Thermo King V-520 Series User manual

Revision C
March 2023 TTKK 5544334433--1188--MMMM--EENN
Truck Edition
V-520, V-520 MAX, V-520 SPECTRUM
Maintenance Manual

©2018 Trane Technologies TK 54343-18-MM-EN
Introduction
This manual is published for informa ional purposes only. Thermo King®makes no represen a ions warran ies express
or implied, wi h respec o he informa ion recommenda ions and descrip ions con ained herein. Informa ion provided
should no be regarded as all-inclusive or covering all con ingencies. If fur her informa ion is required, Thermo King
Service Depar men should be consul ed.
TThheerrmmoo KKiinngg’’ss wwaarrrraann yy sshhaallll nnoo aappppllyy oo aannyy eeqquuiippmmeenn wwhhiicchh hhaass bbeeeenn ““ssoo iinnss aalllleedd,, mmaaiinn aaiinneedd,, rreeppaaiirreedd
oorr aall eerreedd aass,, iinn hhee mmaannuuffaacc uurreerr’’ss jjuuddggmmeenn ,, oo aaffffeecc ii ss iinn eeggrrii yy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
Revision istory
Revision A (08/18) New format and other general updates.
Revision B (06/2022) Updated maintenance inspection schedule and clutch air gap specification.
Revision C (03/2023) Updated MAX units for R-452A refrigerant, see service bulletin SB874.
General Information
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 Operator’s Manual TK 54342
V-520 Series Parts Manual TK 53990
V-520 SPECTRUM Parts Manual TK 54016
Direct Smart Reefer Microprocessor Control System Diagnostic Manual TK 52573
V-520 Series Diagrams Manual TK 56674
V-520 Series Installation Manual TK 54014
Vehicle Powered Truck Installation Standards and Procedures TK 56430
Vehicle Powered Truck Refrigerant Charging Procedure TK 56392
Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo
King units.

TK 54343-18-MM-EN 3
Recover Refrigerant
NNoottee In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas
Regulations must be observed when working on refrigeration systems.
A Thermo King®, we recognize he need o preserve he environmen and limi he po en ial harm o he ozone layer
ha can resul from allowing refrigeran o escape in o he a mosphere.
We s ric ly adhere o a policy ha promo es he recovery and limi s he loss of refrigeran in o he a mosphere.
When working on ranspor empera ure con rol sys ems, a recovery process ha preven s or minimizes refrigeran
loss o he a mosphere is required by law. In addi ion, service personnel mus be aware of he appropria e European
Union, Na ional, Federal, S a e, and/or Local regula ions governing he use of refrigeran s and cer ifica ion of
echnicians. For addi ional informa ion on regula ions and echnician programs, con ac your local THERMO KING
dealer.
SSeerrvviiccee TToooollss - Use he proper service ools. Gauge manifold se s should include appropria e shu off valves or
disconnec s near he end of each service line.
RReeccoovveerryy EEqquuiippmmeenn - Recovery equipmen mus be used. Proper recovering, s oring and recycling of refrigeran s is
an impor an par of all service work.
SSeerrvviiccee PPrroocceedduurreess - Recommended procedures mus be used o minimize refrigeran loss.
CCoommppoonneenn ss mmaayy bbee iissoollaa eedd by closing service valves and performing sys em pump-downs.
CCoommppoonneenn ss uunnaabbllee oo bbee iissoollaa eedd for service mus be repaired only af er refrigeran is properly recovered.
R-134a/R-404A/R-452A
R-134aR-404AR452A
NNOOTTIICCEE
EEqquuiippmmeenn DDaammaaggee!!
UUssee oonnllyy PPoollyyoolleess eerr--bbaasseedd rreeffrriiggeerraa iioonn ccoommpprreessssoorr ooiill iinn RR--113344aa//RR--440044AA//RR--445522AA ssyyss eemmss.. SSeeee TThheerrmmoo KKiinngg
PPaarr ss MMaannuuaall ffoorr ppaarr nnuummbbeerr..
NNOOTTIICCEE
SSyyss eemm CCoonn aammiinnaa iioonn!!
DDoo nnoo mmiixx PPoollyyoolleess eerr aanndd ss aannddaarrdd ssyynn hhee iicc ccoommpprreessssoorr ooiillss.. KKeeeepp PPoollyyoolleess eerr ccoommpprreessssoorr ooiill iinn iigghh llyy
sseeaalleedd ccoonn aaiinneerrss.. IIff PPoollyyoolleess eerr ooiill bbeeccoommeess ccoonn aammiinnaa eedd wwii hh mmooiiss uurree oorr ss aannddaarrdd ooiillss,, ddiissppoossee ooff
pprrooppeerrllyy––DDOO NNOOTT UUSSEE..
NNOOTTIICCEE
SSyyss eemm CCoonn aammiinnaa iioonn!!
WWhheenn sseerrvviicciinngg TThheerrmmoo KKiinngg RR--113344aa,, RR--2233,, RR--440044AA,, RR--445522AA oorr RR--551133AA uunnii ss,, uussee oonnllyy hhoossee sseerrvviiccee oooollss
cceerr iiffiieedd ffoorr aanndd ddeeddiiccaa eedd oo RR--113344aa//RR--2233//RR--440044AA//RR--445522AA//RR--551133AA rreeffrriiggeerraann aanndd PPoollyyoolleess eerr ccoommpprreessssoorr ooiillss..
RReessiidduuaall nnoonn--HHFFCC rreeffrriiggeerraann ss oorr ooiillss wwiillll ccoonn aammiinnaa ee RR--113344aa//RR--2233//RR--440044AA//RR--445522AA//RR--551133AA ssyyss eemmss..PPlleeaassee
cchheecckk sseerriiaall## ppllaa ee ffoorr yyppee aanndd vvoolluummee ooff RReeffrriiggeerraann cchhaarrggeedd.. PPlleeaassee ddoo nnoo bblleenndd wwii hh oo hheerr rreeffrriiggeerraann ss
hhaann hhee oorriiggiinnaall cchhaarrggeedd rreeffrriiggeerraann
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4TK 54343-18-MM-EN
About This Manual
Purpose
The purpose of his manual is o provide general main enance informa ion necessary o main ain he clima e con rol
uni a peak opera ing s andards. This includes safe y informa ion, uni informa ion such as bills of ma erial and ki
numbers, general uni informa ion, main enance procedures and rela ed informa ion (such as wiring and schema ic
diagrams), and some diagnos ic and roubleshoo ing informa ion.
NNoottee This manual may cover more than one unit. Therefore, it may contain information not applicable to your unit.
Contents
This manual is organized in o he following chap ers:
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 make up your unit.
Use them for the following purposes:
1. To 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 matrix, call TK Service for more information.
2. To communicate with TK Service Department: If you need to call TK
Service, you must know your model number(s) in order for the service
representative to help you.
Specifications Lists unit specifications.
Unit Description Gives an overview description of your unit including standard and optional
features, illustrations, and general a/c theory.
Maintenance Inspection Schedule Table of routine maintenance procedures.
Maintenance Chapters Provide detailed maintenance procedures required for your unit. (Electrical,
Refrigeration, Compressor, Clutch, Structural)
Diagnosis Chapters Provides troubleshooting information for diagnosing problems.
Diagrams Wiring, Schematic and Refrigeration diagrams applicable to the unit.
Before you Call Thermo King Service!
Who o call: Your Thermo King Service Represen a ive.
Before you call Thermo King Service, have he following informa ion on hand:
• Bill of Ma erial (usually loca ed on he uni serial pla e)
• Model Number - found on side of he uni
Blank Pages
This manual may con ain blank pages a he end of chap ers. This is normal. There is no informa ion missing from he
manual.
Roadside/Curbside Terminology
Roadside/Curbside erminology: These erms can be confusing because of differences be ween Nor h America and
Europe. Please no e:
Curbside: The side of the truck to the driver’s right when the driver is in his seat and facing forward.
Roadside: The side of the truck to the driver’s left when the driver is in his seat and facing forward.
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TK 54343-18-MM-EN 5
Using the Model Systems Tables in “Model Systems (System Designations)”
The Model Sys ems Tables in his sec ion lis impor an uni informa ion ha you will need o communica e wi h he
Thermo King Service Depar men .
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