Maintenance Manual

VM-300/305
VM-300/305 MAX
VM-305 MAX
Bitemp

Thermo King Europe • Monivea Road • Mervue, Galway • Ireland

 The maintenance information in this section covers R-134a/R-404A unit models:
VM-400 -10 12V P/N 10205705
VM-300 12V P/N 10205503
VM-300 24V P/N 10205504
VM-300 MAX 12V P/N 10205507
VM-300 MAX 24V P/N 10205508
VM-305 1PH 12V P/N 10205527
VM-305 1PH 24V P/N 10205528
VM-305 3PH 12V P/N 10205461
VM-305 3PH 24V P/N 10205462
VM-305 415V/3/50HZ 24V P/N 10205466
VM-305 415V/3/50HZ 12V P/N 10205465
VM-305 MAX 3PH 12V P/N 10205479
VM-305 MAX 3PH 24V P/N 10205480
VM-305 MAX 3PH Bitemp 270mm 12V P/N 10205485
VM-305 MAX 3PH Bitemp 270mm 24V P/N 10205486
VM-305 MAX 3PH Bitemp SLE 12V P/N 10205487
VM-305 MAX 3PH Bitemp SLE 24V P/N 10205488
VM-305 MAX 415V/3/50HZ 12V P/N 10205518
VM-305 MAX 415V/3/50HZ 24V P/N 10205519
VM-305 MAX 3PH EL 24V P/N 10205524

For further information refer to the common section TKSP 031.

The information in this section is provided to assist owners, operators and service people in the
proper upkeep and preventive maintenance of Thermo King units. For detailed descriptions of
Thermo King refrigeration systems, see Thermo King Refrigeration Systems Maintenance Manual.

This section 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 section 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
plant as, in the manufacturer's judgment, to affect its stability".
No warranties, express or implied, including warranties of fitness for a particular purpose of 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 failures.
 Table Of Contents

1 Specifications ..................................................................................................... 1-1

1.1 Refrigeration Specifications (VM-300/305) .......................................................... 1-1
1.2 Refrigeration Specifications (VM-300/305 Max, VM-305 Max Bitemp) ................ 1-1
1.3 Electrical system .................................................................................................. 1-2
2 Electric Box (with PCB P.E.-8)........................................................................... 2-1
2.1 P.C. Board............................................................................................................ 2-1
2.2 Connectors ........................................................................................................... 2-1
2.3 Fuses ................................................................................................................... 2-1
2.4 Stand-By Fuses.................................................................................................... 2-2
2.5 Relays .................................................................................................................. 2-2
2.6 Stand-By Relays .................................................................................................. 2-2
3 Electric Box (with P.C. Board P.E.-9)................................................................ 3-1
3.1 P.C. Board............................................................................................................ 3-1
3.2 Connectors ........................................................................................................... 3-1
3.3 Common Fuses .................................................................................................... 3-1
3.4 Stand-By Fuses (On Stand-by Units) ................................................................... 3-2
3.5 Common Relays................................................................................................... 3-2
3.6 Stand-By Relays (On Stand-by Units).................................................................. 3-2
4 VM-305 Max Bitemp Electric Box
(with P.C. Board P.E.-11).................................................................................... 4-1
4.1 P.C. Board............................................................................................................ 4-1
4.2 Connectors ........................................................................................................... 4-1
4.3 Fuses ................................................................................................................... 4-1
4.4 Relays .................................................................................................................. 4-2
5 Unit Description.................................................................................................. 5-1
5.1 Unit Features........................................................................................................ 5-2

TK 50978-1-MS (09/00 E)
 1 SPECIFICATIONS
1.1 REFRIGERATION SPECIFICATIONS (VM-300/305)
Compressor: SELTEC TM 16HD / FRASCOLD 1.5 HP
Compressor Oil Charge: O'Road: 177 cc / Stand-by: 1250 cc
Compressor Oil Type: Polyol Ester P/N 203413
Refrigerant Charge & Type: VM-300 2.0 kg R-134a
VM-305 2.2 kg R-134a
Defrost Method: Hot gas
Defrost Termination Switch: Opens 8.9 ± 3°C
Closes 2.2 ± 3°C
High Pressure Cutout Switch: Opens 2068 -0 +172 kPa (300 -0 +25 psi)
Closes 1379 ± 138 kPa (200 ± 20 psi)
Low Pressure Cutout Switch: Opens 5 to 11 inch. vacuum
Closes 27.6 to 48.3 kPa (4 to 7 psi)
Condenser Fan Pressure Switch: Opens 896 ± 69 kPa (130 ±10 psi)
Closes 1241 ± 69 kPa (180 ±10 psi)
Defrost Timer: Initiation Interval: from 1 minute to 10 hours
Termination when defrost termination switch opens.

1.2 REFRIGERATION SPECIFICATIONS (VM-300/305 MAX, VM-305 MAX BITEMP)

Compressor: SELTEC TM 16HD / FRASCOLD 1.5 HP
Compressor Oil Charge: O'Road: 177 cc / Stand-by: 1250 cc
Compressor Oil Type: Polyol Ester P/N 203413
Refrigerant Charge & Type: VM-300 MAX 1.75 kg R-404A
VM-305 MAX 1.9 kg R-404A
VM-305 MAX Bitemp 2.2 kg R-404A
Defrost Method: Hot gas
Defrost Termination Switch: Opens 8.9 ± 3°C
Closes 2.2 ± 3°C
High Temperature Switch: Opens 93 ± 3°C
Closes 110 ± 3°C
High Pressure Cutout Switch: Opens 2759 ± 70 kPa (450 ± 10 psi)
Closes 1724 ± 70 kPa (375 ± 10 psi)
Low Pressure Cutout Switch: Opens 5 to 11 inch. vacuum
Closes 27.6 to 48.3 kPa (4 to 7 psi)
Defrost Timer: Initiation Interval: from 1 minute to 10 hours
Termination when defrost termination switch opens.

CAUTION!
When the oil is removed from the compressor, oil level should be noted so that the same level can be
maintained in the replacement compressor.

TK 50978-1-MS (09/00 E)
1-2 Specifications

Polyol Ester compressor oil should be used in standard Thermo King units. PAG-type or mineral oils
should not be added to systems using R-134a or R-404A.

1.3 ELECTRICAL SYSTEM

Condenser and Evaporator Fan Motors

Power Full Load Full Load
Voltage Number Rating W rpm Current

Evaporator 14 V 2 98 1850-2500 7A
Evaporator 27 V 2 94 1850-2500 3.5 A
Condenser 14 V 1 98 1850-2500 7A
Condenser 27 V 1 94 1850-2500 3.5 A
SLE Evaporator 13 V 2 100 2800 6.2 A
SLE Evaporator 26 V 2 100 2800 3.7 A

Stand-by AC Compressor
Power Rating in Full Load
Voltage Phase Frequency HP Current

230 1 50 Hz 1.5 10.6

230/400 3 50 Hz 1.5 9.2/5.3 A

Fuses (P.E.-9)
Evap. Fan Evap. Fan M-12B Gral. Std-by Transf.
Voltage Fuse 1 Fuse 2 Fuse 3 Fuse 4/1 Fuse 5 Fuse 6
12 V 15 A 15 A 20 A 1A 3A 4A
24 V 10 A 10 A 15 A 1A 3A 4A

Fuses (P.E.-8)
Transf. Std-by Clutch Coil Cond. Fan Evap. Fan M-12B Gral.
Voltage Fuse 1 Fuse 2 Fuse 3/1 Fuse 3/2 Fuse 3/3 Fuse 4

12 V 4A 3A 10 A 15 A 20 A 1A
24 V 4A 3A 5A 10 A 15 A 1A

Fuses (P.E.-11) (VM-305 MAX Bitemp)

Voltage Fuse 1 Fuse 2 Fuse 3 Fuse 4 Fuse 4/1 Fuse 5 Fuse 6 Fuse 7

12 V 15 A 15 A 25 A 3A 1A 15 A 15 A 6.3 A
24 V 10 A 10 A 20 A 3A 1A 10 A 10 A 6.3 A

TK 50978-1-MS (09/00 E)
Specifications 1-3

Hot Gas Solenoid Coils

Voltage Current Resistance

12 V 2.3 A 5.2 Ω
24 V 1.3 A 20 Ω

Liquid Injection Solenoid Coils

Voltage Current Resistance
12 V 0.71 A 15 ÷ 19 Ω
24 V 0.35 A 62 ÷ 72 Ω

TK 50978-1-MS (09/00 E)
 2 ELECTRIC BOX (WITH PCB P.E.-8)
2.1 P.C. BOARD
All Printed Circuit Boards manufactured by Thermo King
can be easily identified by the P/N stamped on them.
Even though that all P.C. Boards have a similar layout,
there are some differences from one to the others,
depending the unit model and which
functions they carry out (12/24V).
2.2 CONNECTORS
All connector codes (C-1, C-2 & C-3) are stamped on the
P.C. Board.
Pins on connectors are numbered counter-clockwise. (see
drawing)
— C-1 & C-2 (8 Pin)
— C-3 (6 Pin)
2.3 FUSES
The fuses 3/1, 3/2 & 3/3 are located on the P.C. Board.
Fuse 3/1: Protects Compressor Clutch Coil or Defrost
Solenoid Coil (when defrost is energized) from overload.
Fuse 3/2: Protects Condenser Fan Motor from overload.
Fuse 3/3: Protects Evaporator Fan Motors from overload.
TK 50978-1-MS (09/00 E)
2-2 Electric Box (with PCB P.E.-8)

Fuse 4: Protects Cab Control box from overload. It is ER: Electric Stand-By Relay
located inside Cab Control Box.
When energized turns on the CMC relay (turning on the AC
Motor) and disconnects O'road compressor clutch.

CMC: Compressor Motor Contactor

When energized turns on AC Motor of the stand-by
compressor. It is located beside the electric box.

OL: AC Motor Overload Relay

Switches off the unit when the current draw through the AC
Motor is excessive. It is located beside the electric box.

2.4 STAND-BY FUSES

Fuse 1. Protects Transformer from overload. It is located on
the Electric Box beside the OL Relay.
Fuse 2: Protects Cab Control Box and Relays CR & ER
when the unit is working on Stand-by mode operation.
NOTE: Refer to Electrical System (Unit 1.3) for fuse
rating.

2.5 RELAYS
All of them are located on the P.C. Board.

PR: Power Relay

Is energized when the Cab Control Box ON/OFF Switch is
pressed (Unit Start) and the box temperature is higher than
the setpoint temperature.

FR: Evaporator Fan Relay

When energized battery voltage turns on Evaporator and
Condenser Fan Motors. Condenser fan only works if CFPS
is closed.

D: Defrost Relay
It controls operation of the defrost cycle.
The Defrost Relay is energized when the Cab Control Box
Defrost Switch or the Defrost Timer completes the circuit
through the Defrost Termination Switch to ground.
Defrost Relay will remain energized until the defrost
process is terminated by the Defrost Termination Switch
(DK) or the Cab Control Box ON/OFF Switch is pressed.

2.6 STAND-BY RELAYS

The relays CR, and ER are located on the P.C. Board.

CR: Commutation Relay.

When energized changes from Battery Supply to Power
Cord Supply.

TK 50978-1-MS (09/00 E)
3 ELECTRIC BOX (WITH P.C. BOARD P.E.-9)

3.1 P.C. BOARD 3.3 COMMON FUSES

All Printed Circuit Boards manufactured by Thermo King The fuses 1, 2, 3 & 4 are located on the P.C. Board.
can be easily identified by the P/N stamped on them.
Fuse 1: Protects Evaporator fan (EF1) from overload.
Even though all P.C.Boards have a similar layout, there are
Fuse 2: Protects Evaporator fan (EF2) from overload.
some differences from one to the others, depending on the
unit model and on which functions they carry out (12/24V). Fuse 3: Protects:
Condenser Fan Motor
3.2 CONNECTORS Compressor Clutch Coil
All connector codes (C-1, C-2, C-3 & C-4) are stamped on Defrost Solenoid Coil (when defrost is energized)
the P.C. Board. Liquid Injection Valve Coil
Pins on connectors are numbered counter-clockwise. (see Solenoid Valves PS2 and PS3
drawing) from overload.
— C-1 & C-2 (6 Pin)
— C-3 & C-4 (8 Pin)

TK 50978-1-MS (09/00 E)
3-2 Electric Box (with P.C. Board P.E.-9)

Fuse 4/1: Protects Cab Control box from overload. It is
located inside Cab Control Box.
ER: Electric Stand-By Relay
When energized turns on the CMC relay (turning on the AC
Motor) and disconnects O'road compressor clutch.
CMC and OL are located beside the Electric Box.

Fuse 4/1 CMC: Compressor Motor Contactor

When energized turns on AC Motor of the stand-by
compressor.

OL: AC Motor Overload Relay

Switches off the unit when the current draw through the AC
3.4 STAND-BY FUSES (ON STAND-BY Motor is excessive.
UNITS)
Fuse 4: Protects Cab Control Box and Relays CR1, CR2 &
ER when the unit is working on Stand-by mode operation. It
is located on the P.C. Board.
Fuse 6: Protects Transformer from overload. It is located
beside on the Electric Box.
NOTE: Refer to Electrical System (Unit 1.3) for fuse
rating.

3.5 COMMON RELAYS

All of them are located on the P.C. Board.

PR: Power Relay

Is energized when the Cab Control Box ON/OFF Switch is
pressed (Unit Start) and the box temperature is higher than
the setpoint temperature.

EFR: Fan Relay

When energized battery or power cord voltage turns on the
evaporator fans (EF1 and EF2).

D: Defrost Relay
It controls operation of the defrost cycle.
The Defrost Relay is energized when the Cab Control Box
Defrost Switch or the defrost timer completes the cycle.
Defrost Relay will remain energized until the defrost
process is terminated by the Defrost Termination Switch
(DK) or the Cab Control Box ON/OFF Switch is pressed.

3.6 STAND-BY RELAYS (ON STAND-BY

UNITS)
CR1, CR2 and ER are located on the P.C. Board.

CR1 & CR2: Commutation Relays

When energized change from Battery Supply to Power Cord
Supply.

TK 50978-1-MS (09/00 E)
 4 VM-305 MAX BITEMP ELECTRIC BOX
(WITH P.C. BOARD P.E.-11)

4.1 P.C. BOARD 4.3 FUSES

All Printed Circuit Boards manufactured by Thermo King The fuses 1, 2, 3 & 4 are located on the P.C. Board.
can be easily identified by the P/N stamped on them.
Fuse 1: Protects Evaporator fan (EF1) from overload.

4.2 CONNECTORS Fuse 2: Protects Evaporator fan (EF2) from overload.

Fuse 3: Protects:
All connector codes (C-1, C-2, C-3, C-4,C-5 and C-6) are
stamped on the P.C. Board. Condenser Fan Motor
Pins on connectors are numbered counter-clockwise. (see Compressor Clutch Coil
drawing) Defrost Solenoid Coil (when defrost is energized)
— C-1, C-2, C-3 & C-4 (8 Pin) Liquid Injection Valve Coil
Solenoid Valves PS2 and PS3
— C-5 & C-6 (6 Pin)
from overload.

TK 50978-1-MS (09/00 E)
4-2 VM-305 Max Bitemp Electric Box (with P.C. Board P.E.-11)

Fuse 4/1: Protects Cab Control box from overload. It is CMC: Compressor motor contactor.
located inside Cab Control Box.
When energized turns on AC Motor of the stand-by
compressor.

OL: AC Motor Overload Relay

Fus e 4/1
Switches off the unit when the current draw through the AC
Motor is excessive. It is located on the Electric Box beside
Fuse 1.

PS3R: Pilot Solenoid Relay

When the cab control box M-12B calls for cool it energizes
Fuse 4: Protects Cab Control Box and Relays CR1, CR2 & PS3 opening the main refrigerator circuit
ER when the unit is working on Stand-by mode operation. It
is located on the P.C. Board. PS2R: Pilot Solenoid Relay
Fuse 5: Protects Evaporator fan (EF3) from overload.
When the remote cab control box M-14 calls for cool it
Fuse 6: Protects Evaporator fan (EF4) from overload. energizes PS2 opening the second refrigerator circuit
Fuse 7: Protects Transformer from overload. It is located
beside the Electric Box.
NOTE: Refer to Electrical System (Unit 1.3) for fuse
rating.

4.4 RELAYS
All of them are located on the P.C. Board.

PR: Power Relay

Is energized when the Cab Control Box ON/OFF Switch is
pressed (Unit Start) and the box temperature is higher than
the setpoint temperature.

EFR: Fan Relay

When energized battery or power cord voltage turns on the
evaporators fans EF1 and EF2.

D: Defrost Relay
It controls operation of the defrost cycle.
The Defrost Relay is energized when the Cab Control Box
Defrost Switch or the defrost timer completes the cycle.
Defrost Relay will remain energized until the defrost
process is terminated by the Defrost Termination Switch
(DK) or the Cab Control Box ON/OFF Switch is pressed.

CR1 & CR2: Commutation Relays

When energized change from Battery Supply to Power Cord
Supply. They are located on the P.C. Board.

ER: Electric Stand-By Relay

When energized turns on the CMC relay (turning on the AC
Motor) and disconnects O'road compressor clutch or the
Liquid Injection Valve.

TK 50978-1-MS (09/00 E)

The Thermo King VM-300/VM-305 and VM-300 MAX/
VM-305 MAX truck refrigeration systems are a one-piece
nosemounted unit. The compressor is mounted on and
driven by the truck engine. Refrigeration hoses and tubing
are used to connect the unit to the compressor.
Models VM-300/VM-305 and VM-300 MAX/VM-
305 MAX have a semihermetic compressor in the
condenser section for electric standby operation.
VM-305 MAX Bitemp provides an additional evaporator
to cool a second compartment.
The units are designed for low and medium temperature
applications on vans and small-sized trucks with one or
two refrigerated compartments. The models are:
VM-300: Cool and defrost on engine driven compressor to
refrigerate one compartment with R-134a.
VM-300 MAX: Cool and defrost on engine driven
compressor to refrigerate one compartment with R-404A.
VM-305: Cool and defrost on both truck engine driven
and electric standby compressor operation to refrigerate
one compartment with R-134a.
VM-305 MAX: Cool and defrost on both truck engine
driven and electric standby compressor operation to
refrigerate one compartment with R-404A.
VM-305MAX Bitemp.: Cool and defrost on both truck
engine driven and electric standby compressor operation to
refrigerate one compartment with R404A.
The control circuits operate on 12V or 24VDC supplied by
the truck batteries for over-the-road operation. On standby
operation, the power is rectified from an AC transformer.
Each refrigeration system is protected by a high pressure
cutout switch and a low pressure cutout switch.
Unit operation is performed from a cab control box. It
includes an On-Off switch, manual defrost switch,
thermometer, thermostat, thermostat adjustment, and
indicator lights
VM-305 MAX Bitemp provides an additional cab control
box to operate the second compartment. It is switched on
and off from the main cab control box and includes
thermometer, thermostat, thermostat adjustment and
indicator lights.
The engine compressor is driven by a belt from the engine.
The standby compressor is mounted in the condenser
section. Both compressors use the same refrigeration
system circuit. Check valve isolates one compressor from
the other during operation.
Compressor operation is controlled by the thermostat,
energizing the clutch during engine operation or the
compressor contactor during stand-by operation.
5 UNIT DESCRIPTION
Selection of engine operation or standby operation is
automatic. When plugged into standby power, engine
operation is automatically locked out. If the truck engine is
turned on while the power cord is still plugged into a
power receptacle, the unit will remain working in electric
mode; the engine driven compressor cannot be started until
the power cord is unplugged from the unit.
Defrost: A hot gas solenoid valve provides defrost to the
units. An electronic defrost timer can initiate defrost
automatically. Defrost is normally terminated by the
defrost termination switch mounted on the evaporator coil.
On VM-305 MAX Bitemp defrost termination is
controlled by the switch on the main evaporator for both.
Defrost cycle can also be terminated pressing the ON/OFF
Switch twice.
Oil Separator: An oil separator is a standard feature on all
these units. The oil separator separates compressor oil from
refrigerant vapor and returns the oil to the compressor
through the oil fill hole by using a special adapter. The oil
separator helps providing positive oil return at high
compressor speeds and low operating temperatures. This
feature enhances compressor lubrication and extends
compressor life.
Liquid Injection System: If the discharge gas leaving the
compressor reaches a temperature of 110 ±3ºC the high
temperature switch closes, providing voltage to the liquid
injection solenoid. The solenoid opens a valve allowing
liquid refrigerant to flow from the liquid near the receiver
outlet valve to the metering orifice attached to the suction
line fitting on the compressor. As the refrigerant passes
through the metering orifice it expands and evaporates
cooling the suction gas entering the compressor. This
cooling effect is transferred to the discharge gas leaving the
compressor from the adjacent cavity in the compressor
head. When the discharge gas is cooled to 93 ±3ºC the high
temperature switch opens, the liquid solenoid valve closes
and refrigerant no longer flows through the liquid injection
system.
Evaporating Pressure Regulator: This regulator
maintains the remote evaporator pressure at a given level
or higher. This regulator is mounted at the outlet side of the
remote evaporator.
S/S EFR Selector: Allows the user to choose if the
evaporator fan works all the time or if it runs controlled by
the power relay (thermostat).
THERMISTOR: Disconnects AC motor if its temperature
reaches a threshold value.
TK 50978-1-MS (09/00 E)
5-2 Unit Description

5.1 UNIT FEATURES

• In cab controller - M-12B
(M-12B + M-14 for Bitemp units only)
• Digital Thermometer
• Electronic Thermostat - Adjustable

M12B M14

-22ºC ÷ +14ºC 0ºC ÷ +14ºC

-32ºC ÷ +14ºC

• Defrost Timer
• Hot Gas Defrost
• Defrost Termination Switch
• Manual Defrost Switch
• Receiver Tank with Outlet Service Valve
• Oil Separator
• Liquid Injection (MAX units only)
• Condenser Fan Pressure Switch (R-134a units only)
• Seltec TM 16HD O'Road Compressor
• Semihermetic 1.5HP Stand-by Compressor
(Only stand-by units)

TK 50978-1-MS (09/00 E)