or Truck Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Model Systems (System Designations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigerant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AC Semi-Hermetic Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Evaporator Drain Tube Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
P.C. Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electronic Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Null Mode - All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Heat Mode - Model 10 and 20 Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Purge Mode - Model 30 and 50 Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Heat Mode - Model 30 and 50 Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electric Standby Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Single-Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Multi-Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table of Contents
8
Entering the Setpoint Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
In Single-Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
In Multi-Temperature Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Initiating the Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Manual Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Auto Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Alarm Code Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Viewing Information Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Hourmeter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Procedure after loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Weekly Pretrip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Weekly Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Refrigeration/Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Structural . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Testing Liquid Injection Solenoid Valve and Metering Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Condenser Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Condenser Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Evaporator Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Evaporator Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Electric Standby Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Evacuating and Charging the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Solenoid Valve Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Evacuation and Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Testing the Refrigerant Charge with an Empty Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Testing the Refrigerant Charge with a Loaded Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Checking Compressor Oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Refrigeration System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Cleanup Procedure for Small Truck Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Engine Driven Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Electric Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
High Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Defrost Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Liquid Injection Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Condenser Blocking Solenoid Test (Model 30 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Liquid Solenoid Test (SPECTRUM Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Suction Bypass Solenoid Test (SPECTRUM Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Liquid Injection Metering Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Table of Contents
9
Liquid Line Check Valve (Model 30 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Liquid Line Check Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Liquid Line Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Discharge Check Valve (Model 20 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Discharge Check Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Discharge Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Suction Pressure Regulator Valve (Model 20 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Suction Pressure Regulator Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Suction Pressure Regulator Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Low Pressure Cutout Switch (LPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Low Pressure Cutout Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Low Pressure Cutout Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Compressor Pressure Regulator Valve (Model 30 and 50 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Compressor Pressure Regulator Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Compressor Pressure Regulator Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Suction Bypass CPR Valve (SPECTRUM Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SPECTRUM Advanced Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Advanced Control System Components and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Suction Bypass CPR Valve Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Suction Bypass CPR Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Replacing Refrigerant Hoses (Speedy Clip System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Compressor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Refrigerant Handling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Refrigerant Handling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Compressor Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1. Compressor Rotation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2. Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3. Pulley or Rotor Spin Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4. Air Gap Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5. Coil Resistance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6. Pressure or Pumping Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Recommended Pressures and Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Recommended Pressure Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Oil Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil Checking Is Not Required Under Normal Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
When Oil Addition or Balancing is Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil Addition When Replacing System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Compressor Replacement Oil Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Compressor Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Charging the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Initial Installation Pressure Regulator Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Ear Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Clutch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pressure Release Valve (PRV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Belt Tensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine Driven Compressor Belt and Pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Unit Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Over-the-Road Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Table of Contents
10
Electric Standby Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Electric Standby Service Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Refrigeration Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Wiring, Schematic, and Refrigeration Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

11
Safety Precautions
General Practices
1. Always wear goggles or safety glasses.
Refrigerant liquid, refrigeration oil, and
battery acid can permanently damage the eyes.
2. Never close the compressor discharge service
valve with the unit operating.
3. Never operate the unit with the compressor
discharge valve closed.
4. Keep your hands, clothing and tools clear of
the fans and belts when the unit is running.
This should also be considered when opening
and closing the compressor service valves.
5. Make sure gauge manifold hoses are in good
condition. Never let them come in contact
with a belt, fan motor pulley, or any hot
surface.
6. Never apply heat to a sealed refrigeration
system or container.
7. Fluorocarbon refrigerants in the presence of
an open flame produce toxic gases that are
severe respiratory irritants capable of causing
death.
8. Make sure all mounting bolts are properly
torqued and are of correct length for their
particular application.
9. Use extreme caution when drilling holes in the
unit. The holes may weaken structural
components, and holes drilled into electrical
wiring can cause fire or explosion. Holes
drilled into the refrigeration system will
release refrigerant.
10. Use caution when working around exposed
coil fins. The fins can cause painful
lacerations.
11. Use caution when working with a refrigerant
or refrigeration system in any closed or
confined area with a limited air supply (for
example, a truck body or garage). Refrigerant
tends to displace air and can cause oxygen
depletion resulting in suffocation and possible
death.
12. When using ladder or scaffolding, use caution
and follow manufacturer recommendations.
Auto Start/Stop
Refrigerant
When removing refrigerant from a unit, a
recovery process that prevents or minimizes
refrigerant loss to the atmosphere is required by
law.
When a refrigerant is exposed to the atmosphere
in the liquid state, it evaporates rapidly, freezing
anything it contacts. If refrigerant contacts the
skin, severe frostbite can result.
First Aid
In the event of frostbite, the objectives of First
Aid are to protect the frozen area from further
injury, to warm the affected area rapidly and to
maintain respiration.
•Eyes: For contact with liquid, immediately
flush eyes with large amounts of water and get
prompt medical attention.
•Skin: Flush area with large amounts of
lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap burns
with dry, sterile, bulky dressing to protect
from infection/injury. Get medical attention.
Wash contaminated clothing before reuse.
•Inhalation: Move victim to fresh air and use
cardiopulmonary resuscitation (CPR) or
mouth-to-mouth ventilation if necessary. Stay
with victim until arrival of emergency medical
personnel.
CAUTION: The unit may start
automatically and at any time when the
unit On/Off switch is in the On position.
Units with CYCLE-SENTRYTM start
automatically in both CYCLE-SENTRY
mode and Continuous mode. Be sure to
turn the On/Off switch Off before opening
doors or inspecting or working on any part
of the unit.

Safety Precautions
12
Refrigeration Oil
Observe the following precautions when working
with or around synthetic or polyol ester refrigerant
oil:
• Do not allow refrigerant oil to contact your
eyes.
• Do not allow prolonged or repeated contact
with skin or clothing.
• To prevent irritation, you should wash
thoroughly immediately after handling
refrigerant oil. Rubber gloves are
recommended when handling polyol ester oil.
First Aid
•Eyes: Immediately flush eyes with large
amounts of water for at least 15 minutes while
holding the eyelids open. Get prompt medical
attention.
•Skin: Remove contaminated clothing. Wash
thoroughly with soap and water. Get medical
attention if irritation persists.
•Inhalation: Move victim to fresh air and
restore breathing if necessary. Stay with
victim until arrival of emergency personnel.
•Ingestion: Do not induce vomiting. Contact a
local poison control center or physician
immediately.
Electrical Hazards
Microprocessor Service
Precautions must be taken to prevent electrostatic
discharge when servicing the microprocessor
controller and related components. Potential
differences considerably lower than those which
produce a small spark from a finger to a door
knob can severely damage or destroy solid-state
integrated circuit components.
The following procedures must be rigidly adhered
to when servicing units to avoid microprocessor
damage or destruction.
1. Disconnect all power to the unit.
2. Avoid wearing clothing that generates static
electricity (wool, nylon, polyester, etc.).
3. Do wear a static discharge wrist strap (see
Tool Catalog) with the lead end connected to
the microprocessor’s ground terminal. These
straps are available at most electronic
equipment distributors. Do not wear these
straps with power applied to the unit.
4. Avoid contacting the electronic components
on the circuit boards of the unit being
serviced.
5. Leave the circuit boards in their static proof
packing materials until ready for installation.
6. If a defective controller is to be returned for
repair, it should be returned in the same static
protective packing materials from which the
replacement component was removed.
7. After servicing the controller or any other
circuits, the wiring should be checked for
possible errors before restoring power.
8. Never use testers consisting of a battery and a
light bulb to test circuits on any
microprocessor based equipment.
9. Before connecting or disconnecting the
battery, the Microprocessor Power On/Off
switch must be turned to the Off position. It is
located on the roadside of the unit, lower left
corner.

Safety Precautions
13
Welding of Units or Truck Bodies
When electric welding is to be performed on any
portion of the temperature control unit, truck or
truck chassis when the temperature control unit is
attached, it is necessary to ensure that welding
currents are not allowed to flow through the
electronic circuits of the unit.
These procedures must be rigidly adhered to when
servicing units to avoid damage or destruction of
the controller.
1. Disconnect all power to the unit.
2. Disconnect all wire harnesses from the
controller.
3. Switch all of the electrical circuit breakers in
the control box to the Off position.
4. Weld unit or container per normal welding
procedures. Keep ground return electrode as
close to the area to be welded as practical.
This will reduce the likelihood of stray
welding currents passing through any
electrical or electronic circuits.
5. When the welding operation is completed, the
unit power cables, wiring and circuit breakers
must be restored to their normal condition.
High Voltage
When servicing or repairing a temperature control
unit, the possibility of serious or even fatal injury
from electrical shock exists. Extreme care must be
used when working with a refrigeration unit that
is connected to a source of operating power, even
if the unit is not operating. Lethal voltage
potentials can exist at the unit power cord, inside
the control box, at the motors and within the
wiring harnesses.
Precautions
1. Be certain the Unit On/Off switch is turned
Off before connecting or disconnecting the
standby power plug. Never attempt to stop the
unit by disconnecting the power plug.
2. Be certain the unit power plug is clean and dry
before connecting it to a power source.
3. When working on high voltage circuits on the
temperature control unit, do not make any
rapid moves. If a tool drops, do not grab for it.
People do not contact high voltage wires on
purpose. It occurs from an unplanned
movement.
4. Use tools with insulated handles that are in
good condition. Never hold metal tools in
your hand if exposed, energized conductors
are within reach.
5. Treat all wires and connections as high
voltage until a meter and wiring diagram show
otherwise.
6. Never work alone on high voltage circuits on
the temperature control unit. Another person
should always be present to shut off the
temperature control unit and to provide aid in
the event of an accident.
7. Have electrically insulated gloves, cable
cutters and safety glasses available in the
immediate vicinity in the event of an accident.
First Aid
Immediate action must be initiated after a person
has received an electrical shock. Obtain
immediate medical assistance if available.
The source of shock must be immediately
removed by either shutting down the power or
removing the victim from the source. If it is not
possible to shut off the power, the wire should be
cut with either an insulated instrument (e.g., a
wooden handled axe or cable cutters with heavy
insulated handles) or by a rescuer wearing
electrically insulated gloves and safety glasses.
Whichever method is used do not look at the wire
while it is being cut. The ensuing flash can cause
burns and blindness.

Safety Precautions
14
If the victim must be removed from a live circuit,
pull the victim off with a non-conductive material.
Use the victim’s coat, a rope, wood, or loop your
belt around the victim’s leg or arm and pull the
victim off. Do not touch the victim. You can
receive a shock from current flowing through the
victim’s body. After separating the victim from
the power source, check immediately for the
presence of a pulse and respiration. If a pulse is
not present, start CPR (Cardiopulmonary
Resuscitation) and call for emergency medical
assistance. If a pulse is present, respiration may be
restored by using mouth-to-mouth resuscitation,
but call for emergency medical assistance.
Low Voltage
Control circuits used in the temperature control
unit are low voltage (12 and 24 Vdc). This voltage
potential is not considered dangerous, but the
large amount of current available (over 30 amps)
can cause severe burns if shorted or ground.
Do not wear jewelry, watch or rings when
working on the unit. If these items contact an
electrical circuit, severe burns may result.
Battery Installation and Cable
Routing
WARNING: Improperly installed battery
could result in a fire or explosion! A
Thermo King approved battery must be
installed and properly secured to the
battery tray.
WARNING: Improperly installed battery
cables could result in fire or explosion!
Battery cables must be installed, routed
and secured properly to prevent them from
rubbing, chaffing or making contact with
hot, sharp or rotating components.
WARNING: Do not attach fuel lines or
any additional wiring harnesses to the
battery cables as this could cause an
electrical fire!
CAUTION: Do not connect other
manufacturer’s equipment or accessories
to the Thermo King unit. This could result
in severe damage to equipment and void
the warranty!
CAUTION: Set all unit electrical controls
to the OFF position before connecting
battery cables to the battery to prevent unit
from starting unexpectedly and causing
personal injury.
CAUTION: Always wear protective
clothing, gloves and eye wear when
handling and installing batteries. Battery
acid can cause serious burns when
exposed to eyes or skin. If battery acid
contacts skin or clothing, wash
immediately with soap and water. If acid
enters your eye, immediately flood it with
running cold water for at least twenty
minutes and get medical attention
immediately.
CAUTION: Always cover battery
terminals to prevent them from making
contact with metal components during
battery installation. Battery terminals
grounding against metal could cause the
battery to explode.

15
Model Systems (System Designations)
Thermo King Model V-520 Truck Refrigeration Systems
NOTE: When calling the dealer or factory for information or parts please have the Bill of Material
number for your particular unit handy.
System Designation System
Number Install Kit Refrigerant Schematic, Wiring Diagrams
V-520 10 900829 800319 R-134a 2E54898, 2E54899
V-520 20 900830 800319 R-134a 1PH = 2E54900, 2E54901
3PH = 2E54902, 2E54903
V-520 30 902041 800319 R-134a 2E54898, 2E54899
V-520 50 902049 800319 R-134a 1PH = 2E54900, 2E54901
3PH = 2E54902, 2E54903
V-520 MAX 10 900831 800319 R-404A 2E54898, 2E54899
V-520 MAX 20 900833 800319 R-404A 1PH = 2E54900, 2E54901
3PH = 2E54902, 2E54903
V-520 MAX 30 902053 800319 R-404A 2E54898, 2E54899
V-520 MAX 50 902054 800319 R-404A 1PH = 2E54900, 2E54901
3PH = 2E54902, 2E54903
V-520 SPECTRUM 10 900834 800323 R-404A 1E49423, 1E49424
V-520 SPECTRUM 20 900835 800323 R-404A 1PH = 1E49440, 1E49441
3PH = 1E49443, 1E49442
V-520 SPECTRUM 50 902235 800768 R-404A 1PH = 2E54904, 2E54905
3PH = 2E54906, 2E54907

16
Specifications
Electrical System
Fuses 12 Volt 24 Volt
Fuse 1: Power Supply Circuit to PCB1 5 amps 5 amps
Fuse 2: Condenser Fan Motor (CFM1) 15 amps 10 amps
Fuse 3: Evaporator Fan Motor (EF1) 15 amps 10 amps
Fuse 4: Evaporator Fan Motor (EF2) 15 amps 10 amps
Fuse 5: Compressor Clutch 1 (CCL1), Liquid Injection Switch (LIS),
Liquid Injection Valve (LIV), Host Hot Gas Defrost Solenoid Valve
(PS1), Compressor Motor Contactor (CC), 26A Circuit to Heat
Option
20 amps 10 amps
Fuse 6: Condenser Fan 1, 2 (CFM1and CFM2) 2 amps 2 amps
Fuse 7: Condenser Fan Motor (CFM2) 15 amps 10 amps
Fuse 8: Remote Liquid Solenoid Valve (PS2), Host Liquid Solenoid
Valve (PS3), Remote Hot Gas Defrost Solenoid Valve (PS4),
Suction Bypass Solenoid (PS6)
20 amps 10 amps
Fuse 9: Evaporator Fan Motor (EFM3) 15 amps 10 amps
Fuse 10: Evaporator Fan Motor (EFM4) 15 amps 10 amps
Fuse 11: Defrost Drain Heaters (DH1 and DH2) 2 amps 2 amps
Fuse 20: Transformer Input (L1) 4 amps 4 amps
Fuse 21: Battery Relay (Located in 2 wire near battery) 15 amps 15 amps
Transformer Output Fuses(X1 and X4) 5 amps 5 amps
Condenser Fan Motors
Voltage Full Load rpm Full Load Current
13 Vdc 3000 9.2 Amps
Evaporator Fan Motors
Voltage Full Load rpm Full Load Current
13 Vdc 2700 6.2 Amps
Coils for Hot Gas Defrost, Liquid, Block Off, and Suction Bypass Solenoids
Voltage Current Resistance
12 Vdc 2.3 amps 5.2 ohms
Coil for Liquid Injection Valve Solenoid
Voltage Current Resistance
12 Vdc 0.7 amps 17.0 ohms
Drain Heaters (Each) - MAX Only
Voltage Current Resistance
12 Vdc 0.9 amps 14.0 ohms

Specifications
17
Refrigerant System
R-134A REFRIGERATION SYSTEM (V-520)
Refrigerant Charge: V-520 - Model 10 7.93 lb (3.60 kg) R-134a
V-520 - Model 20 7.93 lb (3.60 kg) R-134a
V-520 - Model 30 8.00 lb (3.63 kg) R-134a
V-520 - Model 50 8.00 lb (3.63 kg) R-134a
Defrost Termination Switch: Opens 48.0 ± 5.4 F (8.9 ± 3.0 C)
Closes 36.0 ± 5.4 F (2.2 ± 3.0 C)
Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)
Closes 230 ± 5 F (110 ± 3 C)
Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum (-17 to -34 kPa)
Closes 4 to 7 psig (28 to 48 kPa)
Engine Driven Compressor Pressure Regulator (CPR) Valve Setting -
Model 30 and 50 Only 50.0 psig (345 kPa)
Electric Standby Suction Pressure Regulator (SPR) Valve Setting - Model
20 and 50 Only 39.0 psig (269 kPa)
R-404A REFRIGERATION SYSTEM (V-520 Max)
Refrigerant Charge: V-520 MAX - Model 10 8.15 lb (3.70 kg) R-404A
V-520 MAX - Model 20 8.15 lb (3.70 kg) R-404A
V-520 MAX - Model 30 8.25 lb (3.74 kg) R-404A
V-520 MAX - Model 50 8.25 lb (3.74 kg) R-404A
V-520 SPECTRUM - Model 10 9.75 lb (4.42 kg) R-404A
V-520 SPECTRUM - Model 20 9.75 lb (4.42 kg) R-404A
V-520 SPECTRUM - Model 50 9.85 lb (4.47 kg) R-404A
Defrost Termination Switch: Opens 48.0 ± 5.4 F (8.9 ± 3.0 C)
Closes 36.0 ± 5.4 F (2.2 ± 3.0 C)
Liquid Injection Switch (LIS): Opens 200 ± 5 F (93 ± 3 C)
Closes 230 ± 5 F (110 ± 3 C)
Low Pressure Cutout: Opens 5 to 11 in. Hg vacuum(-17 to -34 kPa)
Closes 4 to 7 psig (28 to 48 kPa)
Engine Driven Compressor Pressure Regulator (CPR) Valve Setting -
Model 30 and 50 Only 50.0 psig (345 kPa)
Electric Standby Suction Pressure Regulator (SPR) Valve Setting - Model
20 and 50 Only 39.0 psig (269 kPa)
Suction Bypass CPR Valve Setting - SPECTRUM Only See “Suction Bypass CPR Valve
Setup Procedure” on page 58.

Specifications
18
Belt Tension (Using Tool P/N 204-427)
AC Semi-Hermetic Compressor
Electric Standby Power Requirements
Electric Heaters
Compressors
Main Compressor 10 cu. in. (163 cc), Engine Driven, Swash Plate, 6
Cylinder
Electric Standby Compressor - Model 20 and 50 Only D211Y, Reciprocating, 3 Cylinder,
System Oil Capacity: Model 10 12 oz (355 cc)
Model 20 64 oz (1893 cc)
Model 30 18 oz (532 cc)
Model 50 70 oz (2070 cc)
SPECTRUM Model 10 16 oz (473 cc)
SPECTRUM Model 20 68 oz (2011 cc)
SPECTRUM Model 50 74 oz (2188 cc)
Compressor Oil Type Polyol Ester P/N 203-515
Defrost Method: Hot gas
Defrost Timer: Initiation Interval Adjustable, 1 hour to 10 hours
Termination Interval Termination is not timed.
Defrost is terminated by Klixon switch.
CAUTION: Failure to use correct Thermo King recommended oil will invalidate your warranty.
Field Reset
Engine Driven Compressor Belt Check vehicle manufacturer specifications
Voltage/Phase/Frequency Horsepower Kilowatts RPM Full Load
(Amps) Locked Rotor Amps
230V/3PH/60Hz 2 1.5 1740 14.1 86.9
230V/1PH/60Hz 2 1.5 1740 16.0 83.2
400V/3PH/60Hz 2 1.5 1740 8.1 29.9
400V/3PH/50Hz 2 1.5 1450 6.8 24.9
Supply Circuit Breaker 20 amp
Extension Cord Size 25 ft - 10 gauge, up to 75 ft - 8 gauge
Voltage Power Rating Watts Current Resistance
208/230 2000 14.7 Amps 16.2 ohms at 230 V