Installation Manual Truck Edition V-500 Series - Thermo King

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This manual was written to assist with the installation of a Thermo King V-500 condenser unit and a ES-500 remote evaporator onto trucks designed and built for refrigerated applications. Due to its complexity, you should not attempt this installation unless you: • Are an experienced mechanic. Can safely lift 34 kilos (75 lbs.) Are certified or trained 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. Introduction This manual is published for informational purposes only. Thermo King makes no representations 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 consulted. 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. 2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Tips for a Successful Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 V-500 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ES-500 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation of Vehicle Powered Compressor . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation of V-500 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation of ES-500 / ES-500 MAX Evaporator . . . . . . . . . . . . . . . . . . . . . 18 Fabricating Refrigeration Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installation of Hoses to the Vehicle’s Compressor . . . . . . . . . . . . . . . . . . . 26 Installation of the Jet Cool System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installation of Hoses to Condenser Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Table of Contents Installation of Hoses to Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 System Leak Check and Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electrical Connections - Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installation of Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Installation of the In-Cab Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Installation of the Electric Standby Power Supply (Option) . . . . . . . . . . . . 42 Electrical Connections - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Refrigeration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Wiring Schematics and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 3
Page 1: Installation Manual Truck Edition V
Page 5 and 6: Recover Refrigerant At Thermo King,
Page 7 and 8: WARNING: Never drill holes in the u
Page 9 and 10: Always keep electrical harness and
Page 11 and 12: Required Tools 11
Page 13 and 14: ES-500 Dimensions A. 22.0 in. (562
Page 15 and 16: Installation of Vehicle Powered Com
Page 17 and 18: Installation of V-500 Condenser 17
Page 19 and 20: Installation of ES-500 / ES-500 MAX
Page 21 and 22: Cut the Hose 1. Cut the hose to pro
Page 23 and 24: Snap on the Cage. 5. Snap the cage
Page 25 and 26: CAUTION: TK 2000 Speedy Clip System
Page 27 and 28: Installation of Hoses to the Vehicl
Page 29 and 30: Installation of the Jet Cool System
Page 31 and 32: Installation of Hoses to Condenser
Page 33 and 34: Installation of Hoses to Evaporator
Page 35 and 36: System Leak Check and Evacuation 35
Page 37 and 38: Electrical Connections - Evaporator
Page 39 and 40: Installation of Drain Hoses 39
Page 41 and 42: Installation of the In-Cab Controll
Page 43 and 44: Installation of the Electric Standb
Page 45 and 46: Electrical Connections -Battery 45
Page 47 and 48: System Charging 47
Page 49: Refrigeration Diagrams 49

Installation Manual Truck Edition V-500 Series - Thermo King

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