Trane Thermo King V-220 Series User manual

Revision A
May 2018 TTKK 5566332211--1188--IIMM--EENN
Vehicle Powered Truck Edition
V-220/V-320 Series
Single Temperature Systems
Installation Manual

©2018 Trane Techn l gies TK 56321-18-IM-EN
Introduction
This manual was written t assist with the basic installati n f a Therm King®c mp nents nt trucks designed and
built f r refrigerated applicati ns. The TThheerrmm KKiinngg IInnssttaallllaattii nn SSttaannddaarrddss aanndd PPrr cceedduurreess GGuuiiddee (TK 56430)
pr vides m re detailed inf rmati n that must be f ll wed t safely and pr perly c mplete the entire installati n.
Due t its c mplexity, y u sh uld n t attempt this installati n unless y u:
• Are an experienced mechanic.
• Can safely lift 34 kil s (75 lbs.).
• In the U.S., EPA 608 certified and trained in the repair and maintenance f transp rt refrigerati n systems.
• Have a basic understanding f electricity and electrical wiring.
• Have the necessary t ls and equipment t c mplete the installati n.
• Have a truck b dy designed and built t meet the requirements f this installati n.
• F ll w all safety precauti ns utlined in the Therm King Installati n Standards and Pr cedures Guide (TK 56430).
This manual is published f r inf rmati nal purp ses nly. Therm King makes n representati ns warranties express
r implied, with respect t the inf rmati n rec mmendati ns and descripti ns c ntained herein. Inf rmati n pr vided
sh uld n t be regarded as all-inclusive r c vering all c ntingencies. If further inf rmati n is required, Therm King
C rp rati n Service Department sh uld be c nsulted.
TThheerrmm KKiinngg’’ss wwaarrrraannttyy sshhaallll nn tt aappppllyy tt aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ss iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
rr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, tt aaffffeecctt iittss iinntteeggrriittyy..””
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 Histor
Revision A (05/18) New manual format.
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TK 56321-18-IM-EN 3
SSaaffeettyy PPrreeccaauuttii nnss ............................................................................................................................................................ 55
Danger, Warning, Cauti n, and N tice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Precauti ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rec ver Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EEnnggiinnee DDrriivveenn CC mmpprreessss rr IInnssttaallllaattii nn ................................................................................................................ 77
PPrreeppaarriinngg CC nnddeennsseerr ff rr IInnssttaallllaattii nn...................................................................................................................... 88
C ver and Fan H using Rem val (All M dels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fan H using M dificati ns (N sem unt Installati ns Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CC nnddeennsseerr IInnssttaallllaattii nn .. .. .............. .. .. .. .. .. ...... ...... .. .. .. .............. .. .. .. .. .......... ...... .. .. .. .. .......... .. .. .. .. .............. .. .. .. .. .. ............ 1144
EEvvaapp rraatt rr IInnssttaallllaattii nn ................ .. .. .. .. .. .............. .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. ........ 1155
HH ssee CC nnnneeccttii nnss VV--222200 1100 .......... .. .. .. .. .. ................................ .. .. .. .................. .. .. .. .. .............. .. .. .. .. .. ...... ...... .. .. .. .......... 1166
HH ssee CC nnnneeccttii nnss VV--222200 MMAAXX 1100............ ................ ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. 1177
HH ssee CC nnnneeccttii nnss VV--222200 2200 .......... .. .. .. .. .. ................................ .. .. .. .................. .. .. .. .. .............. .. .. .. .. .. ...... ...... .. .. .. .......... 1188
HH ssee CC nnnneeccttii nnss VV--222200 MMAAXX 2200............ ................ ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. 1199
HH ssee CC nnnneeccttii nnss VV--332200 1100 .......... .. .. .. .. .. ................................ .. .. .. .................. .. .. .. .. .............. .. .. .. .. .. ...... ...... .. .. .. .......... 2200
HH ssee CC nnnneeccttii nnss VV--332200 MMAAXX 1100............ ................ ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. 2211
HH ssee CC nnnneeccttii nnss VV--332200 2200 .......... .. .. .. .. .. ................................ .. .. .. .................. .. .. .. .. .............. .. .. .. .. .. ...... ...... .. .. .. .......... 2222
HH ssee CC nnnneeccttii nnss VV--332200 MMAAXX 2200............ ................ ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. 2233
HH ssee CC nnnneeccttii nnss VV--332200 MMAAXX 3300............ ................ ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. 2244
HH ssee CC nnnneeccttii nnss VV--332200 MMAAXX 5500............ ................ ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. .................. .. 2255
HH ssee CC nnnneeccttii nnss tt AAccccuummuullaatt rr AAsssseemmbbllyy VV--332200 MMAAXX 3300//MMAAXX 5500 ..............................................2266
WWiirriinngg CC nnnneeccttii nnss VV--222200//VV--332200 1100 && MMAAXX 1100 .. .. .. ...... ...... .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .......... .. .. .. .. ...... 2277
WWiirriinngg CC nnnneeccttii nnss MM ddeell 2200 && MMAAXX 2200WWiirriinngg CC nnnneeccttii nnss MM ddeell 2200 && 5500 .............................. 2288
WWiirriinngg CC nnnneeccttii nnss VV--332200 MMAAXX 3300 && MMAAXX 5500 ................................................................................................ 2299
IInn--CCaabb CC nnttrr lllleerr IInnssttaallllaattii nn.. .. .. .. .. .. .. ...... ...... .. .. .. .............. .. .. .. .. .......... ...... .. .. .. .............. .. .. .. .. .......... .. .. .. .. .. .. ............ 3300
SSttaannddbbyy RReecceeppttaaccllee BB xx IInnssttaallllaattii nn ((MM ddeellss 2200 aanndd 5500 OOnnllyy)).............................................................. 3311
EEvvaapp rraatt rr DDrraaiinn HH ssee IInnssttaallllaattii nn................ .. .. .. .. .......... .. .. .. .. .................. .. .. .. .. .................. .. .. .. .............. .. .. .. .. ...... 3333
ES-100N/ES150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ES-220/ES-320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ES-200/ES-300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of Contents

4TK 56321-18-IM-EN
CC mmpplleettiinngg tthhee IInnssttaallllaattii nn........ .. .. .. .. .. .. .............. .. .. .. .............. .. .. .. .. .. .............. .. .. .. .... .. .. .. .............. .. .. .. .... .. .. .. ............ 3366
SSuuccttii nn PPrreessssuurree RReegguullaatt rr ((SSPPRR)) AAddjjuussttmmeenntt PPrr cceedduurreess -- MMAAXX 2200 .. .. .. .. .............. .. .. .. .. .. ...... ...... .. 3377
CC mmpprreessss rr PPrreessssuurree RReegguullaatt rr ((CCPPRR)) AAddjjuussttmmeenntt PPrr cceedduurreess -- MMAAXX 3300 ....................................3399
CC mmpprreessss rr PPrreessssuurree RReegguullaatt rr ((CCPPRR)) AAddjjuussttmmeenntt PPrr cceedduurreess -- MMAAXX 5500 ....................................4400
CC mmpprreessss rr OOiill AAmm uunnttss aanndd TTyyppee .. .. .. .......... .. .. .. .. .................. .. .. .. .. .................................... .. .. .. .. .......... .. .. .. .. ...... 4411
RReecc mmmmeennddeedd RReeffrriiggeerraanntt CChhaarrggee bbyy MM ddeell.................................................................................................. 4433
CC nnddeennsseerr aanndd EEvvaapp rraatt rr DDiimmeennssii nnss ............................................................................................................4444
TTaabbllee ff CC nntteennttss

TK 56321-18-IM-EN 5
Safet Precautions
Danger, Warning, Caution, and Notice
Therm King®rec mmends that all service be perf rmed by a Therm King dealer and t be aware f several general
safety practices.
Safety advis ries appear thr ugh ut this manual as required (refer t examples bel w). Y ur pers nal safety and the
pr per perati n f this unit depend up n the strict bservance f these precauti ns.
DDAANNGGEERR
EExxaammppllee!!
IInnddiiccaatteess aann iimmmmiinneennttllyy hhaazzaarrdd uuss ssiittuuaattii nn wwhhiicchh,, iiff nn tt aavv iiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh rr sseerrii uuss iinnjjuurryy..
WWAARRNNIINNGG
EExxaammppllee!!
IInnddiiccaatteess aa pp tteennttiiaallllyy hhaazzaarrdd uuss ssiittuuaattii nn wwhhiicchh,, iiff nn tt aavv iiddeedd,, cc uulldd rreessuulltt iinn ddeeaatthh rr sseerrii uuss iinnjjuurryy..
CCAAUUTTIIOONN
EExxaammppllee!!
IInnddiiccaatteess aa pp tteennttiiaallllyy hhaazzaarrdd uuss ssiittuuaattii nn wwhhiicchh,, iiff nn tt aavv iiddeedd,, cc uulldd rreessuulltt iinn mmiinn rr rr mm ddeerraattee iinnjjuurryy aanndd
uunnssaaffee pprraaccttiicceess..
NN TTIICCEE
EExxaammppllee!!
IInnddiiccaatteess aa ssiittuuaattii nn tthhaatt cc uulldd rreessuulltt iinn eeqquuiippmmeenntt rr pprr ppeerrttyy--ddaammaaggee nnllyy aacccciiddeennttss..
Safet Precautions
IImmppoorrttaanntt:: Additional Safety Precautions must be followed when installing this unit. See “Section 2 - Safety
Precautions” in the Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK
56430).
CCAAUUTTIIOONN
RRiisskk ff IInnjjuurryy!!
TThheerrmm KKiinngg cc nnddeennsseerr uunniittss aanndd rreemm ttee eevvaapp rraatt rrss aarree sshhiippppeedd wwiitthh aa 3355 kkPPaa ((55 ppssii)) hh llddiinngg cchhaarrggee ff
HHeelliiuumm.. BBee ccaarreeffuull wwhheenn rreemm vviinngg ccaapp.. TThhiiss hh llddiinngg cchhaarrggee mmaayy bbee ssaaffeellyy vveenntteedd iinntt tthhee aattmm sspphheerree..
NN TTIICCEE
CC mmpprreessss rr DDaammaaggee!!
SSEEVVEERREE CCOOMMPPRREESSSSOORR DDAAMMAAGGEE wwiillll rreessuulltt ffrr mm ppeerraattiinngg tthhee uunniitt bbeeff rree cc mmpplleettiinngg tthhee iinnssttaallllaattii nn wwhhiicchh
iinncclluuddeess:: iinnssttaalllliinngg tthhee cc mmpp nneennttss,, rreelleeaassiinngg tthhee hh llddiinngg cchhaarrggee,, cc nnnneeccttiinngg rreeffrriiggeerraattii nn lliinneess,, lleeaakk tteessttiinngg,,
eevvaaccuuaattii nn,, cclleeaann--uupp,, aanndd cchhaarrggiinngg ff tthhee ssyysstteemm wwiitthh tthhee pprr ppeerr aamm uunntt aanndd ttyyppee ff rreeffrriiggeerraanntt..
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.
At Therm King®, we rec gnize the need t preserve the envir nment and limit the p tential harm t the z ne layer
that can result fr m all wing refrigerant t escape int the atm sphere.
We strictly adhere t a p licy that pr m tes the rec very and limits the l ss f refrigerant int the atm sphere.

6TK 56321-18-IM-EN
When w rking n transp rt temperature c ntr l systems, a rec very pr cess that prevents r minimizes refrigerant
l ss t the atm sphere is required by law. In additi n, service pers nnel must be aware f the appr priate Eur pean
Uni n, Nati nal, Federal, State, and/ r L cal regulati ns g verning the use f refrigerants and certificati n f
technicians. F r additi nal inf rmati n n regulati ns and technician pr grams, c ntact y ur l cal THERMO KING
dealer.
SSeerrvviiccee TT llss - Use the pr per service t ls. Gauge manif ld sets sh uld include appr priate shut ff valves r
disc nnects near the end f each service line.
RReecc vveerryy EEqquuiippmmeenntt - Rec very equipment must be used. Pr per rec vering, st ring and recycling f refrigerants is
an imp rtant part f all service w rk.
SSeerrvviiccee PPrr cceedduurreess - Rec mmended pr cedures must be used t minimize refrigerant l ss.
CC mmpp nneennttss mmaayy bbee iiss llaatteedd by cl sing service valves and perf rming system pump-d wns.
CC mmpp nneennttss uunnaabbllee tt bbee iiss llaatteedd f r service must be repaired nly after refrigerant is pr perly rec vered.
SSaaffeettyy PPrreeccaauuttii nnss

TK 56321-18-IM-EN 7
Engine Driven Compressor Installation
IImmppoorrttaanntt:: See Section 5 - Compressor Selection and Installation Standards in the Thermo King Vehicle Powered Truck
Installation Standards and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
IImmppoorrttaanntt:: Failure to add the correct amount and type of oil will damage the compressor! Refer to “Compressor il
Requirements,” p. .
IImmppoorrttaanntt:: It is critical that a P–trap is installed in the suction line bbeeffoorree the roadside compressor. See Section 6 –
Refrigerant Hose and Fittings Standards in the Thermo King Vehicle Powered Truck Installation Standards
and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!

8TK 56321-18-IM-EN
Preparing Condenser for Installation
Cover and Fan Housing Removal (All Models)
T access the unit m unting h les:
1. Rem ve plastic c ndenser c ver.
2. Rem ve the fan h using assembly. (Rem ve the fan c nnect r)
3. Rem ve “P wer Off Device” C nnect r and Electric B x C ver
4. M unting h les are n w accessible

TK 56321-18-IM-EN 9
PPrreeppaarriinngg CC nnddeennsseerr ff rr IInnssttaallllaattii nn

10 TK 56321-18-IM-EN
Fan Housing Modifications (Nosemount Installations Onl )
Turn fan h using ver and use a hand saw t trim the area sh wn f r refrigerati n h se clearance.
NNoottee:: The fan housing assembly will be reinstalled later.
1. Access for Hoses and Harnesses
PPrreeppaarriinngg CC nnddeennsseerr ff rr IInnssttaallllaattii nn