Ingersoll-Rand THERMO KING NAD Truck Edition V-200 Series User manual

Installation Manual
Providing equipment and services to manage controlled-temperature environments for
food and other temperature-sensitive products, our Climate Control Technologies sector
encompasses both transport and stationary refrigeration solutions. Our product brands include
Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a
manufacturer of refrigeration and food merchandising equipment.
www.thermoking.com www.hussmann.com www.ingersollrand.com
©2008 Ingersoll-Rand Company
Printed in U.S.A. on Recycled Paper
NAD Truck Edition
V-200 and V-300 Series
TK 51856-1-IM (Rev. 7, 02/12)

Installation Manual
NAD Truck Edition
V-200 and V-300 Series
TK 51856-1-IM (Rev. 7, 02/12)
Copyright©2003 Thermo King Corp., Minneapolis, MN, U.S.A.

V-200 and V-300 Installation Manual
Release History
Released 04/03
Rev. 0 05/03
Rev. 1 06/03 Page 38: changed electrical hose to electrical harness.
Rev. 2 10/03 Pages 76-83: replaced text and art, changed heater option information at rear of manual.
Rev. 3 11/03
Rev. 4 01/04
Rev. 5 05/11
Rev. 6 05/04
Rev. 7 02/12 Pages 48-49; added new remote receptacle, removed MTC from manual

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Introduction
This installation manual was written to help assist with the installation of Thermo King V-200 and V-300 Series refrigeration units with remote evaporators
onto either a truck or a van designed and built for refrigerated applications. Due to its complexity, do not attempt this installation unless you:
• Are an experienced mechanic.
• Can safely lift 34 kg (75 lb).
• Are certified or approved in the repair and maintenance of transport
refrigeration systems.
• Have a basic understanding of electricity and electrical wiring.
• Have the necessary tools and equipment to complete the installation.
• Have a truck body designed and built to meet the requirements of this
installation.
This manual is published for informational purposes only. Thermo King makes no representations or warranties, express or implied, with respect to the
information, recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies.
If further information is required, Thermo King Corporation Service Department should be contacted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s judgment, to
affect its integrity”.
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential
damages whatsoever, arising out of the use of this manual or any information, recommendations or descriptions contained herein.

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Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Tips for a Successful Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Unpacking and Inspecting Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Installation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Installation of the Engine Driven Compressor . . . . . . . . . . . . . . . . . . . . . . .16
Installation of the Roof Mounted Condenser Unit . . . . . . . . . . . . . . . . . . . . .18
Installation of the Nose Mounted Condenser Unit . . . . . . . . . . . . . . . . . . . .20
Installation of the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Fabricating Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Installation of Hoses to the Vehicle’s Compressor . . . . . . . . . . . . . . . . . . . .30
Installation of the Jet Cool System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Installation of Hoses to the Condenser Unit . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation of Hoses to the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
System Leak Check and Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical Connections to the Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation of the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation of the In-Cab Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation of the Electric Standby Power Supply (OPTION) . . . . . . . . . . . 48
Electrical Connections to the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installing the Heater (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54