Sb200tg Thermo King

Operators Manual
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
Operators Manual
SB-200TG
Downloaded from www.Manualslib.com manuals search engine
Copyright 2007 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)
Copyright 2007 Thermo King Corp., Minneapolis, MN, USA

Printed in USA

these procedures correctly may cause damage to the Thermo King unit or other property or personal
injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or any
other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting
from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo King
unit.
Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no
representations or warranties, express or implied, with respect to the information, recommendations and
descriptions contained in this manual and such information, recommendations and descriptions should
not be regarded as all-inclusive or covering all contingencies. If you have questions or require further
information, please contact your local Thermo King dealer.
The procedures described herein should be undertaken only by qualified personnel. Failure to implement
these procedures correctly may cause damage to the Thermo King unit or other property or personal
injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or any
other direct, indirect, special or consequential damage or liability whatsoever, arising out of or resulting
from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo King
unit.

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
First AidRefrigerant . . . . . . . . . . . . . . . . . . . . . . . 13 ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .23
First AidRefrigerant Oil . . . . . . . . . . . . . . . . . . . . 13 EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Safety Decals And Locations . . . . . . . . . . . . . . . . . . . 14 Thermo King X430L Compressor . . . . . . . . . . . . . . . .24
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 EPA Emission Control System
Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . .17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Thermo King Corporation Responsibilities . . . . . .18
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Owner Responsibilities . . . . . . . . . . . . . . . . . . . . .19
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . 11 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 12
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
First AidRefrigerant . . . . . . . . . . . . . . . . . . . . . . . 13 ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .23
First AidRefrigerant Oil . . . . . . . . . . . . . . . . . . . . 13 EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Safety Decals And Locations . . . . . . . . . . . . . . . . . . . 14 Thermo King X430L Compressor . . . . . . . . . . . . . . . .24

Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Initiating a Start of Trip . . . . . . . . . . . . . . . . . . . . . . . . 60
Upper and Lower Display . . . . . . . . . . . . . . . . . . . 37 Displaying and Clearing Alarm Codes . . . . . . . . . . . . 61
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remote Status Light (Optional) . . . . . . . . . . . . . . . . 43 Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manual Pretrip Inspection Alarm Code 84 (Restart Null) . . . . . . . . . . . . . . . . . . . 65
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 45 Alarm Code 85 (Forced Unit Operation) . . . . . . . . . . . 65
Table of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table of Contents
TG-VI Microprocessor Controller . . . . . . . . . . . . . . . . . 25 Unit Operation with TG-VI Controller . . . . . . . . . . . 47

CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . 27 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DAS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . 49
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . . 29 Starting the Unit with a Unit Self Check Test . . . . . . . 50
Opening the Secondary Door Latch . . . . . . . . . . . 29 Displaying Operating Data During Normal Operation 52
Closing the Front Doors . . . . . . . . . . . . . . . . . . . . . . . . 30 Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . 53
Engine Compartment Components . . . . . . . . . . . . . . . 31 Selection of Operating Modes . . . . . . . . . . . . . . . . . . 54
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . 32 Selecting CYCLE-SENTRY or Continuous Mode . . . 55
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . 56
TG-VI Controller Description . . . . . . . . . . . . . . . . . . 35 Checking Software Revision . . . . . . . . . . . . . . . . . . . 57
TG-VI Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Printing a Trip Report . . . . . . . . . . . . . . . . . . . . . . . . . 58
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Initiating a Start of Trip . . . . . . . . . . . . . . . . . . . . . . . . 60
Upper and Lower Display . . . . . . . . . . . . . . . . . . . 37 Displaying and Clearing Alarm Codes . . . . . . . . . . . . 61
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remote Status Light (Optional) . . . . . . . . . . . . . . . . 43 Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Manual Pretrip Inspection Alarm Code 84 (Restart Null) . . . . . . . . . . . . . . . . . . . 65
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 45 Alarm Code 85 (Forced Unit Operation) . . . . . . . . . . . 65
Table of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . 66

California Proposition 65 Warning . . . . . . . . . . . . .119
Maintenance Inspection Schedule . . . . . . . . . . . . . 97
Table of Contents
Loading and Enroute Inspections . . . . . . . . . . . . . . 83 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . . 83
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . 85 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . 86
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Serial Number Locations . . . . . . . . . . . . . . . . . . . . .113
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . .117
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . 95 Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . .118
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 96
California Proposition 65 Warning . . . . . . . . . . . . .119
Maintenance Inspection Schedule . . . . . . . . . . . . . 97

6
Table of Contents

Figure 7:TK486V (Tier 2) . . . . . . . . . . . . . . . . . . . . . . 23 Figure 22:Standard Display . . . . . . . . . . . . . . . . . . . . .52
Figure 8:Control and Switch Panels . . . . . . . . . . . . . . 25 Figure 23:Changing the Setpoint . . . . . . . . . . . . . . . . .53
Figure 9:Door Latch Location . . . . . . . . . . . . . . . . . . . 29 Figure 24:Selecting CYCLE-SENTRY
Figure 10:Opening Secondary Door Latch . . . . . . . . . 29 or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Figure 11:Engine Compartment . . . . . . . . . . . . . . . . . 31 Figure 25:Initiating a Manual Defrost Cycle . . . . . . . . .56
Figure 12:Relay Board . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 26:Checking Software Revision . . . . . . . . . . . .57
Figure 13:TG-VI Control Panel With all Possible Figure 27:Printing a Trip Report . . . . . . . . . . . . . . . . . .58
Icons and Characters Displayed . . . . . . . . . . . . . . . . . 35 Figure 28:Initiating a Start of Trip . . . . . . . . . . . . . . . . .60
List of Figures
Figure 1:Belt Warning Figure 14:Display Screen With all Possible Icons and
(Located on condenser housing) . . . . . . . . . . . . . . . . 14 Characters Displayed . . . . . . . . . . . . . . . . . . . . . . . . . .36
Figure 2:Belt Replacement Caution Figure 15:Upper and Lower Displays . . . . . . . . . . . . . .37
(Located on condenser housing) . . . . . . . . . . . . . . . . 14 Figure 16:Standard Display . . . . . . . . . . . . . . . . . . . . .39
Figure 3:Automatic Start Caution. . . . . . . . . . . . . . . . . 15 Figure 17:Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Figure 4:Fan Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 18:Remote Status Light . . . . . . . . . . . . . . . . . .43
Figure 5:Door Latch Warning Figure 19:TG-VI Microprocessor Controller . . . . . . . . .47
(Located on curbside door) . . . . . . . . . . . . . . . . . . . . . 16 Figure 20:Control and Switch Panels . . . . . . . . . . . . . .48
Figure 6:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Figure 21:Unit Self Check . . . . . . . . . . . . . . . . . . . . . .50
Figure 7:TK486V (Tier 2) . . . . . . . . . . . . . . . . . . . . . . 23 Figure 22:Standard Display . . . . . . . . . . . . . . . . . . . . .52
Figure 8:Control and Switch Panels . . . . . . . . . . . . . . 25 Figure 23:Changing the Setpoint . . . . . . . . . . . . . . . . .53
Figure 9:Door Latch Location . . . . . . . . . . . . . . . . . . . 29 Figure 24:Selecting CYCLE-SENTRY
Figure 10:Opening Secondary Door Latch . . . . . . . . . 29 or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Figure 11:Engine Compartment . . . . . . . . . . . . . . . . . 31 Figure 25:Initiating a Manual Defrost Cycle . . . . . . . . .56
Figure 12:Relay Board . . . . . . . . . . . . . . . . . . . . . . . . 34 Figure 26:Checking Software Revision . . . . . . . . . . . .57
Figure 13:TG-VI Control Panel With all Possible Figure 27:Printing a Trip Report . . . . . . . . . . . . . . . . . .58
Icons and Characters Displayed . . . . . . . . . . . . . . . . . 35 Figure 28:Initiating a Start of Trip . . . . . . . . . . . . . . . . .60

8
List of Figures
Figure 29:Alarm Symbol Location . . . . . . . . . . . . . . . . 61 Figure 35:Compressor Serial Number Location . . . . 113
Figure 30:Loading Considerations . . . . . . . . . . . . . . . . 84 Figure 36:Engine Serial Number Location . . . . . . . . 114
Figure 31:Unit Battery . . . . . . . . . . . . . . . . . . . . . . . . . 90 Figure 37:Unit Serial Number Plate Locations . . . . . 114
Figure 32:Sequence for Connecting Jumper Cables . . 90 Figure 38:Unit Serial Number Plate . . . . . . . . . . . . . 115
Figure 33:Unit Engine . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 34:Sequence for Disconnecting
Jumper Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

efficient and dependable temperature control system available.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
They are equipped with the factory recommended tools to
perform all service functions
They have factory trained and certified technicians
They have genuine Thermo King replacement parts
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
Introduction
There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational
your Thermo King unit, but a few minutes studying this purposes only and the information furnished herein should
manual will be time well spent. not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Performing pre-trip checks and enroute inspections on a
Thermo King Service Directory for the location and
regular basis will minimize on-the-road operating problems. A
telephone number of the local dealer.
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
They are equipped with the factory recommended tools to
perform all service functions
They have factory trained and certified technicians
They have genuine Thermo King replacement parts
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.

10
Introduction
10

DANGER: NEVER operate the unit with the King technician.
compressor discharge valve closed. Doing so could
cause the compressor to explode, causing death or WARNING: Do not apply heat to a closed cooling
serious injury. system. Before applying heat to a cooling system,
drain it. Then flush it with water and drain the water.
WARNING: Always wear goggles or safety glasses Antifreeze contains water and ethylene glycol. The
when working with or around the refrigeration system ethylene glycol is flammable and can ignite if the
or battery. Refrigerant or battery acid can cause antifreeze is heated enough to boil off the water.
permanent damage if it comes in contact with your
eyes.
11
Safety Precautions
Thermo King recommends that servicing be done only by a
WARNING: Keep hands and loose clothing clear of
Thermo King dealer. However, you should be aware of several
fans and belts at all times when the unit is operating
safety practices. This chapter gives basic safety precautions for
or when opening or closing compressor service
working with Thermo King units and describes the safety
valves.
stickers on your unit that you should be familiar with.
WARNING: Exposed coil fins can cause painful
General Safety Practices lacerations. Service work on the evaporator or
condenser coils should be done by a certified Thermo
DANGER: NEVER operate the unit with the King technician.
compressor discharge valve closed. Doing so could
cause the compressor to explode, causing death or WARNING: Do not apply heat to a closed cooling
serious injury. system. Before applying heat to a cooling system,
drain it. Then flush it with water and drain the water.
WARNING: Always wear goggles or safety glasses Antifreeze contains water and ethylene glycol. The
when working with or around the refrigeration system ethylene glycol is flammable and can ignite if the
or battery. Refrigerant or battery acid can cause antifreeze is heated enough to boil off the water.
permanent damage if it comes in contact with your
eyes.
11

can start at any time when the unit On/Off switch is
in the on position and the unit is operating in
DANGER: Fluorocarbon refrigerants can produce
CYCLE-SENTRY.
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
WARNING: Turn the unit On/Off switch to the Off
irritants CAPABLE OF CAUSING DEATH.
position before inspecting any part of the unit.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
12
Safety Precautions
CAUTION: Use extreme caution when drilling holes Electrical Hazard

in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Do not drill into CAUTION: Turn off the high voltage power supply
structural components. and disconnect the electric cable before working on
the unit. Units with electric standby present a
potential electrical hazard.
Automatic Start/Stop Operation
This unit is capable of automatic operation and could start at Refrigerant
any time without warning.
Although fluorocarbon refrigerants are classified as safe, use
WARNING: CYCLE-SENTRY Operation. The unit caution when working with refrigerants or in areas where they
can start at any time when the unit On/Off switch is are being used.
in the on position and the unit is operating in
DANGER: Fluorocarbon refrigerants can produce
CYCLE-SENTRY.
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
WARNING: Turn the unit On/Off switch to the Off
irritants CAPABLE OF CAUSING DEATH.
position before inspecting any part of the unit.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
12

WARNING: Protect skin and clothing from First AidRefrigerant Oil
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended. Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
WARNING: Wash thoroughly immediately after medical attention.
handling refrigerant oil to prevent irritation. Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
13
Safety Precautions
WARNING: Fluorocarbon refrigerants evaporate First Aid

rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state. First AidRefrigerant
Eyes: For contact with liquid, immediately flush eyes with
Refrigerant Oil large amounts of water. Get prompt medical attention.
Observe the following precautions when working with or Skin: Flush areas with large amounts of warm water. Do not
around refrigerant oil: apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact. Inhalation: Move victim to fresh air and restore breathing if
WARNING: Protect skin and clothing from First AidRefrigerant Oil

prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended. Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
WARNING: Wash thoroughly immediately after medical attention.
handling refrigerant oil to prevent irritation. Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
13

(Located on condenser housing)
AKB66
Figure 2: Belt Replacement Caution

14
Safety Precautions
Ingestion: Do not induce vomiting. Immediately contact Safety Decals And Locations
local poison control center or physician.
AKB65
Figure 1: Belt Warning

AKB66
Figure 2: Belt Replacement Caution

14

AKB67 AKB68
Figure 3: Automatic Start Caution

(Locations vary depending on model. Decals are Figure 4: Fan Caution
located near areas that contain moving parts which (Locations vary depending on model. Decals are
can cause severe injuries if hands or clothing become located near areas that contain fans which can cause
tangled when unit automatically starts.) severe injuries when unit automatically starts.)
15
Safety Precautions
AKB67 AKB68
Figure 3: Automatic Start Caution

(Locations vary depending on model. Decals are Figure 4: Fan Caution
located near areas that contain moving parts which (Locations vary depending on model. Decals are
can cause severe injuries if hands or clothing become located near areas that contain fans which can cause
tangled when unit automatically starts.) severe injuries when unit automatically starts.)
15

REQUIERE ASOTAR LA PUERTA ANTES
DE CONDUCIR EL TRAILER.
AL NO CERRAR LA PUERTA CON
FIRMEZA EL VIENTO PODRA
DESPRENDER LA PUERTA DE LA
UNIDAD DE REFRIGERACIN Y
CAUSAR DAOS A OTROS.
AEA2422
Figure 5: Door Latch Warning

(Located on curbside door)
16
Safety Precautions
WARNING
NEW DOOR LATCH DESIGN
REQUIRES DOOR TO BE SLAMMED
SHUT BEFORE MOVING TRAILER.
FAILURE TO CLOSE DOOR FIRMLY
CAN ALLOW WIND TO TEAR DOOR
FROM REFRIGERATION UNIT AND
CAUSE INJURY TO OTHERS.
ATENCIN
NUEVO DESEO DE CERRADURA
REQUIERE ASOTAR LA PUERTA ANTES
DE CONDUCIR EL TRAILER.
AL NO CERRAR LA PUERTA CON
FIRMEZA EL VIENTO PODRA
DESPRENDER LA PUERTA DE LA
UNIDAD DE REFRIGERACIN Y
CAUSAR DAOS A OTROS.
AEA2422
Figure 5: Door Latch Warning

(Located on curbside door)
16

establishment, or by the owner, using any replacement part.
specific emission related parts for a period of five years or
Thermo King will reimburse the owner for their expenses,
3,000 hours of operation, whichever comes first, after date
including diagnostic charges for such emergency repair. These
of delivery to the initial owner.
expenses shall not exceed Thermo Kings suggested retail price
If an emission-related part or component fails during the for all warranted parts replaced, and labor changes based on
warranty period, it will be repaired or replaced. Any such part Thermo Kings recommended time allowance for the warranty
or component repaired or replaced under warranty is warranted repair and the geographically appropriate hourly labor rate.
for the warranty period.
17
EPA Emission Control System Warranty

Statement
Thermo King warrants to the initial owner and each subsequent During the term of this warranty, Thermo King will provide,
owner that the certified, non-road diesel engine in your unit is: through a Thermo King authorized service dealer or other
1. Designed, built and equipped so as to conform, at the time establishment authorized by Thermo King, repair or
of sale, with all applicable regulations adopted by the replacement of any warranted part at no charge to the non-road
United States Environmental Protection Agency (EPA). engine owner.
In emergency, repairs may be performed at any service
2. Free from defects in materials and workmanship in
establishment, or by the owner, using any replacement part.
specific emission related parts for a period of five years or
Thermo King will reimburse the owner for their expenses,
3,000 hours of operation, whichever comes first, after date
including diagnostic charges for such emergency repair. These
of delivery to the initial owner.
expenses shall not exceed Thermo Kings suggested retail price
If an emission-related part or component fails during the for all warranted parts replaced, and labor changes based on
warranty period, it will be repaired or replaced. Any such part Thermo Kings recommended time allowance for the warranty
or component repaired or replaced under warranty is warranted repair and the geographically appropriate hourly labor rate.
for the warranty period.
17

This warranty covers the following emission-related parts and workmanship of a warranted part or component is found,
components: Thermo King will provide:
Fuel Injection System New, remanufactured, or repaired parts or components

required to correct the defect.
Intake Manifold
NOTE: Items replaced under this warranty become the
Exhaust Manifold property of Thermo King.
Miscellaneous hoses, clamps, connectors and sealing Labor, during normal working hours, required to make the
devices used in the above systems. warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
18
EPA Emission Control System Warranty Statement
Any replacement part can be used for maintenance or repairs. If failure of one of these parts or components results in failure
The owner should ensure that such parts are equivalent in of another part or component, both will be covered by this
design and durability to genuine Thermo King parts. However, warranty.
Thermo King is not liable for parts that are not genuine
Thermo King parts.
Responsibilities
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency. This warranty is subject to the following:
As a condition of reimbursement, replaced parts and received

invoices must be presented at a place of business of a Thermo Thermo King Corporation
King authorized service dealer or other establishment Responsibilities
authorized by Thermo King. During the emission warranty period, if a defect in material or
This warranty covers the following emission-related parts and workmanship of a warranted part or component is found,
components: Thermo King will provide:
Fuel Injection System New, remanufactured, or repaired parts or components

required to correct the defect.
Intake Manifold
NOTE: Items replaced under this warranty become the
Exhaust Manifold property of Thermo King.
Miscellaneous hoses, clamps, connectors and sealing Labor, during normal working hours, required to make the
devices used in the above systems. warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
18

defects in Thermo King material or workmanship. responsible for incidental or consequential damages such as
downtime or loss of engine powered equipment.
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
Any application or installation Thermo King deems
improper as explained in this Operators Manual, or any
other manuals provided for the unit.
19
Owner Responsibilities Attachments, accessory items, or parts not authorized for

use by Thermo King.
During the emission warranty period, the owner is responsible
for: Improper off-road engine maintenance, repair or abuse.
The performance of all required maintenance. A warranty Owners unreasonable delay in making the product
claim will not be denied because the scheduled available after being notified of a potential product
maintenance was not performed. However, if the lack of problem.
required maintenance was the reason for the repair, then This warranty is in addition to Thermo Kings standard
the claim will be denied. warranty applicable to the off-road engine product involved.
Premium of overtime cost. Remedies under this warranty are limited to the provision of
Cost to investigate complaints that are not caused by material and services as specified herein. Thermo King is not
defects in Thermo King material or workmanship. responsible for incidental or consequential damages such as
downtime or loss of engine powered equipment.
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
Any application or installation Thermo King deems
improper as explained in this Operators Manual, or any
other manuals provided for the unit.
19

20
20

heating using a quiet running Thermo King TK486V engine.
Figure 6: Front View
21
Unit Description
Unit Overview
The Thermo King SB-200TG is a one piece, self-contained,
diesel powered, air cooling/heating unit operating under the
control of a TG-VI programmable microprocessor controller.
The unit mounts on the front of the trailer with the evaporator
extending through an opening in the front wall.
The unit is available as a Model 30 and features cooling and
heating using a quiet running Thermo King TK486V engine.
Figure 6: Front View
21

Vibration Isolation System
Aluminum Undermount Fuel Tank 50 Gal.

(186 Liter)
DAS Data Logger /
Remote Status Light
22
Unit Description
Design Features Key Features & Options SB-200TG

The following chart lists key design features and options. EMI-3000
Standard Features High-Capacity Condenser Coil
Option/Factory installed Easy-Access Door Design
Option/Dealer Installed Composite Exterior Panels
Long-Life Coolant/Silicone Hoses
Standard Unit Color White
Standard Grille Color Black
Directional Air Delivery
Vibration Isolation System
Aluminum Undermount Fuel Tank 50 Gal.

(186 Liter)
DAS Data Logger /
Remote Status Light
22

systems using RED Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
Figure 7: TK486V (Tier 2)
23
Unit Description
Diesel Engine ELC (Extended Life Coolant)

The unit uses a quiet running TK486V (Tier 2), which is a ELC (Extended Life Coolant) is standard equipment. The
4-cylinder, water cooled, direct injection diesel engine. The maintenance interval for ELC is five years or 12,000 hours. A
engine is coupled directly to the compressor. Belts transmit nameplate on the coolant expansion tank identifies units with
power to the unit fans, alternator and water pump. ELC (see Safety Decals and Locations). The new engine
coolant, Chevron Extended Life Coolant, is RED in color
instead of the previous GREEN or BLUE-GREEN colored
conventional coolants.
CAUTION: Do not add GREEN or

BLUE-GREEN conventional coolant to cooling
systems using RED Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
Figure 7: TK486V (Tier 2)
23

API Rating CI-4 Mineral Oil
Five Year or 12,000 Hour ELC (Extended Life Coolant)
The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.
NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.
NOTE: The new EMI 3000 oil filters and new EMI 3000 air
cleaners are NOT interchangeable with the older style oil
filters and air cleaners.
24
Unit Description
EMI 3000 Thermo King X430L Compressor

EMI 3000 is an extended maintenance interval package. It is The unit is equipped with a Thermo King X430L, four-cylinder
standard equipment. The EMI 3000 package consists of the compressor with 30 cu. in. (492 cm3) displacement. The unit is
following key components: also equipped with a compressor oil filter.
New EMI 3000-Hour Cyclonic Air Cleaner Assembly and
Air Cleaner Element
New EMI 3000-Hour Fuel Filter (black with gold
lettering)
New EMI 3000-Hour Dual Element Oil Filter (black with
gold lettering)
API Rating CI-4 Mineral Oil
Five Year or 12,000 Hour ELC (Extended Life Coolant)
The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.
NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.
NOTE: The new EMI 3000 oil filters and new EMI 3000 air
cleaners are NOT interchangeable with the older style oil
filters and air cleaners.
24

Defrost Control: The controller is programmed to
automatically initiate timed or demand defrost cycles. The COMPUTER PRINTER
AJA1070
operator can also manually initiate a defrost cycle. See
Defrost on page 27.
1. Control Panel 4. Computer Port (Optional)
Alarm: Can detect and display alarm conditions. Refer to the
Operating and Alarm Codes Sections later in this manual. 2. Display 5. Printer Port (Optional)
3. Keypad 6. On/Off Switch
Figure 8: Control and Switch Panels
25
Unit Description
TG-VI Microprocessor Controller

1
Thermo King has applied the newest technological advances to 2
develop a programmable microprocessor controller that
controls unit functioning and displays operating information
quickly and accurately. ANA03
Features include:
3
Thermometer: Displays return air temperature with 0.1
degree accuracy.
Thermostat: Provides temperature control from -20 to 80 F 4
5
(- 28 to 27 C) in 1.0 degree increments. 6
Defrost Control: The controller is programmed to
automatically initiate timed or demand defrost cycles. The COMPUTER PRINTER
AJA1070
operator can also manually initiate a defrost cycle. See
Defrost on page 27.
1. Control Panel 4. Computer Port (Optional)
Alarm: Can detect and display alarm conditions. Refer to the
Operating and Alarm Codes Sections later in this manual. 2. Display 5. Printer Port (Optional)
3. Keypad 6. On/Off Switch
Figure 8: Control and Switch Panels
25

the temperature in the trailer.
Low Speed Heat
On very hot days, with the setpoint at a low temperature, the
High Speed Heat unit may cycle between high speed cool and low speed cool
Defrost. without switching into a heating cycle.
On very cold days, the unit may cycle between high speed heat
and low speed heat. The unit may switch into cooling for short
periods of time.
26
Unit Description
In CYCLE-SENTRY Operation Mode:

CAUTION: Firmly close the controller access door
after operating the microprocessor controller or High Speed Cool
before starting a trip. The control panel might be Low Speed Cool
damaged in transit if the door is not firmly closed.
Null (Engine Off)
Depending on the air temperature in the trailer sensed by the
TG-VI Microprocessor Controller, the unit will operate in one Low Speed Heat
of the following modes: High Speed Heat
In Continuous Run Operation Mode: Defrost.
High Speed Cool Generally, the unit will operate in low speed switching back
Low Speed Cool and forth from cooling to heating as necessary, thus controlling
the temperature in the trailer.
Low Speed Heat
On very hot days, with the setpoint at a low temperature, the
High Speed Heat unit may cycle between high speed cool and low speed cool
Defrost. without switching into a heating cycle.
On very cold days, the unit may cycle between high speed heat
and low speed heat. The unit may switch into cooling for short
periods of time.
26

WARNING: Set the unit ON/OFF switch to OFF minutes if required.
before opening doors or inspecting any part of the Manual Defrost: The operator manually initiates a defrost
unit. With the unit ON/OFF switch in the ON position, cycle.
the unit may start at any time without warning.
NOTE: The unit will not perform a Manual Defrost cycle
unless the ON/OFF switch is set to ON, the unit is running in
Continuous or CYCLE-SENTRY mode, (or shut down in
CYCLE-SENTRY Null mode), and the coil temperature is
below 45 F (7.2 C).
27
Unit Description
CYCLE-SENTRY Start-Stop Controls Defrost

The CYCLE-SENTRY Start-Stop fuel saving system provides Frost gradually builds-up on evaporator coils as a result of
optimum operating economy. normal operation. The unit uses hot refrigerant to defrost the
evaporator coils. Hot refrigerant gas passes through the
CYCLE-SENTRY automatically starts the unit on
evaporator coil and melts the frost. The water flows through
microprocessor demand, and shuts down the unit when all
collection drain tubes onto the ground. The methods of defrost
demands are satisfied.
initiation are Manual and Automatic.
The system automatically monitors and maintains
compartment temperatures, the engine block temperature and Automatic Defrost: The controller is programmed to
battery charge levels at a point where quick, easy starts are automatically initiate timed or demand defrost cycles. Defrost
possible. intervals are set at the factory at 2, 4 6, 8, 10, or 12 hours. The
unit can enter a demand defrost cycle as often as every 30
WARNING: Set the unit ON/OFF switch to OFF minutes if required.
before opening doors or inspecting any part of the Manual Defrost: The operator manually initiates a defrost
unit. With the unit ON/OFF switch in the ON position, cycle.
the unit may start at any time without warning.
NOTE: The unit will not perform a Manual Defrost cycle
unless the ON/OFF switch is set to ON, the unit is running in
Continuous or CYCLE-SENTRY mode, (or shut down in
CYCLE-SENTRY Null mode), and the coil temperature is
below 45 F (7.2 C).
27

laptop or desktop computer and Thermo King WinTrac 4.1 (or
higher) software. The computer is connected to the computer
port on the front of the control box. See Figure 8: Control and
Switch Panels, on page 25. Detailed graph or table trip reports
can then be created.
A hand-held printer can be connected to the printer port on the
front of the control box to print out the DAS sensor readings.
Refer to the DAS Data Acquisition System Manual TK 50565
for more information.
28
Unit Description
DAS (Optional)
The DAS (Data Acquisition System) is an independent data
logger that logs information from dedicated external DAS
sensors and inputs. The DAS features (up to six) directly
connected sensors. The DAS is also connected through a serial
port to the unit microprocessor. Sensor readings can be viewed
on the microprocessor keyboard panel using the SELECT key.
See Figure 8: Control and Switch Panels, on page 25. The
DAS allows unit operating information, operating events,
alarm codes and compartment temperatures to be logged as
well. The data can be retrieved using an IBM PC compatible
laptop or desktop computer and Thermo King WinTrac 4.1 (or
higher) software. The computer is connected to the computer
port on the front of the control box. See Figure 8: Control and
Switch Panels, on page 25. Detailed graph or table trip reports
can then be created.
A hand-held printer can be connected to the printer port on the
front of the control box to print out the DAS sensor readings.
Refer to the DAS Data Acquisition System Manual TK 50565
for more information.
28

2
1. Door Latch
2. Secondary Door Latch Nameplate 1. Spring Latch
Figure 9: Door Latch Location 2. Spring Catch
Figure 10: Opening Secondary Door Latch
29
Unit Description
Opening the Front Doors Opening the Secondary Door Latch

Pull the door latch handle to open the door and access the These units are also equipped with a secondary door latch. A
engine compartment. secondary door latch nameplate is located below the front
doors. After opening the door latch, reach between the front
doors and lift the spring latch over the spring catch while
opening the door.
1. Door Latch
2. Secondary Door Latch Nameplate 1. Spring Latch
Figure 9: Door Latch Location 2. Spring Catch
Figure 10: Opening Secondary Door Latch
29

30
Unit Description
Closing the Front Doors

Slam the door to close it. Do not push the door closed while
holding the door latch handle open or the door will not close
properly.
30

Compressor Oil Sight Glass: Use this sight glass to check
the compressor oil level. Check the compressor oil when there
is evidence of oil loss (leaks). Refer to the unit Maintenance
Manual for the correct procedure.
4 3
Engine Oil Dipstick: Use the engine oil dipstick to check
1. Air Filter Restriction Indicator the engine oil level.
2. Receiver Tank Sight Glass
3. Engine Oil Dipstick CAUTION: Make sure the engine is turned off before
attempting to check the engine oil.
4. Compressor Oil Sight Glass
Figure 11: Engine Compartment
31
Unit Description
Engine Compartment Components

The following maintenance items can be checked visually.
1 2
WARNING: The unit can start at any time without
warning. Place the On/Off switch in the Off position
before inspecting any part of the unit.
Air Filter Restriction Indicator: The air filter restriction
indicator is attached to the engine intake manifold. When the
diaphragm indicates 25, service the air filter. Press the button
on the top of the restriction indicator to reset after servicing the
air cleaner.
Compressor Oil Sight Glass: Use this sight glass to check
the compressor oil level. Check the compressor oil when there
is evidence of oil loss (leaks). Refer to the unit Maintenance
Manual for the correct procedure.
4 3
Engine Oil Dipstick: Use the engine oil dipstick to check
1. Air Filter Restriction Indicator the engine oil level.
2. Receiver Tank Sight Glass
3. Engine Oil Dipstick CAUTION: Make sure the engine is turned off before
attempting to check the engine oil.
4. Compressor Oil Sight Glass
Figure 11: Engine Compartment
31

Unit Protection Devices stays closed for a specified time, the microprocessor shuts the
Fuse Link (Current Limiter): The fuse link is located in the unit down and records alarm code 19.
positive battery cable. The fuse link protects the electric
Preheat Buzzer: The preheat buzzer sounds when the
system from a short. If the fuse link burns out, replace it by
controller energizes the preheat relay. This warns anyone near
replacing the positive battery cable.
the unit that the controller is about to start the engine.
High Pressure Cutout Switch: The high pressure cutout
switch (HPCO) is located on the compressor discharge
manifold. If the compressor discharge pressure becomes
excessive, the switch opens the circuit to the run relay to stop
the unit. The microprocessor will record Alarm Code 10.
32
Unit Description
Receiver Tank Sight Glass: This sight glass indicates the High Pressure Relief Valve: This valve is designed to
level of refrigerant in the receiver tank. relieve excessive pressure in the refrigeration system. It is
located on the receiver tank. If the high pressure relief valve
Operate the unit in high speed cool for approximately 15
opens, much of the refrigerant will be lost. Take the unit to a
minutes to stabilize operating conditions and temperature
Thermo King dealer if this occurs.
before attempting to check the refrigerant.
NOTE: If the ball floats, there is sufficient refrigerant in the Low Oil Level Switch: The low oil level switch closes if the
unit for that load at that particular trailer temperature. This oil drops below an acceptable level. If it stays closed for a
test does not determine if the unit contains a full charge or an specified time, the microprocessor shuts the unit down and
overcharge of refrigerant. records Alarm Code 66.
Low Oil Pressure Switch: The low oil pressure switch
closes if the oil pressure drops below an acceptable level. If it
Unit Protection Devices stays closed for a specified time, the microprocessor shuts the
Fuse Link (Current Limiter): The fuse link is located in the unit down and records alarm code 19.
positive battery cable. The fuse link protects the electric
Preheat Buzzer: The preheat buzzer sounds when the
system from a short. If the fuse link burns out, replace it by
controller energizes the preheat relay. This warns anyone near
replacing the positive battery cable.
the unit that the controller is about to start the engine.
High Pressure Cutout Switch: The high pressure cutout
switch (HPCO) is located on the compressor discharge
manifold. If the compressor discharge pressure becomes
excessive, the switch opens the circuit to the run relay to stop
the unit. The microprocessor will record Alarm Code 10.
32

F18 15A High Speed Solenoid
F4 2A Run Relay
F21 15A #8F Circuit
F5 2A Hot Gas Solenoid
F22 2A Electric Heater Contactor
F6 2A Pilot Solenoid
F25 2A Cycle-Sentry Light
F7 2A Starter Relay
F26 2A Emergency Heat
F8 2A Preheat Relay
F27 2A Spare Fuse
F9 40A #2 Circuit
F28 15A Spare Fuse
F10 2A Cool Light/Damper Motor Heater
F29 30A Spare Fuse
F11 2A VHN (Ammeter Shunt)
F30 40A Spare Fuse
33
Unit Description
Fuses: A number of fuses, located on the relay board, protect Fuse Size Function
various circuits and components. Not all of the fused circuits
and components are used in this system. The relay board (see F12 2A Data Logger
Figure 12 on page 34) is located inside the control box. Refer F13 2A VHP (Ammeter Shunt)
to TK 53687 the TG-VIc Diagnostic Manual for more F14 2A High Speed Light
information about the fuses.
None No Fuse - All Thermo King and Bosch
Fuse Size Function F15 Alternators
2A 2A Fuse - All Prestolite Alternators
F1 2A High Speed Relay
F16 2A Electric Motor Contactor
F2 2A Defrost Relay
F17 2A Defrost Light
F3 15A Damper Solenoid/Motor
F18 15A High Speed Solenoid
F4 2A Run Relay
F21 15A #8F Circuit
F5 2A Hot Gas Solenoid
F22 2A Electric Heater Contactor
F25 2A Cycle-Sentry Light
F7 2A Starter Relay
F26 2A Emergency Heat
F8 2A Preheat Relay
F27 2A Spare Fuse
F9 40A #2 Circuit
F28 15A Spare Fuse
F10 2A Cool Light/Damper Motor Heater
F29 30A Spare Fuse
F11 2A VHN (Ammeter Shunt)
F30 40A Spare Fuse
33

AJA1069
Figure 12: Relay Board
34
Unit Description
Fuse Size Function

F31 2A Modulation
F32 2A Remote Lights
F33 2A Oil Level Switch/ Door Switch
F34 2A Emergency Run
F36 30A Main Power Fuse
F37 30A Main Power Fuse
AJA1069
Figure 12: Relay Board
34

2 setpoint. You can also:
Initiate a manual defrost cycle
Change the thermostat setpoint
ANA03
Change operating modes
1. Display Screen Check gauges, hourmeters, and alarm codes
2. Keypad
Run a unit self check.
Figure 13: TG-VI Control Panel With all Possible Icons
Several other functions are also available. This chapter
and Characters Displayed
describes the TG-VI control panel. For operating procedures,
see Unit Operation in this manual.
001 35
TG-VI Controller Description

TG-VI Overview
This unit is controlled by a ThermoGuard TG-VI
1 microprocessor. The TG-VI control panel consists of a display
screen and a keypad. The TG-VI control panel is shown in
Figure 13. This display shows all possible icons and characters.
Not all icons and characters will be displayed at the same time
in normal operation.
Unit operation is as simple as turning it on and entering a
2 setpoint. You can also:
Initiate a manual defrost cycle
Change the thermostat setpoint
ANA03
Change operating modes
1. Display Screen Check gauges, hourmeters, and alarm codes
2. Keypad
Run a unit self check.
Figure 13: TG-VI Control Panel With all Possible Icons
Several other functions are also available. This chapter
and Characters Displayed
describes the TG-VI control panel. For operating procedures,
see Unit Operation in this manual.
001 35

6 5
The default display is called the Standard Display. See Figure
16: Standard Display, on page 39. The upper and lower ANA03
displays, the icons, the Standard Display, and other display

screens are described later in this section. 1. Upper Display 6. Lower Display
2. CYCLE-SENTRY Icon 7. Defrost Icon
3. Alarm Icon 8. Heat Icon
4. Electric Icon 9. Cool Icon
5. Setpoint Icon
Figure 14: Display Screen With all Possible Icons and
Characters Displayed
36
IMPORTANT: To prevent damage to the controller, always

push the controller access door firmly closed.
1
Display Screen 2
9
The display screen indicates operating status, including
temperature, setpoint, mode, alarm codes, and other 8 3
information depending on the unit status. The display consists
of an upper and lower display in the center and icons around
the edges. The display shown here is displaying all possible
icons and characters. Not all icons and characters will be 7 4
displayed at the same time in normal operation.
6 5
The default display is called the Standard Display. See Figure
16: Standard Display, on page 39. The upper and lower ANA03
displays, the icons, the Standard Display, and other display

screens are described later in this section. 1. Upper Display 6. Lower Display
2. CYCLE-SENTRY Icon 7. Defrost Icon
3. Alarm Icon 8. Heat Icon
4. Electric Icon 9. Cool Icon
5. Setpoint Icon
Figure 14: Display Screen With all Possible Icons and
Characters Displayed
36

AJA1077
1. Upper Display
2. Lower Display
Figure 15: Upper and Lower Displays
37
Upper and Lower Display

The center of the display screen has a five character row of
large digits called the upper display and a four character row of
small digits called the lower display. 1
The upper and lower displays show operating data for the
screen you are viewing.
An example of operating data would be return temperature
(upper display) and setpoint (lower display) on the Standard
Display screen. See Figure 15: Upper and Lower Displays,
on page 37. 2
AJA1077
1. Upper Display
2. Lower Display
Figure 15: Upper and Lower Displays
37

Setpoint Icon: Indicates that the lower
display is the setpoint temperature.
Heat Icon: Indicates that the unit is heating.
Electric Standby Icon: Indicates that the

unit is running in electric standby mode.
Model 50 unit only.
38
Display Icons Defrost Icon: Indicates that the unit is

defrosting.
Lit icons indicate the operating modes of the unit and show if
alarm codes are present. They appear around the left, right, and
bottom edges of the display, and are listed here in that order.
CYCLE-SENTRY Icon: Indicates that the
NOTE: Not all units are equipped with all functions. unit is in CYCLE-SENTRY mode. This
Optional functions are noted. However, all icons light up feature may be optional on some units.
when the unit is powered on, regardless of whether the unit
has that function. Alarm Icon: Indicates that one or more
alarm conditions are present.
Cool Icon: Indicates that the unit is cooling.
Setpoint Icon: Indicates that the lower

display is the setpoint temperature.
Heat Icon: Indicates that the unit is heating.
Electric Standby Icon: Indicates that the

unit is running in electric standby mode.
Model 50 unit only.
38

indicating that the lower display shown is the setpoint. AJA1077
The cool icon is displayed in the upper left corner of the 1. CYCLE-SENTRY Icon
display.
2. Setpoint Icon
The CYCLE-SENTRY icon will also show if the unit is in
CYCLE-SENTRY. 3. Setpoint Temperature (Lower Display)
4. Cool Icon
5. Return Air Temperature (Upper Display)
Figure 16: Standard Display
39
Standard Display
The Standard Display is the default display screen showing
setpoint temperature and return air temperature. See Figure
16: Standard Display, on page 39.
5 1
On the Standard Display screen:
The upper display shows the return air temperature in
Fahrenheit or Celsius depending on the units
programming. 4
The lower display shows the setpoint temperature.
3 2
The setpoint icon shows to the right of the lower display,
indicating that the lower display shown is the setpoint. AJA1077
The cool icon is displayed in the upper left corner of the 1. CYCLE-SENTRY Icon
display.
2. Setpoint Icon
The CYCLE-SENTRY icon will also show if the unit is in
CYCLE-SENTRY. 3. Setpoint Temperature (Lower Display)
4. Cool Icon
5. Return Air Temperature (Upper Display)
39

[YES] if on, [no] if off.
2 4
[dIS]: Discharge air temperature.
1 5
[tLH]: Total unit hours.
[EnH]: Diesel engine hours.
ANA03 Hr4]: : Hourmeter 4 hours. Displays only if
hourmeter 4 is enabled.
1. SELECT Key 4. ENTER Key
2. UP Key 5. TK LOGO Key Hr5]: : Hourmeter 5 hours. Displays only if
3. DOWN Key
Figure 17: Keypad
40
Keypad SELECT Key: Scrolls through the following

This section describes the keypad keys that control the screens in the Standard Display mode:
operating system. [Pnt]: Print latest trip report. Displays only if
DAS is connected and Print Shortcut is
enabled.
[Alr]: Alarm codes, if any.
[DEF]: Defrost prompt.
[CYCLS]: CYCLE-SENTRY mode. Upper
3 display shows [CYCLS], lower display shows
[YES] if on, [no] if off.
2 4
[dIS]: Discharge air temperature.
1 5
[tLH]: Total unit hours.
[EnH]: Diesel engine hours.
ANA03 Hr4]: : Hourmeter 4 hours. Displays only if
1. SELECT Key 4. ENTER Key
2. UP Key 5. TK LOGO Key Hr5]: : Hourmeter 5 hours. Displays only if
3. DOWN Key
Figure 17: Keypad
40

[dS1]-[dS6]: Up to six DAS sensors. ENTER Key: Enters new temperature
Displays only if DAS is connected. setpoints and initiates or enters other settings.
[dFI]: Defrost interval in range.
[dFn]: Defrost interval not in range
[ddr]: Defrost duration.
TK LOGO Key: Initiates unit self check and
NOTE: If a DAS is installed, the unit must be on for displays software revision. Also used to print
approximately 15 seconds with no keypad keys pressed for the a trip report and initiate a start of trip on units
microprocessor to confirm the presence of the DAS. equipped with a DAS.
41
SELECT Key (Continued) UP Key: On the Standard Display screen, it

increases the setpoint. On other screens, it
[Hr6]: : Hourmeter 6 hours. Displays only if
changes the displayed prompt or other setting.
[oIL]: Engine oil pressure.
[EnT]: Engine coolant temp. DOWN Key: On the Standard Display screen,
[rPn]: Engine revolutions per minute. it decreases the setpoint. On other screens, it
changes the displayed prompt or other setting.
[bAt]: Battery voltage.
[coL]: Coil temperature.
[dS1]-[dS6]: Up to six DAS sensors. ENTER Key: Enters new temperature
Displays only if DAS is connected. setpoints and initiates or enters other settings.
[dFI]: Defrost interval in range.
[dFn]: Defrost interval not in range
[ddr]: Defrost duration.
TK LOGO Key: Initiates unit self check and
NOTE: If a DAS is installed, the unit must be on for displays software revision. Also used to print
approximately 15 seconds with no keypad keys pressed for the a trip report and initiate a start of trip on units
microprocessor to confirm the presence of the DAS. equipped with a DAS.
41

42
42

functioning properly. Check the unit as soon as possible to
correct the alarm condition.
ANA23
Flashing status lights: The T (in green) and the K (in
amber) are illuminated and blinking when the unit has a
shutdown alarm code and the load integrity is at risk. Correct Figure 18: Remote Status Light
the alarm condition immediately.
43
Remote Status Light (Optional)

The Remote Status Light mounts on the cargo box for easy
viewing of the units mode. The remote light indicates
operating status as follows:
Green status light: Illuminates the T portion of the TK
logo when the unit is functioning properly with no alarm
codes.
Amber status light: Illuminates the K portion of the TK
logo when the unit has a check alarm code, but is still
functioning properly. Check the unit as soon as possible to
correct the alarm condition.
ANA23
Flashing status lights: The T (in green) and the K (in
amber) are illuminated and blinking when the unit has a
shutdown alarm code and the load integrity is at risk. Correct Figure 18: Remote Status Light
the alarm condition immediately.
43

44
Remote Status Light (Optional)
44

Fuel: Make sure the diesel fuel supply is adequate to WARNING: Do not remove the expansion tank cap
guarantee engine operation to the next check point. Allow for while the coolant is hot.
maximum fuel consumption of one gallon per hour of engine
operation. The engine is designed to operate on Ethylene Glycol based
Engine Oil: Check the engine oil level. It should be at the coolant. This is the only recommended coolant type. Failure to
Full mark when the dipstick is threaded all the way into the oil use the proper antifreeze mixture could cause plugging or
pan. Do not overfill. engine overheating. Do not mix brands, use water alone or mix
rust inhibitors.
CAUTION: Turn the engine off before checking the Do not overfill the coolant.
engine oil level.
45
Manual Pretrip Inspection

(Before Starting the Unit)
Pretrip inspections are an important part of a preventative Engine Coolant: Check the engine coolant level. The engine
maintenance program designed to minimize operating coolant must have antifreeze protection to 30 F (34 C).
problems and breakdowns. Perform this pre-trip inspection Maintain a minumum of 50% Ethylene Glycol based coolant
before every trip involving refrigerated cargo. and 50% water mixture. Do not mix solution any stronger than
NOTE: Pretrip inspections are not intended to take the place 68% Ethylene Glycol based coolant and 32% water for use in
of regular maintenance inspections. extreme temperatures.
Fuel: Make sure the diesel fuel supply is adequate to WARNING: Do not remove the expansion tank cap
guarantee engine operation to the next check point. Allow for while the coolant is hot.
maximum fuel consumption of one gallon per hour of engine
operation. The engine is designed to operate on Ethylene Glycol based
Engine Oil: Check the engine oil level. It should be at the coolant. This is the only recommended coolant type. Failure to
Full mark when the dipstick is threaded all the way into the oil use the proper antifreeze mixture could cause plugging or
pan. Do not overfill. engine overheating. Do not mix brands, use water alone or mix
rust inhibitors.
CAUTION: Turn the engine off before checking the Do not overfill the coolant.
engine oil level.
45

corrosion. Electrolyte should be at the Full mark. condition. The doors should latch securely and the weather
Belts: Make sure belts are in good condition and adjusted to seals should fit tightly.
the proper tension. For more information about belt tension, IMPORTANT: To prevent damage to the controller, always
see the Specifications chapter. push the controller access door firmly closed.
Electrical: Check the electrical connections to make sure they
are securely fastened. Wires and terminals should be free of
corrosion, cracks, and moisture.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
46
Manual Pretrip Inspection (Before Starting the Unit)
Keep the radiator clean and clear of debris by gently spraying Damper: Make sure the damper in the evaporator air outlets
with water. move freely, with no sticking or binding.
NOTE: Used Ethylene Glycol based coolant is a regulated Coils: Make sure the condenser and evaporator coils are clean
substance requiring proper disposal. Check for local disposal and free of debris.
regulations. Do not store in open containers. Keep away from
Cargo Box: Check the interior and exterior of the trailer for
children and animals.
damage. Any damage to the walls or insulation must be
CAUTION: If air is suspected to be trapped in the repaired.
system, it must be bled out. If the engine runs with air Defrost Drains: Check the defrost drain hoses and fittings to
trapped in the block, the engine may be damaged. make sure they are open.
Battery: Make sure the battery terminals are tight and free of Doors: Make sure that the doors and weather seals are in good
corrosion. Electrolyte should be at the Full mark. condition. The doors should latch securely and the weather
Belts: Make sure belts are in good condition and adjusted to seals should fit tightly.
the proper tension. For more information about belt tension, IMPORTANT: To prevent damage to the controller, always
see the Specifications chapter. push the controller access door firmly closed.
Electrical: Check the electrical connections to make sure they
are securely fastened. Wires and terminals should be free of
corrosion, cracks, and moisture.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
46

This manual is published for informational purposes only and
the information furnished herein should not be considered as
all-inclusive or meant to cover all contingencies.
The following are general instructions for operating the TG-VI
Microprocessor Controller. It is recommended that you become
completely familiar with its operation before attempting to
start or operate the unit.
ANA03
Figure 19: TG-VI Microprocessor Controller
47
Unit Operation with TG-VI Controller

Thermo King has applied the latest advances in computer
technology to develop a device that controls temperature and
unit functioning, and displays operating information quickly
and accurately.
There is nothing complicated about learning to operate the
TG-VI Microprocessor Controller, but you will find that a few
minutes studying the contents of this manual will be time well
spent.
This manual is published for informational purposes only and
the information furnished herein should not be considered as
all-inclusive or meant to cover all contingencies.
The following are general instructions for operating the TG-VI
Microprocessor Controller. It is recommended that you become
completely familiar with its operation before attempting to
start or operate the unit.
ANA03
Figure 19: TG-VI Microprocessor Controller
47

On/Off Switch COMPUTER PRINTER
AJA1070
The On/Off switch energizes the electrical control system for
the unit. In the On position, the unit will operate under the
control of the microprocessor. In the Off position, the electric 1. Control Panel 4. Computer Port (Optional)
control system is de-energized and the unit will not operate. 2. Display 5. Printer Port (Optional)
WARNING: When the On/Off switch is in the On 3. Keypad 6. On/Off Switch
position, the unit may start at any time without prior Figure 20: Control and Switch Panels
warning.
48
Control Panel
1
WARNING: Do not operate the unit until you are 2
completely familiar with the location and function of
each control.
ANA03
Two sets of controls are used to operate a unit that has a TG-VI
Microprocessor Controller. The Microprocessor control panel 3
contains the Display Screen (2) and Keypad (3) used to control
microprocessor operations.
Basic operation of the unit is controlled with the On/Off 4
5
switch (6) located on the Switch Panel. 6
On/Off Switch COMPUTER PRINTER

AJA1070
The On/Off switch energizes the electrical control system for
the unit. In the On position, the unit will operate under the
control of the microprocessor. In the Off position, the electric 1. Control Panel 4. Computer Port (Optional)
control system is de-energized and the unit will not operate. 2. Display 5. Printer Port (Optional)
WARNING: When the On/Off switch is in the On 3. Keypad 6. On/Off Switch
position, the unit may start at any time without prior Figure 20: Control and Switch Panels
warning.
48

position, the unit may start at any time without prior
warning.
WARNING: Never use starting fluid.
49
Starting the Diesel Engine

Turn the On/Off switch to the On position. If no key is pressed,
the engine will automatically preheat and start in about 10
seconds. If a key is pressed (to change setpoint or view display
screens), the engine will automatically preheat and start about
10 seconds after the last key is pressed.
If the unit is in CYCLE-SENTRY mode and cooling, heating
or defrosting is required, the engine will automatically preheat
and start.
WARNING: When the On/Off switch is in the On

position, the unit may start at any time without prior
warning.
WARNING: Never use starting fluid.
49

4. Clear any alarms.
5. Press and hold the TK key for at least 3 seconds. USC
(Unit Self Check) will appear on the display.
6. Press the ENTER key while USC is displayed. AMA61
7. Lod (load) will appear on the display and the Unit Self 2
Check will start.
1. TK Logo Key
2. Enter Key
Figure 21: Unit Self Check
50
Starting the Unit with a Unit Self

Check Test
This procedure is used for a complete check of the trailer, unit,
and unit control circuits. It should be used when first starting
the unit for a trip before the cargo is loaded.
1. Perform a Pretrip Inspection. See the manual Pretrip
Inspection in the previous chapter.
2. This procedure is automatic and can be performed on the
way to the loading area or while waiting to load.
3. Place the On/Off switch in the On position. 1
4. Clear any alarms.

5. Press and hold the TK key for at least 3 seconds. USC
(Unit Self Check) will appear on the display.
6. Press the ENTER key while USC is displayed. AMA61
7. Lod (load) will appear on the display and the Unit Self 2
Check will start.
1. TK Logo Key
2. Enter Key
Figure 21: Unit Self Check
50

12. The diesel engine RPM is checked in both high and low
speed.
13. The operation of the defrost damper is checked.
14. The ability of the unit to cool in low speed is checked.
15. The ability of the unit to heat is checked.
16. A second low speed cooling capacity check is performed
to insure that the unit can switch from cool to heat and
back to cool.
51
8. If any alarms were not cleared before starting the Unit Self 17. At the completion of the Unit Self Check, the check results
Check, they will be displayed at this time. They can be will appear on the display. They will remain until any key
cleared by pressing the ENTER key. on the controller is pressed. Check results are shown as
either PASS, CHEC or FAIL:
9. The controller will now automatically preheat and start the
diesel engine. [PASS]The unit is running and no alarms have been
10. All segments of the display will be lighted at the same recorded. The unit has passed the USC.
time. [CHEC]The unit is running but Check Alarms have
been recorded.
11. All programmable settings will be sequentially displayed.
These settings may be verified by the operator if [FAIL]The unit has shut down. View and correct any
necessary. alarms. See Figure 29: Alarm Symbol Location, on
page 61.
12. The diesel engine RPM is checked in both high and low
speed.
13. The operation of the defrost damper is checked.
14. The ability of the unit to cool in low speed is checked.
15. The ability of the unit to heat is checked.
16. A second low speed cooling capacity check is performed
to insure that the unit can switch from cool to heat and
back to cool.
51

technician to display the setpoint to a tenth of a degree.
1
Press the SELECT key to display the prompt and display
screens. See SELECT Key on page 40 for list of these screens.
AJA1077
1. Select Key
52
Displaying Operating Data

During Normal Operation
During normal operation, the standard display appears on the
screen. Return air temperature is displayed in the upper
readout, and the setpoint is displayed in the lower readout. In
this example, the return air temperature is 50.8 F and the
setpoint temperature is 35 F.
NOTE: If the unit is turned off by the optional remote
control, the display will read [Standby].
NOTE: The TG-VI can be programmed by a service
technician to display the setpoint to a tenth of a degree.
1
Press the SELECT key to display the prompt and display
screens. See SELECT Key on page 40 for list of these screens.
AJA1077
1. Select Key
52

automatically. The longer the key is depressed, the faster
the scrolling speed.
2. Press and release the ENTER key within 10 seconds to
enter the new setpoint into memory.
The display will briefly show Lod (load) in the lower AJA1077
readout.The new setpoint will appear on the display. The unit
now operates with the new setpoint.
1. Up Key 3. Setpoint
CAUTION: Make sure the ENTER key was pressed in 2. Down Key 4. Enter Key
the first 10 seconds, or the original setpoint will
Figure 23: Changing the Setpoint
return to the screen and control the unit.
53
Changing the Setpoint

The setpoint temperature of the Thermo King unit can be
quickly and easily changed.
3
1. With the standard display on the screen, press the UP or
DOWN key until the setpoint is at the desired temperature
setting.
Press and release either key repeatedly to cause the 2
temperature to change by 1 (or 0.1 degrees if programmed
to do so). 1 4
Hold either key down to cause the temperature to scroll
automatically. The longer the key is depressed, the faster
the scrolling speed.
2. Press and release the ENTER key within 10 seconds to
enter the new setpoint into memory.
The display will briefly show Lod (load) in the lower AJA1077
readout.The new setpoint will appear on the display. The unit
now operates with the new setpoint.
1. Up Key 3. Setpoint
CAUTION: Make sure the ENTER key was pressed in 2. Down Key 4. Enter Key
the first 10 seconds, or the original setpoint will
Figure 23: Changing the Setpoint
return to the screen and control the unit.
53

CYCLE-SENTRY Operation: The above listings are not all inclusive. Consult your grower or
Frozen foods (in adequately insulated trailers) shipper if you have any questions about the operating mode
selection of your type of load.
Boxed or processed meats
Poultry
Fish
Dairy products
Candy
Chemicals
54
Selection of Operating Modes Film
The Thermo King CYCLE-SENTRY system is designed to All non-edible products.

save refrigeration fuel costs. The savings vary with the Examples of products normally requiring Continuous Run
commodity, ambient temperatures and trailer insulation. Operation for air flow:
However, not all temperature controlled products can be
Fresh fruits and vegetables, especially asparagus,
properly transported using CYCLE-SENTRY operation.
bananas, broccoli, carrots, citrus, green peas, lettuce,
Certain highly sensitive products normally require continuous
peaches, spinach, strawberries, sweet corn, etc.
air circulation. Use the following guidelines to select the
proper operating mode to protect the commodity you are Non-processed meat products (unless pre-cooled to
transporting. recommended temperature)
Examples of products normally acceptable for Fresh flowers and foliage.
CYCLE-SENTRY Operation: The above listings are not all inclusive. Consult your grower or
Frozen foods (in adequately insulated trailers) shipper if you have any questions about the operating mode
selection of your type of load.
Boxed or processed meats
Poultry
Fish
Dairy products
Candy
Chemicals
54

required to maintain the setpoint and to keep the engine warm ANA11
and the battery charged.
1. The unit must be turned on. Clear all alarms. 1. Select Key 3. Down Key
2. Press the SELECT key (cycling arrows) until the display 2. Up Key
shows CYCLS and YES or NO. Figure 24: Selecting CYCLE-SENTRY
3. Press the UP or DOWN keys to choose YES or NO. YES or Continuous Mode
operates the unit in CYCLE-SENTRY. NO operates the NOTE: The ENTER key must be pressed within 10 seconds to
unit in Continuous Run. load the new mode.
4. Press the ENTER key (equals sign) when the desired mode The display will briefly show Lod (load) and then the new
is shown in the display. mode will appear.
55
Selecting CYCLE-SENTRY or
Continuous Mode
NOTE: The CYCLE-SENTRY icon will appear when the
CYCLE-SENTRY mode is selected and the ON/OFF switch is
in the ON position.
Continuous Mode: When Continuous mode is selected, the 2 3
unit will run continuously to maintain the setpoint and provide
1
constant airflow.
CYCLE-SENTRY Mode: : When the CYCLE-SENTRY
Mode is selected, the unit starts and stops automatically as
required to maintain the setpoint and to keep the engine warm ANA11
and the battery charged.
1. The unit must be turned on. Clear all alarms. 1. Select Key 3. Down Key
2. Press the SELECT key (cycling arrows) until the display 2. Up Key
shows CYCLS and YES or NO. Figure 24: Selecting CYCLE-SENTRY
3. Press the UP or DOWN keys to choose YES or NO. YES or Continuous Mode
operates the unit in CYCLE-SENTRY. NO operates the NOTE: The ENTER key must be pressed within 10 seconds to
unit in Continuous Run. load the new mode.
4. Press the ENTER key (equals sign) when the desired mode The display will briefly show Lod (load) and then the new
is shown in the display. mode will appear.
55

1
NOTE: The ENTER key must be pressed to enter a Defrost
cycle. The display will return to the Standard Display in
about 10 seconds and the defrost mode will not be entered
unless the ENTER key is pressed.
AMA60
1. Select Key 2. Enter Key

Figure 25: Initiating a Manual Defrost Cycle
56
Initiating a Manual Defrost Cycle

1. The unit must be running in Continuous or
CYCLE-SENTRY mode or be in CYCLE-SENTRY Null
mode and the coil temperature must be below 45 F (7 C).
2. Press the SELECT key until the dEF (defrost) prompt
appears in the display.
3. Press the ENTER key to enter a Defrost cycle. The display
will briefly show Lod (load). The unit will then enter a
Defrost cycle. The Defrost cycle will terminate 2
automatically.
1
NOTE: The ENTER key must be pressed to enter a Defrost
cycle. The display will return to the Standard Display in
about 10 seconds and the defrost mode will not be entered
unless the ENTER key is pressed.
AMA60
1. Select Key 2. Enter Key

Figure 25: Initiating a Manual Defrost Cycle
56

1 2
The number shown in the upper part of the display is the
software revision number.
ARA914
1. Select Key 2. TK Logo Key

Figure 26: Checking Software Revision
57
Checking Software Revision

There are currently several different software revisions in use.
This information may be requested in the event that service is
required. To determine the software revision installed in your
unit, perform the following steps.
1. Place the On/Off switch in the ON position.
2. Press and hold the TK LOGO key for at least three seconds.
The Unit Self Check [USC] prompt screen will appear.
3. Press the SELECT key (cycling arrows) until rEU
(revision) appears in the lower part of the display.
1 2
The number shown in the upper part of the display is the
software revision number.
ARA914

Figure 26: Checking Software Revision
57

before pressing any keys to allow the microprocessor to
confirm the presence of the DAS.
NOTE: If the Print Shortcut is enabled, pressing the 3
SELECT key at the standard display will take you directly
to the print screen.
COMPUTER PRINTER
3. Press and hold the TK LOGO key for at least three seconds. ARA915
4. Press the SELECT key (cycling arrows) until Pnt (print) 1. Select Key 2. TK Logo Key
appears in the lower part of the display. 3. Printer Port
Figure 27: Printing a Trip Report
58
Printing a Trip Report

This procedure is only available on units equipped with an
optional DAS datalogger. It prints the current DAS record
directly to an handheld printer. Only data from the directly
connected DAS sensors can be printed. Graphs are not
available with a handheld printer.
1. Connect the printer to the Printer Port on the front of
control panel. 1 2
2. Place the On/Off switch in the On position. The standard
display should appear on the screen. Wait for 15 seconds
NOTE: If the Print Shortcut is enabled, pressing the 3
SELECT key at the standard display will take you directly
to the print screen.
COMPUTER PRINTER
3. Press and hold the TK LOGO key for at least three seconds. ARA915
4. Press the SELECT key (cycling arrows) until Pnt (print) 1. Select Key 2. TK Logo Key
appears in the lower part of the display. 3. Printer Port
Figure 27: Printing a Trip Report
58

59
5. Press the ENTER key. The display will briefly show Lod
(load) and the printing process will begin.
6. Place the On/Off switch in the Off position to stop
printing.
NOTE: If printing is initiated without a printer connected, or
if the printer cable is not connected properly, printing will be
aborted after 30 seconds and the standard display will appear.
59

Manual is also available on the Internet at
HTTP://WWW.BLUETREE.IE.
7. Place the On/Off switch in the On position. The standard 1 2
The Unit Self Check [USC] prompt screen will appear. ARA916
9. Press the SELECT key (cycling arrows) until Pnt (print)

appears in the lower part of the display.
Figure 28: Initiating a Start of Trip
60
Initiating a Start of Trip 10. Press the ENTER key. The display will briefly show Lod
(load). A Start Of Trip Marker has been inserted.
This procedure is only available on units equipped with an
optional DAS datalogger. A Start Of Trip places a marker in If no keys are pressed for 30 seconds, the standard display will
the datalogger memory. It is typically initiated when the cargo automatically reappear on the display.
is being loaded. The Start Of Trip marker then shows when the
trip started in the data that is downloaded or printed from the
DAS datalogger. A Start Of Trip can be initiated through the
use of WinTrac datalogging software, or manually in the field.
The following procedure covers manual initiation. For more
information on datalogging, see the WinTrac User Manual
included with the WinTrac software. The WinTrac User
Manual is also available on the Internet at
HTTP://WWW.BLUETREE.IE.
7. Place the On/Off switch in the On position. The standard 1 2
The Unit Self Check [USC] prompt screen will appear. ARA916
9. Press the SELECT key (cycling arrows) until Pnt (print)

appears in the lower part of the display.
Figure 28: Initiating a Start of Trip
60

displayed on the screen, press the SELECT key.
2. If more than one alarm is present, each will be displayed
for several seconds.
NOTE: Some of the codes will only be meaningful to an
authorized TK service technician. If you are unable to clear
ANA12
an alarm code, carefully record the number of the code and
refer the matter to an authorized dealer.
1. Alarm Symbol 3. Select Key
NOTE: Do not reset the alarm system until all the alarm 2. Enter Key
codes have been recorded, the alarm information has been
checked. Figure 29: Alarm Symbol Location
61
Displaying and Clearing Alarm

Codes
1
For detailed alarm code information refer to the Alarm
Codes chapter in this manual.
NOTE: Alarms are indicated by the appearance of an alarm
symbol (exclamation point within a triangle) in the
upper-right on the screen. Check alarms and stored alarms
are indicated by a steady alarm symbol. Shutdown alarms are
indicated by a flashing alarm symbol. 2
1. The unit On/Off switch must be On. If the alarm symbol is 3
displayed on the screen, press the SELECT key.
2. If more than one alarm is present, each will be displayed
for several seconds.
NOTE: Some of the codes will only be meaningful to an
authorized TK service technician. If you are unable to clear
ANA12
an alarm code, carefully record the number of the code and
refer the matter to an authorized dealer.
1. Alarm Symbol 3. Select Key
NOTE: Do not reset the alarm system until all the alarm 2. Enter Key
codes have been recorded, the alarm information has been
checked. Figure 29: Alarm Symbol Location
61

Alarm code 74 requires an authorized service technician to
reprogram the TG-VI.
62
3. To reset the alarm system.

a. Press the SELECT KEY to display the alarm screen.
b. Press the ENTER KEY to clear the alarm. Enter must be
pushed to clear each alarm if more than one alarm is
present
After all alarms are cleared, the alarm symbol will
disappear. After about ten seconds, the standard display
will appear on the screen.
NOTE: If the alarm condition is not corrected, alarms may
continue to appear.
Alarm code 74 requires an authorized service technician to
reprogram the TG-VI.
62

technician. Code 84. The alarm can clear automatically if the condition
NOTE: The chart on the following pages shows all possible does not reoccur.
alarm codes for all possible applications. Not all codes will be
NOTE: The corrective actions listed on the Table of Alarm
applicable to each individual unit.
Codes are suggestions only. Always consult your company
for final decisions.
63
Alarm Codes
Introduction Repair
An alarm is generated when the microprocessor senses an The operator can repair certain faults, other faults can only be
abnormal condition. Alarms direct an operator or service repaired by your Thermo King Dealer. Refer to the table on the
technician to the source of a problem. following pages for the proper corrective action.
Multiple alarms can be present at one time. All generated NOTE: Document all alarm faults and report them to the
alarms will be stored in memory until cleared by the operator. service technician.
Document all alarm occurrences and report them to the service NOTE: Alarms with an asterisk (*) can exist with Alarm
technician. Code 84. The alarm can clear automatically if the condition
NOTE: The chart on the following pages shows all possible does not reoccur.
alarm codes for all possible applications. Not all codes will be
NOTE: The corrective actions listed on the Table of Alarm
applicable to each individual unit.
Codes are suggestions only. Always consult your company
for final decisions.
63

appear and remain on.
the problem.
Shutdown Alarm: Indicates conditions that could damage
NOTE: The corrective actions listed above and on the
the unit. The unit will automatically shut down, the alarm icon
following chart are suggestions only. Always consult your
will appear, and the entire display will flash on and off.
company for final decisions.
NOTE: Alarms that occurred during a unit pre-trip or self
check will be preceded by a dash (-). Refer to the Alarm Type
column on the following chart.
NOTE: Some alarms are self-clearing. These alarms will
clear automatically when the operating condition causing the
alarm returns to normal.
64
Alarm Codes
Alarm Types Corrective Action

The three types of alarms are described below. They can occur There are three levels of corrective action that can be taken
individually or with other alarms. More than one alarm can be when an alarm condition occurs.
present at one time.
OK To Run: An alarm condition exists but does not affect
Stored Alarm: Indicates a condition exists that should be unit operation. Corrective action can occur at a later date.
investigated, but does not affect unit operation. The alarm icon
Check As Specified: An alarm condition exists that could
will appear for 30 seconds when the unit On/Off switch is
affect unit operation. Follow directions in the Corrective
turned on, then it disappears.
Action column on the following chart.
Check Alarm: Notice to take corrective action before an
Take Immediate Action: An alarm condition exists that
abnormal condition becomes severe. The alarm icon will
will damage the unit or load. Take immediate action to correct
appear and remain on.
the problem.
Shutdown Alarm: Indicates conditions that could damage
NOTE: The corrective actions listed above and on the
the unit. The unit will automatically shut down, the alarm icon
following chart are suggestions only. Always consult your
will appear, and the entire display will flash on and off.
company for final decisions.
NOTE: Alarms that occurred during a unit pre-trip or self
check will be preceded by a dash (-). Refer to the Alarm Type
column on the following chart.
NOTE: Some alarms are self-clearing. These alarms will
clear automatically when the operating condition causing the
alarm returns to normal.
64

65
Alarm Codes
Alarm Code 84 (Restart Null) Alarm Code 85

Alarm Code 84 is a temporary abnormal condition resulting (Forced Unit Operation)
from other alarms. The unit shuts down for approximately 15 Alarm Code 85 is also a temporary abnormal condition
minutes. The unit will restart after approximately 15 minutes, resulting from other alarm(s). The unit goes into an abnormal
or after the condition has reset, and in most cases the other mode which allows the unit to continue to run without shutting
alarm(s) will have been cleared. If after 3 attempts, the down, the unit may however run with reduced capacity. When
condition continues to occur, the alarm that caused the the alarm that caused 85 is no longer active, Alarm Code 85
shutdown will appear on the display and the unit will shut will be reset.
down until the alarm is cleared. Code 84 will automatically
clear after the final attempt at restarting has occurred.
65

01 Microprocessor Power Up Reset Will not affect unit operation, data log only - clear alarm. X
02 Evaporator Coil Sensor Monitor box temp, repair as required. X
Unit controls on discharge air sensor, monitor box temp,
03 Return Air Sensor X
repair as required.
Unit controls on return air sensor, monitor box temp, repair
04 Discharge Air Sensor X
as required.
05 Ambient Air Sensor Unit operating with reduced features, repair as required. X
06 Engine Water Temp Sensor Unit operating with reduced features, repair as required. X
07 Engine RPM Sensor Unit operating with reduced features, repair as required. X
66
Alarm Codes
Table of Alarm Codes

*Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur.
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Level Of
Code Description Corrective Action
Action
Check
Ok To
Down
Shut
Run
00 No Fault None required. X
01 Microprocessor Power Up Reset Will not affect unit operation, data log only - clear alarm. X
02 Evaporator Coil Sensor Monitor box temp, repair as required. X
Unit controls on discharge air sensor, monitor box temp,
03 Return Air Sensor X
repair as required.
Unit controls on return air sensor, monitor box temp, repair
04 Discharge Air Sensor X
as required.
05 Ambient Air Sensor Unit operating with reduced features, repair as required. X
06 Engine Water Temp Sensor Unit operating with reduced features, repair as required. X
07 Engine RPM Sensor Unit operating with reduced features, repair as required. X
66

09* High Evaporator Temperature Unit shut down to prevent damage, repair immediately. X
High Discharge Pressure or Unit shut down to prevent damage, clear and retry, if
10* X
Temp reoccurs repair immediately.
Unit Controlling on Alternate Secondary alarm related to Alarm Code 3 or 4, monitor box
11 X
Sensor temp, repair as required.
12 Sensor Shutdown Unit shut down to prevent damage, repair immediately. X
Monitor box temp with independent thermometer, repair as
13 Check Sensor Calibration X
required.
14 Defrost Terminated by Time Clear alarm, repair after delivery. X
67
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Remote zone controls on coil sensor, monitor box temp,
08 Remote Return Air Sensor X
repair as required.
09* High Evaporator Temperature Unit shut down to prevent damage, repair immediately. X
High Discharge Pressure or Unit shut down to prevent damage, clear and retry, if
10* X
Temp reoccurs repair immediately.
Unit Controlling on Alternate Secondary alarm related to Alarm Code 3 or 4, monitor box
11 X
Sensor temp, repair as required.
12 Sensor Shutdown Unit shut down to prevent damage, repair immediately. X
Monitor box temp with independent thermometer, repair as
13 Check Sensor Calibration X
required.
14 Defrost Terminated by Time Clear alarm, repair after delivery. X
67

Engine was not manually started, clear alarm and manually
16 Manual Start Not Completed X
start engine.
17* Engine Failed to Crank Attempt to start in Continuous mode, repair as required. X
18* High Engine Water Temperature Check belts and coolant level, repair as required. X
Check engine oil level, add oil as needed, repair as
19* Low Engine Oil Pressure X
required.
Check fuel level, attempt to start in Continuous mode, repair
20* Engine Failed to Start X
as required.
21 Cooling Cycle Check Monitor box temp, repair as required. X
22 Heating Cycle Check Monitor box temp, repair as required. X
68
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Glow Plug/Intake Air Heater
15 Repair after delivery. X
Check
Engine was not manually started, clear alarm and manually
16 Manual Start Not Completed X
start engine.
17* Engine Failed to Crank Attempt to start in Continuous mode, repair as required. X
18* High Engine Water Temperature Check belts and coolant level, repair as required. X
Check engine oil level, add oil as needed, repair as
19* Low Engine Oil Pressure X
required.
Check fuel level, attempt to start in Continuous mode, repair
20* Engine Failed to Start X
as required.
21 Cooling Cycle Check Monitor box temp, repair as required. X
22 Heating Cycle Check Monitor box temp, repair as required. X
68

25 Alternator Check Check alternator charging rate, repair immediately. X X
26 Check Refrigeration Capacity Monitor box temp, repair as required. X
27 Unassigned
Pretrip or self-check was terminated, check for other alarms
28 Pretrip or Self-check Abort X
and repeat.
Unit or zone may not defrost, monitor box temp, repair as
29 Damper Circuit X
required.
30 Damper Stuck Closed Damper is stuck closed, repair immediately. X
31 Oil Pressure Switch Oil pressure switch is not functioning. X
69
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
23* Cooling Cycle Fault Unit shut down to prevent damage, repair immediately. X
24* Heating Cycle Fault Unit shut down to prevent damage, repair immediately. X
25 Alternator Check Check alternator charging rate, repair immediately. X X
26 Check Refrigeration Capacity Monitor box temp, repair as required. X
27 Unassigned
Pretrip or self-check was terminated, check for other alarms
28 Pretrip or Self-check Abort X
and repeat.
Unit or zone may not defrost, monitor box temp, repair as
29 Damper Circuit X
required.
30 Damper Stuck Closed Damper is stuck closed, repair immediately. X
31 Oil Pressure Switch Oil pressure switch is not functioning. X
69

Check modulation circuit breaker or fuse, monitor box temp,
34 Modulation Circuit X
repair as required.
35 Run Relay Circuit Check run relay circuit, repair immediately. X
Electric Motor Failed to Check standby source of power and motor drive belt, repair
36* X
Run/Loose Belt immediately.
37 Check Engine Water Level Check coolant level, add as needed. X
Phase Reversed /Overload Standby power phased wrong or motor overload tripped,
38
Tripped repair immediately. X
Unit operating with reduced heating, monitor box temp,
39 Water Valve Circuit X
repair as required.
70
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
32 Refrigeration Capacity Low Unit shut down to prevent damage, repair immediately. X
33 Check Engine RPM Check and note RPM, repair as required. X
Check modulation circuit breaker or fuse, monitor box temp,
34 Modulation Circuit X
repair as required.
35 Run Relay Circuit Check run relay circuit, repair immediately. X
Electric Motor Failed to Check standby source of power and motor drive belt, repair
36* X
Run/Loose Belt immediately.
37 Check Engine Water Level Check coolant level, add as needed. X
Phase Reversed /Overload Standby power phased wrong or motor overload tripped,
38
Tripped repair immediately. X
Unit operating with reduced heating, monitor box temp,
39 Water Valve Circuit X
repair as required.
70

41 Engine Water Temp Check Check belts and coolant level, repair as required. X
Temporary overheat condition, if condition persists repair as
42 Unit Forced to Low Speed X
required.
43 Unit Forced to Low Speed Mod X
required.
Check fuel level in unit fuel tank, add fuel, purge fuel lines
44* Fuel System X
and restart as required.
Unit operating with reduced modulation control, repair as
45 Hot Gas Circuit X
required.
46 Air Flow Check Cargo may be restricting air flow, check load. X
71
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Check high speed operation, monitor box temp, repair as
40 High Speed Circuit X
required.
41 Engine Water Temp Check Check belts and coolant level, repair as required. X
42 Unit Forced to Low Speed X
required.
43 Unit Forced to Low Speed Mod X
required.
Check fuel level in unit fuel tank, add fuel, purge fuel lines
44* Fuel System X
and restart as required.
Unit operating with reduced modulation control, repair as
45 Hot Gas Circuit X
required.
46 Air Flow Check Cargo may be restricting air flow, check load. X
71

48 Check Belts or Clutch Drive clutch or belts slipping, repair immediately X
Data Tag disconnected or inoperative, affects data tag only,
49 RF Tag Communications Error X
repair as required.
Unit will operate normally, set date and time to clear alarm.
50 Reset Clock X
(see the Unit Operation chapter for procedures).
51 Shutdown Circuit Secondary protection circuit failed, repair as required. X
May have no heat, monitor box temperature, repair as
52 Heat Circuit X
required.
Unit operating with reduced heat performance, monitor box
53 Economizer Valve Circuit X
temp, repair as required.
72
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Multi-temp zone sensor failed, zone shut down, monitor
47 Remote Sensor Shutdown X
temp and repair as required.
48 Check Belts or Clutch Drive clutch or belts slipping, repair immediately X
Data Tag disconnected or inoperative, affects data tag only,
49 RF Tag Communications Error X
repair as required.
Unit will operate normally, set date and time to clear alarm.
50 Reset Clock X
(see the Unit Operation chapter for procedures).
51 Shutdown Circuit Secondary protection circuit failed, repair as required. X
May have no heat, monitor box temperature, repair as
52 Heat Circuit X
required.
53 Economizer Valve Circuit X
72

Engine speed out of spec, check RPM, monitor box temp,
55 Check Engine Speeds X
repair as required.
Unit operating with no low speed evaporator fan, repair as
56 Evap Fan Low Speed X
required (RC units only).
Unit operating with no high speed evaporator fan, repair as
57 Evap Fan High Speed X
Unit operating with no low speed condenser fan, repair as
58 Cond Fan Low Speed X
Unit operating with no high speed condenser fan, repair as
59 Cond Fan High Speed X
73
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
A diagnostic mode timed out, does not affect unit
54 Test Mode Time-out X
performance.
Engine speed out of spec, check RPM, monitor box temp,
55 Check Engine Speeds X
repair as required.
Unit operating with no low speed evaporator fan, repair as
56 Evap Fan Low Speed X
Unit operating with no high speed evaporator fan, repair as
57 Evap Fan High Speed X
Unit operating with no low speed condenser fan, repair as
58 Cond Fan Low Speed X
Unit operating with no high speed condenser fan, repair as
59 Cond Fan High Speed X
73

61 Low Battery Volts Check charge rate and battery voltage, repair as required. X
62 Ammeter Out of Cal Range Ammeter inaccurate, repair as required. X
63* Engine Stopped Engine should be running, try restart, repair as required. X
Does not affect unit operation, perform Pretrip or Unit Self
64 Pretrip Reminder X
Check to clear alarm.
If unit is shutdown, repair immediately. Otherwise, monitor
65 Abnormal Temp Differential X X
box temp and repair as required.
66 Low Engine Oil Level Check engine oil level, add as needed. X
Unit operating with reduced performance, monitor box temp,
67 Liquid Line Solenoid Circuit X
repair as required.
74
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Unit operating without boost capacitors, repair as required
60 Boost Circuit X
(RC units only).
61 Low Battery Volts Check charge rate and battery voltage, repair as required. X
62 Ammeter Out of Cal Range Ammeter inaccurate, repair as required. X
63* Engine Stopped Engine should be running, try restart, repair as required. X
Does not affect unit operation, perform Pretrip or Unit Self
64 Pretrip Reminder X
Check to clear alarm.
If unit is shutdown, repair immediately. Otherwise, monitor
65 Abnormal Temp Differential X X
box temp and repair as required.
66 Low Engine Oil Level Check engine oil level, add as needed. X
67 Liquid Line Solenoid Circuit X
repair as required.
74

69 Remagnetization Circuit X
70 Hourmeter Failure Will not affect unit operation, repair after delivery. X
Maintenance alarm dependent on customer selection, will
71 Hourmeter 4 Exceeds Set Limit X
not affect unit operation.
73 Hourmeter 6 Exceeds Set Limit
not affect unit operation. X
Unit has reset, control parameters. May be inaccurate,
74 P Reverted to Default Settings X
repair immediately.
75
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
68 P Internal Fault Code Clear and retry, monitor box temp, repair as required. X
Clear and retry, if alarm reoccurs or is shutdown repair as
69 Remagnetization Circuit X
70 Hourmeter Failure Will not affect unit operation, repair after delivery. X
73 Hourmeter 6 Exceeds Set Limit
not affect unit operation. X
Unit has reset, control parameters. May be inaccurate,
74 P Reverted to Default Settings X
repair immediately.
75

77 P Internal Fault Code Controller may be defective, repair immediately. X
Data logger missed logging one event, no action required,
79 Data Log Overflow X
clear alarm.
80 Compressor Temp Sensor Compressor protection reduced, repair as required. X
81 High Comp Temp Compressor operating above temp limits, repair as required. X
Compressor shut down to prevent damage, repair
82 High Comp Temp Shutdown X
immediately.
Reduced heating capacity, monitor box temp and engine
83 Low Coolant Temp X
76
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Data logger missed logging one event, no action required,
79 Data Log Overflow X
clear alarm.
80 Compressor Temp Sensor Compressor protection reduced, repair as required. X
81 High Comp Temp Compressor operating above temp limits, repair as required. X
Compressor shut down to prevent damage, repair
82 High Comp Temp Shutdown X
immediately.
Reduced heating capacity, monitor box temp and engine
83 Low Coolant Temp X
76

Temporary forced operation resulting from other alarm
85 Forced Unit Operation X
codes. Refer to detailed explanation at start of chapter.
86 Discharge Press Transducer X
repair as required.
87 Suction Press Transducer X
repair as required.
88 Unassigned
If Check Alarm, unit operating with reduced performance,
89 Electronic Throttling Valve Circuit monitor box temp, repair as required. If Shutdown Alarm, X X
ETV or refrigeration system failure, repair immediately.
77
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Temporary shutdown resulting from other alarm codes.
84 Restart Null X
Refer to detailed explanation at start of chapter.
Temporary forced operation resulting from other alarm
85 Forced Unit Operation X
codes. Refer to detailed explanation at start of chapter.
86 Discharge Press Transducer X
repair as required.
87 Suction Press Transducer X
repair as required.
88 Unassigned
If Check Alarm, unit operating with reduced performance,
89 Electronic Throttling Valve Circuit monitor box temp, repair as required. If Shutdown Alarm, X X
ETV or refrigeration system failure, repair immediately.
77

Low Compressor Suction Suction pressure lower than expected for current conditions,
93 X
Pressure repair as required.
Suction pressure drops less than specified when Loader
94 Loader Valve #1 X
Valve #1 is energized during unit start up, repair as required.
96 Low Fuel Level Check fuel level, add as needed. X
97 Unassigned
98 Check Fuel Level Sensor Low fuel level or defective fuel level sensor. X
78
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
90-
Unassigned
92
Low Compressor Suction Suction pressure lower than expected for current conditions,
93 X
Pressure repair as required.
96 Low Fuel Level Check fuel level, add as needed. X
97 Unassigned
98 Check Fuel Level Sensor Low fuel level or defective fuel level sensor. X
78

100-
Unassigned
104
Receiver Tank Press Solenoid Unit operating with reduced heat performance, monitor box
105 X
Circuit temp, repair as required.
106 Purge Valve Circuit X
107 Condenser Inlet Solenoid Circuit X
repair as required.
108 Door Open Timeout Door open for extended time, close door and clear alarm. X
79
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Compression ratio of discharge to suction pressure has
99 High Compressor Pressure Ratio X
risen above specification, repair as required.
100-
Unassigned
104
Receiver Tank Press Solenoid Unit operating with reduced heat performance, monitor box
105 X
Circuit temp, repair as required.
106 Purge Valve Circuit X
107 Condenser Inlet Solenoid Circuit X
repair as required.
108 Door Open Timeout Door open for extended time, close door and clear alarm. X
79

110 Suction Line Solenoid CIrcuit X
repair as required.
111 Unit Not Configured Correctly Controller not set properly for unit type, repair immediately. X
112 Remote Fan Zone 2-3 Circuit Remote fan failure in indicated zone, repair as required. X
113 Electric Heat Circuit Electric heating problem, repair as required. X
Multiple problems prevent unit operation, check alarm
114 Multiple Alarms, Can Not Run X
codes, repair immediately.
80
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
High discharge press or defective discharge press sensor,
109 High Discharge Pressure/Sensor X
high speed prevented.
110 Suction Line Solenoid CIrcuit X
repair as required.
111 Unit Not Configured Correctly Controller not set properly for unit type, repair immediately. X
112 Remote Fan Zone 2-3 Circuit Remote fan failure in indicated zone, repair as required. X
113 Electric Heat Circuit Electric heating problem, repair as required. X
Multiple problems prevent unit operation, check alarm
114 Multiple Alarms, Can Not Run X
codes, repair immediately.
80

121 Liquid Injection Valve X
repair as required.
81
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
115-
Unassigned
120
121 Liquid Injection Valve X
repair as required.
81

82
Alarm Codes
82

the manifest. 6. Supervise product loading to ensure sufficient air space
around and through the load. Airflow around the cargo
2. Inspect door seals and vent doors for condition and a tight must not be restricted.
seal with no air leakage.
NOTE: If the warehouse is not refrigerated, operate the
3. Inspect the trailer inside and out. Look for: unit with doors closed until cargo is ready to be loaded.
Damaged or loose trailer skin and insulation Then turn off the unit, open cargo doors and load cargo.
When cargo is loaded, close trailer doors and restart the
Damaged walls, air ducts, floor channels or T
unit.
flooring
The unit can be operated with the cargo box doors open
Clogged defrost drain tubes if the truck is backed into a refrigerated warehouse and
the dock door seals fit tightly around the trailer.
Blocked return air bulkhead
001 83
Loading and Enroute Inspections

This chapter describes pre-loading, post loading, and enroute 4. Verify that the setpoint temperature is correct for your
inspection procedures. Thermo King refrigeration units are cargo. Pre-cool the trailer as required.
designed to maintain the required product load temperature
5. Push the microprocessor controller access door firmly
during transit. Follow these recommended loading and enroute
closed after setting temperature setpoint
procedures to help minimize temperature related problems.
CAUTION: Push the controller access door firmly
closed after each use. Damage can occur in transit if
Pre-Loading Inspection the door is not properly closed.
1. Pre-cool products before loading. Note any variances on
the manifest. 6. Supervise product loading to ensure sufficient air space
around and through the load. Airflow around the cargo
2. Inspect door seals and vent doors for condition and a tight must not be restricted.
seal with no air leakage.
NOTE: If the warehouse is not refrigerated, operate the
3. Inspect the trailer inside and out. Look for: unit with doors closed until cargo is ready to be loaded.
Damaged or loose trailer skin and insulation Then turn off the unit, open cargo doors and load cargo.
When cargo is loaded, close trailer doors and restart the
Damaged walls, air ducts, floor channels or T
unit.
flooring
The unit can be operated with the cargo box doors open
Clogged defrost drain tubes if the truck is backed into a refrigerated warehouse and
the dock door seals fit tightly around the trailer.
Blocked return air bulkhead
001 83

7
6. Clear defrost drains
7. Good outside air circulation
6 5 8. Unit inspection
9. Tight seals
ADZ30
Figure 30: Loading Considerations
84
1
2 1. Correct load height (trailers without chutes)
2. Tight doors and gaskets
9
3. Good air circulation around load
3
4. Proper cargo temperature (prior to loading)
8
4 5. Interior/exterior walls and insulation in good
7 condition
6. Clear defrost drains
7. Good outside air circulation
6 5 8. Unit inspection
9. Tight seals
ADZ30
Figure 30: Loading Considerations
84

closed.
3. Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on CAUTION: Push the controller access door firmly
the manifest. closed after each use. Unit damage can occur in
transit if the door is not properly closed.
CAUTION: Cargo must be pre-cooled to the proper
temperature before loading. The unit is designed to
maintain temperature, not cool an above-temperature
load.
85
Post-Loading Inspection 4. Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
Post-loading inspections ensure the cargo has been loaded
properly. To perform a post-load inspection: 5. Make sure the setpoint is at the temperature listed on the
manifest.
1. Inspect the evaporator outlets for blockage.
6. If the unit was stopped, restart using the correct starting
2. Turn the unit off before opening the cargo box doors to procedure. See the Operating Instruction chapter in this
maintain efficient operation. manual.
NOTE: The unit can be operated with the cargo box 7. Start a manual defrost cycle 30 minutes after loading. See
doors open if the truck is backed into a refrigerated the Manual Defrost procedure in this manual.
warehouse and the dock door seals fit tightly around the
trailer. 8. Push the microprocessor controller access door firmly
closed.
3. Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on CAUTION: Push the controller access door firmly
the manifest. closed after each use. Unit damage can occur in
transit if the door is not properly closed.
CAUTION: Cargo must be pre-cooled to the proper
temperature before loading. The unit is designed to
maintain temperature, not cool an above-temperature
load.
85

CAUTION: Stop the unit if the compartment
Inspection Troubleshooting temperature remains higher than the desired
1. If a temperature reading is not within the desired temperature range from the setpoint on two
temperature range, refer to the troubleshooting table on the consecutive 30 minute inspections. Contact the
following pages. Correct problem as required. nearest Thermo King Service Center or your
company office immediately. Take all necessary steps
to protect and maintain proper load temperature.
86
Enroute Inspections 2. Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
Complete the following enroute inspection every four hours.
temperature range. Stop the unit if the compartment
This will help minimize temperature related problems.
temperature is not within the desired temperature range on
two consecutive 30 minute inspections, especially if the
Inspection Procedure compartment temperature appears to be moving away
1. Verify setpoint is correct. from the setpoint.
2. Check the return air temperature reading. It should be 3. Immediately contact the nearest Thermo King Service
within the desired temperature range. Center or your company office.
3. Initiate a manual defrost cycle after each enroute 4. Take all necessary steps to protect and maintain proper
inspection. load temperature.
CAUTION: Stop the unit if the compartment

Inspection Troubleshooting temperature remains higher than the desired
1. If a temperature reading is not within the desired temperature range from the setpoint on two
temperature range, refer to the troubleshooting table on the consecutive 30 minute inspections. Contact the
following pages. Correct problem as required. nearest Thermo King Service Center or your
company office immediately. Take all necessary steps
to protect and maintain proper load temperature.
86

Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
or has just if the temperature returns to the desired temperature range of the setpoint.
completed a defrost
cycle.
The evaporator is Initiate a manual defrost cycle. The defrost cycle will automatically terminate
plugged with frost. when complete. Continue monitoring the return air temperature until the
reading is within the desired temperature range of the setpoint.
87
Inspection Troubleshooting
Problem Cause Remedy
A return air The unit has not Refer to the load log history. Look for above temperature load records,
temperature had time to cool properly pre-cooled cargo compartment, length of time on road, etc. Correct
reading is not down to correct as required. Continue monitoring return air temperature until the reading is
within desired temperature. within the desired temperature range of the setpoint.
temperature The unit may have Check the receiver tank sight glass for refrigerant level. If liquid is not
range of the a low refrigerant showing in the receiver tank sight glass, the refrigerant charge may be low.
setpoint. charge. A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
or has just if the temperature returns to the desired temperature range of the setpoint.
completed a defrost
cycle.
The evaporator is Initiate a manual defrost cycle. The defrost cycle will automatically terminate
plugged with frost. when complete. Continue monitoring the return air temperature until the
reading is within the desired temperature range of the setpoint.
87

88
Problem Cause Remedy

Improper air Inspect the unit and cargo compartment to determine if the evaporator fan(s)
circulation in the are working and properly circulating the air. Poor air circulation may be due
cargo compartment. to improper loading of the cargo, shifting of the load, or fan belt slippage.
Correct as required. Continue monitoring return air temperature until
problem is corrected.
The unit did not Determine the cause for not starting. Correct as required. Continue
start automatically. monitoring the return air temperature until the reading is within the desired
temperature range of the setpoint.
88

battery acid that can burn you. Always wear make sure its ignition is also turned off.
goggles or safety glasses and personal protective
2. Open the front doors on the unit. The battery is located to
equipment when working with a battery. If you get
the right of the engine.
battery acid on you, immediately flush it with water
and get medical attention. 3. Check the discharged battery to make sure it is not
damaged or frozen. Do not jump start a damaged or frozen
CAUTION: Unhook the semi tractor from the battery. Check the vent caps to make sure they are tight.
trailer before using the tractor to jump start the 4. Identify the positive (+) and negative () battery terminals.
unit on the trailer. The negative ground circuit is
complete when the tractor is hooked to the trailer.
This can cause dangerous sparks when the positive
connection is made at the battery.
89
Jump Starting
If the battery in a unit is discharged or run down, the unit may IMPORTANT: Make sure to use a 12-volt battery to jump
be jump started using jumper cables and another battery or start the unit. If you are using a vehicle, make sure it has a
vehicle. Consider the following precautions and be careful 12-volt battery with a negative ground system. Do not use a
when jump starting a unit. hot shot booster device or a 24-volt source.
WARNING: A battery can be dangerous. A battery Read and understand the following procedure completely
contains a flammable gas that can ignite or before connecting any jumper cables. Use good jumper cables
explode. A battery stores enough electricity to burn made with #2 gauge (or larger) cables.
you if it discharges quickly. A battery contains 1. Make sure the unit is turned off. If you are using a vehicle,
battery acid that can burn you. Always wear make sure its ignition is also turned off.
goggles or safety glasses and personal protective
2. Open the front doors on the unit. The battery is located to
equipment when working with a battery. If you get
the right of the engine.
battery acid on you, immediately flush it with water
and get medical attention. 3. Check the discharged battery to make sure it is not
damaged or frozen. Do not jump start a damaged or frozen
CAUTION: Unhook the semi tractor from the battery. Check the vent caps to make sure they are tight.
trailer before using the tractor to jump start the 4. Identify the positive (+) and negative () battery terminals.
unit on the trailer. The negative ground circuit is
complete when the tractor is hooked to the trailer.
This can cause dangerous sparks when the positive
connection is made at the battery.
89

Unit
Engine
3
1. Positive (+) Terminal on Unit Battery

2. Positive (+) Terminal on Good Battery
1
3. Negative () Terminal on Good Battery
1. Red Cover on Positive (+) Battery Terminal 4. Starter Mounting Bolt on Unit Engine
Figure 31: Unit Battery Figure 32: Sequence for Connecting Jumper Cables
90
Jump Starting
CAUTION: Do not use a match or lighter as a 1

light near the battery. Use a flashlight. A flame or
a spark can ignite the gas in the battery and cause 2
Unit
it to explode. (Discharged)
12-Volt
5. Remove the red cover from the positive (+) battery Battery
terminal on the units battery.
Good
12-Volt
Battery
Unit
Engine
3

1
1. Red Cover on Positive (+) Battery Terminal 4. Starter Mounting Bolt on Unit Engine
Figure 31: Unit Battery Figure 32: Sequence for Connecting Jumper Cables
90

negative () battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.
9. Connect the black negative () jumper cable to the lower 1
starter mounting bolt on the units engine.
1. Lower Starter Mounting Bolt
Figure 33: Unit Engine
91
Jump Starting
6. Connect the red positive (+) jumper cable to the positive

(+) battery terminal on the units battery. Do not let the
other end of the jumper cable touch anything that conducts
electricity.
CAUTION: Allowing the positive (+) jumper cable

to short can produce dangerous sparks.
7. Connect the other end of the red positive (+) jumper cable
to the positive (+) battery terminal on the good battery.
8. Connect the black negative () jumper cable to the
negative () battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.
9. Connect the black negative () jumper cable to the lower 1
starter mounting bolt on the units engine.
1. Lower Starter Mounting Bolt
Figure 33: Unit Engine
91

alarm code and will not try to start until the battery Unit
voltage is above 10 volts. Engine
12. After the unit starts, remove the jumper cables in reverse 2
order: black negative () from the unit starter mounting 1
bolt, black negative () from the good battery, red positive
(+) from the good battery, and red positive (+) from the 1. Starter Mounting Bolt on Unit Engine
unit battery (that was discharged).
Figure 34: Sequence for Disconnecting Jumper Cables
92
Jump Starting
10. If you are using a vehicle to jump start the unit, start the
4
vehicle and let it run for a few minutes. This will help
charge the discharged battery. 3
Unit
CAUTION: Be careful around fans and belts. (Discharged)
Keep your hands away from moving parts when an 12-Volt
Battery
engine is running.
11. Turn the unit on and let it start automatically or start it Good
manually. If the unit will not crank or start, contact a 12-Volt
Battery
qualified technician.
NOTE: Some units with microprocessors will show an
alarm code and will not try to start until the battery Unit
voltage is above 10 volts. Engine
12. After the unit starts, remove the jumper cables in reverse 2
order: black negative () from the unit starter mounting 1
bolt, black negative () from the good battery, red positive
(+) from the good battery, and red positive (+) from the 1. Starter Mounting Bolt on Unit Engine
unit battery (that was discharged).
Figure 34: Sequence for Disconnecting Jumper Cables
92

Oil Type API Classification CI-4 or better
Oil Viscosity 5 to 122 F (-15 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 32 F (-30 to 0 C): SAE 5W-30
Engine Oil Pressure The microprocessor will display OK if the oil pressure is within an
acceptable range and LOW if the oil pressure is below this range.
Low Oil Pressure Switch (Normally Closed) 17 3 psi (117 21 kPa)
Engine rpm: Low Speed Operation 1450 + 25 rpm
High Speed Operation 2200 25 rpm
93
Specifications
Engine
Engine TK486V (Tier 2)
Fuel Type No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity: Crankcase 13 quarts (12.3 liters)
Fill to full mark on dipstick
Oil Type API Classification CI-4 or better
Oil Viscosity 5 to 122 F (-15 to 50 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 32 F (-30 to 0 C): SAE 5W-30
Engine Oil Pressure The microprocessor will display OK if the oil pressure is within an
acceptable range and LOW if the oil pressure is below this range.
Low Oil Pressure Switch (Normally Closed) 17 3 psi (117 21 kPa)
Engine rpm: Low Speed Operation 1450 + 25 rpm
High Speed Operation 2200 25 rpm
93

Saturn/General Motors Dex-Cool
Caterpillar ELC
Detroit Diesel POWERCOOL Plus
CAUTION: Do not add GREEN or BLUE-GREEN
conventional coolant to cooling systems using RED
Extended Life Coolant, except in an emergency. If conventional
coolant is added to Extended Life Coolant, the coolant must be
changed after 2 years instead of 5 years.
Coolant System Capacity 7.5 quarts (7.1 liters)
Radiator Cap Pressure 7 psi (48 kPa)
Drive Direct to compressor; belts to fans, alternator and water pump
94
Specifications
Engine (Continued)
Engine Thermostat 160 F (71 C)
Engine Coolant Type ELC (Extended Life Coolant), which is red.
Use a 50/50 concentration of any of the following equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool
Havoline XLC for Europe
Shell Dexcool
Shell Rotella
Saturn/General Motors Dex-Cool
Caterpillar ELC
Detroit Diesel POWERCOOL Plus
CAUTION: Do not add GREEN or BLUE-GREEN
conventional coolant to cooling systems using RED
Extended Life Coolant, except in an emergency. If conventional
coolant is added to Extended Life Coolant, the coolant must be
changed after 2 years instead of 5 years.
Coolant System Capacity 7.5 quarts (7.1 liters)
Radiator Cap Pressure 7 psi (48 kPa)
Drive Direct to compressor; belts to fans, alternator and water pump
94

Electrical Control System
Voltage 12.5 Vdc
Battery One, Group C31, 12 volt, (950 CCA recommended for operation
below -15 F [-26 C])
Battery Charging Alternator 12 V, 37 Amp (brush type)
Voltage Regulator Setting 13.8 to 14.2 Vdc at 77 F (25 C)
Fuses 2 to 40 Amp (see Fuses on page 33)
95
Specifications
Belt Tension
Belt Tension No. on TK Gauge 204-427
Alternator Belt 61
Lower Fan Belt (Engine to Idler) 67
Upper Fan Belt (Fan to Idler) 74
NOTE: These are the field reset settings. Because it is sometimes difficult to use the TK Gauge 204-427 in the
field, adjust each belt to allow 1/2 inch (13mm) deflection at the center of the longest span.
Electrical Control System

Voltage 12.5 Vdc
Battery One, Group C31, 12 volt, (950 CCA recommended for operation
below -15 F [-26 C])
Battery Charging Alternator 12 V, 37 Amp (brush type)
Voltage Regulator Setting 13.8 to 14.2 Vdc at 77 F (25 C)
Fuses 2 to 40 Amp (see Fuses on page 33)
95

96
Specifications
Refrigeration System
Compressor Thermo King X430L
Compressor Oil Charge 4.3 quarts (4.1 liters)
Compressor Oil Type Polyol Ester Type P/N 203-413
Refrigerant Charge - Type 13 lb (5.9 kg) - R404A
Heat/Defrost Method Hot gas
High Pressure Cutout Switch Opens 470 +7/-35 psi (3241 +48/-241 kPa)
Automatic Reset @ 375 38 psi (2586 262 kPa)
96

Engine
Check fuel supply and engine oil level.
Inspect belts for condition and proper tension (belt tension tool No. 204-427).
Check engine oil pressure hot, on high speed (should display OK).
Listen for unusual noises, vibrations, etc.
*3,000 hours or two years, whichever occurs first.
97
Maintenance Inspection Schedule

A closely followed maintenance program will help to keep For more details, refer to the appropriate maintenance manual
your Thermo King unit in top operating condition. The and to the Manual Pretrip Inspection in this manual.
following general schedule is provided to assist in monitoring
that maintenance.
Every Every Annual

Pretrip 1,500 3,000 4,500 Inspect/Service These Items
Hours Hours* Hours
Engine
Check fuel supply and engine oil level.
Inspect belts for condition and proper tension (belt tension tool No. 204-427).
Check engine oil pressure hot, on high speed (should display OK).
Listen for unusual noises, vibrations, etc.
97

Drain water from fuel tank and check vent.
Inspect/clean fuel transfer pump inlet strainer (pre-filter).
Check and adjust engine speeds (high and low speed).
Replace fuel filter/water separator.
Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better.
Check condition of engine mounts.
Check condition of drive coupling bushings per Service Bulletin T&T 171.
98
Every Every Annual

Hours Hours* Hours
Engine (Continued)
Check air cleaner restriction indicator (change when indicator reaches 25
in.). Replace EMI 3000 air cleaner element at 3,000 hours or two years
(whichever occurs first) if air cleaner restriction indicator has not reached 25
in. The EMI 3000 air cleaner element has a nameplate that reads EMI
3000.
Check engine coolant level and antifreeze protection (-30 F [-34 C]).
Drain water from fuel tank and check vent.
Inspect/clean fuel transfer pump inlet strainer (pre-filter).
Check and adjust engine speeds (high and low speed).
Replace fuel filter/water separator.
Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better.
Check condition of engine mounts.
Check condition of drive coupling bushings per Service Bulletin T&T 171.
98

Inspect battery terminals and electrolyte level.
Inspect wire harness for damaged wires or connections.
Inspect alternator wire connections for tightness.
Microprocessor
Run Unit Self Check Test (see Starting the Unit with a Unit Self Check Test
on page 50).
99
Every Every Annual

Hours Hours* Hours
Engine (Continued)
Change ELC (red) engine coolant every 5 years or 12,000 hours.
Test fuel injection nozzles at least every 10,000 hours.
Replace fuel return lines between fuel injection nozzles every 10,000 hours.
Electrical
Check damper door operation
(closes on defrost initiation, opens on defrost termination).
Inspect battery terminals and electrolyte level.
Inspect wire harness for damaged wires or connections.
Inspect alternator wire connections for tightness.
Microprocessor
Run Unit Self Check Test (see Starting the Unit with a Unit Self Check Test
on page 50).
99

Visually inspect unit for fluid leaks.
Visually inspect unit for damaged, loose or broken parts (includes air ducts).
Inspect tapered roller bearing fanshaft and idler for leakage and bearing
wear.
Clean entire unit including condenser and evaporator coils and defrost
drains.
Check all unit, fuel tank and electric motor mounting bolts, brackets, lines,
hoses, etc.
Check evaporator damper door adjustment and operation.
100
Every Every Annual

Hours Hours* Hours
Refrigeration
Check refrigerant level.
Check compressor oil level.
Check compressor efficiency and pump down refrigeration system.
Replace dehydrator and check discharge and suction pressure every 2 years.
Structural
Visually inspect unit for fluid leaks.
Visually inspect unit for damaged, loose or broken parts (includes air ducts).
Inspect tapered roller bearing fanshaft and idler for leakage and bearing
wear.
Clean entire unit including condenser and evaporator coils and defrost
drains.
Check all unit, fuel tank and electric motor mounting bolts, brackets, lines,
hoses, etc.
Check evaporator damper door adjustment and operation.
100

101
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50046 for the Thermo King
Trailer Unit Warranty.
See the EPA Emission Control System Warranty Statement
chapter earlier in this manual for the EPA Emission Control
System Warranty.
101

102
Warranty
102

unit restricts air flow and system efficiency.) 2) bulkhead
ambient air temperature: Temperature of the air
divider. A thick, insulated wall used to separate
surrounding an object.
compartments of a multi-temperature truck or trailer.
amp: Abbreviation for ampere. The basic measuring unit of
calorie: The amount of heat required to raise temperature of
electrical current.
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Celsius: The metric unit of temperature measurement. The
Battery Sentry: Part of the CYCLE-SENTRY system. The preferred alternate to the term centigrade. Abbreviated C.
Battery Sentry module monitors alternator charge rate and will
centigrade. See Celsius.
keep the unit running until the battery is adequately charged.
001 103
Glossary
This glossary is published for informational purposes only and box temperature: The temperature within a
the information being furnished herein should not be temperature-controlled compartment.
considered as all-inclusive or meant to cover all contingencies.
Btu (british thermal unit): The quantity of heat required to
NOTE: Additional terms not found in the glossary may be raise the temperature of one pound of water by one degree
located in the index section of this manual. Fahrenheit. 1 Btu = 252 calories.
accumulator: A device located in the suction line to collect bulkhead: 1) return air bulkhead. A metal or plastic wall
liquid refrigerant and meter it safety back to the compressor as placed at the front of the box to prevent loading of product
gas. tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
ambient air temperature: Temperature of the air
divider. A thick, insulated wall used to separate
surrounding an object.
compartments of a multi-temperature truck or trailer.
amp: Abbreviation for ampere. The basic measuring unit of
calorie: The amount of heat required to raise temperature of
electrical current.
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Celsius: The metric unit of temperature measurement. The
Battery Sentry: Part of the CYCLE-SENTRY system. The preferred alternate to the term centigrade. Abbreviated C.
Battery Sentry module monitors alternator charge rate and will
centigrade. See Celsius.
keep the unit running until the battery is adequately charged.
001 103

formed into a helical or serpentine shape, that may be equipped DE: Dual Evaporator. A multi-temp host unit with two
with thin metal fins to aid heat transfer. evaporators capable of refrigerating two separate, longitudinal
compartments.
cold curtains: Flexible vinyl curtains used to reduce air
exchange between the refrigerated compartment and the defrost: The removal of accumulated ice from an evaporator
outside during door openings. coil. Periodic defrost is necessary when the evaporator coil is
operating below freezing. Defrost is required more frequently
compound gauge: A gauge calibrated in psig (or kPa) to
when the air passing through the evaporator has a high
measure pressure, and in inches of mercury (Kg/cm2) to
moisture content.
measure vacuum.
defrost termination switch: A component that terminates
compressor: The refrigeration component that compresses
defrost operation at a specific temperature.
refrigerant vapor and creates refrigerant flow.
104
Glossary
CFC: Chlorofluorocarbon. A chlorine-based refrigerant condenser: An arrangement of tubing in which the

consisting of chlorine, fluorine and carbon. Example: R12. In vaporized and compressed refrigerant is liquefied as heat is
many countries it is illegal to release this type of refrigerant to removed.
the atmosphere because chlorine damages the earths
cycles per second: See Hertz.
atmosphere. CFC refrigerants are not used in modern Thermo
King units. damper door: A door on the evaporator section that closes
during defrost to prevent hot air from entering the refrigerated
circuit breaker: A thermal device that automatically
cargo compartment.
interrupts an electrical circuit when the current in the circuit
exceeds the predetermined amperage rating of the breaker. See data logger: An electronic device that monitors and stores
amp. unit operating and temperature data for later review. Examples:
DMS, DAS, DRS and AccuTrac.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped DE: Dual Evaporator. A multi-temp host unit with two
with thin metal fins to aid heat transfer. evaporators capable of refrigerating two separate, longitudinal
compartments.
cold curtains: Flexible vinyl curtains used to reduce air
exchange between the refrigerated compartment and the defrost: The removal of accumulated ice from an evaporator
outside during door openings. coil. Periodic defrost is necessary when the evaporator coil is
operating below freezing. Defrost is required more frequently
compound gauge: A gauge calibrated in psig (or kPa) to
when the air passing through the evaporator has a high
measure pressure, and in inches of mercury (Kg/cm2) to
moisture content.
measure vacuum.
defrost termination switch: A component that terminates
compressor: The refrigeration component that compresses
defrost operation at a specific temperature.
refrigerant vapor and creates refrigerant flow.
104

frozen shut or open, causing improper unit operation in either
ERC: Extended Remote Unit Control. (Door switches) An
case. 2) The formation of a solid ice mass over the evaporator
option on Thermo King multi-temperature units to improve
coil reducing air flow.
temperature control when doors are opened during delivery.
When a compartment door is opened, the refrigeration unit for fuse: An electrical safety device (typically a cartridge)
that compartment may be forced to NULL, defrost, or some inserted into an electrical circuit. It contains material that will
other mode. Opening a compartment door may also affect the melt or break when the current is increased beyond a specific
operating mode of other compartments. ERC systems are value. When this occurs, the circuit is opened and electrical
connected in a variety of ways to meet customer needs. current flow is stopped.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
105
Glossary
defrost timer: A solid state module that initiates defrost at evaporator: The part of the refrigeration system that absorbs
selected intervals. Also establishes a maximum defrost heat during the cooling cycle.
duration if normal circuits malfunction.
EW: A wall-mounted Thermo King remote evaporator. See
dehydrator: A device used to remove moisture from ECT and TLE.
refrigerant. Also called a drier.
F: See Fahrenheit.
discharge air temperature: The temperature of air leaving
Fahrenheit: A unit of temperature measurement used in the
the evaporator.
United States. Abbreviated F.
drier: See dehydrator.
freeze up: 1) Failure of a refrigeration system to operate
ECT: A ceiling-mounted Thermo King remote evaporator. See normally due to moisture in the refrigerant and the formation
EW and TLE. of ice at the expansion valve. The expansion valve may be
frozen shut or open, causing improper unit operation in either
ERC: Extended Remote Unit Control. (Door switches) An
case. 2) The formation of a solid ice mass over the evaporator
option on Thermo King multi-temperature units to improve
coil reducing air flow.
temperature control when doors are opened during delivery.
When a compartment door is opened, the refrigeration unit for fuse: An electrical safety device (typically a cartridge)
that compartment may be forced to NULL, defrost, or some inserted into an electrical circuit. It contains material that will
other mode. Opening a compartment door may also affect the melt or break when the current is increased beyond a specific
operating mode of other compartments. ERC systems are value. When this occurs, the circuit is opened and electrical
connected in a variety of ways to meet customer needs. current flow is stopped.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
105

Hertz: A unit of frequency equal to one cycle per second. load: 1) The product being refrigerated and transported.
Abbreviated Hz. 2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
HFC: A refrigerant consisting of hydrogen, fluorine and
when expected to cool a very warm box.)
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered safe for the LPCO (Low Pressure Cut Out Switch): A
environment. pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the modulation: An optional system that reduces load (product)
system if pressure exceeds a predetermined value. dehydration and avoids top freeze.
106
Glossary
fusible link: An electrical safety device (typically a short hp (horsepower): A unit of power equivalent to 746 watts
piece of wire) inserted into an electrical circuit. The wire melts or 550 foot-pounds per second.
or breaks when the current is increased beyond a specific
HPCO (High Pressure Cut Out Switch): A
value. When this occurs, the circuit is opened and electrical
pressure-operated switch that opens to stop unit operation
current flow is stopped.
when discharge pressure reaches a predetermined maximum.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
invertible: A multi-temperature truck or trailer unit designed
refrigerant containing hydrogen, chlorine, fluorine and carbon.
to allow the placement of deep-frozen cargo in any
Example: R22. Because chlorine damages the earths
compartment. See Multi-Temp.
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
used in modern Thermo King units. 0.145 psi.
Hertz: A unit of frequency equal to one cycle per second. load: 1) The product being refrigerated and transported.
Abbreviated Hz. 2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
HFC: A refrigerant consisting of hydrogen, fluorine and
when expected to cool a very warm box.)
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered safe for the LPCO (Low Pressure Cut Out Switch): A
environment. pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the modulation: An optional system that reduces load (product)
system if pressure exceeds a predetermined value. dehydration and avoids top freeze.
106

(opposition to the current flow) in an electrical circuit. refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
pre-cooling: 1) To cool down an empty box
(temperature-controlled area) to the desired load temperature remote evaporator: A separate evaporator unit located in a
prior to loading. 2) To cool cargo to a desired temperature second or third compartment of a multi-temperature truck or
before loading. trailer unit.
pre-heat: The heating of diesel engine glow plugs prior to return air bulkhead: A structure (metal or plastic) mounted
start-up. Some engines use an intake manifold heater rather in the front of a trailer and designed to prevent restriction of
than glow plugs. return air flow to the Thermo King unit due to improper
loading. See bulkhead.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
107
Glossary
movable bulkhead: A thick, insulated, portable wall-like psi: Pounds per square inch. A unit of pressure.
device used to compartmentalize a temperature-controlled 1 psi = 0.069 bar = 6.89 kPa.
truck or trailer. See bulkhead.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
Multi-Temp: A Thermo King truck or trailer unit capable of square inch as displayed by a gauge calibrated to zero when
maintaining different set-points in multiple compartments. open to the atmosphere.
no. 1 diesel fuel: A grade of diesel fuel formulated to receiver tank: A refrigerant storage device included in
prevent jelling in low ambient temperatures. nearly all Thermo King units.
no. 2 diesel fuel: A grade of diesel fuel formulated for refrigerant: The medium of heat transfer in a refrigeration
moderate to warm ambient temperatures. system which absorbs heat by evaporating at a low temperature
and releases heat by condensing at a higher temperature.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit. refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
pre-cooling: 1) To cool down an empty box
(temperature-controlled area) to the desired load temperature remote evaporator: A separate evaporator unit located in a
prior to loading. 2) To cool cargo to a desired temperature second or third compartment of a multi-temperature truck or
before loading. trailer unit.
pre-heat: The heating of diesel engine glow plugs prior to return air bulkhead: A structure (metal or plastic) mounted
start-up. Some engines use an intake manifold heater rather in the front of a trailer and designed to prevent restriction of
than glow plugs. return air flow to the Thermo King unit due to improper
loading. See bulkhead.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
107

thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
TLE: Thin-line evaporator. A Thermo King remote evaporator
designed to be compact (thin) while supplying superior air
flow. See ECT and EW.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
108
Glossary
return air temperature: The temperature of the air Vac (volts alternating current): An electric current that
returning to the evaporator. See box temperature. reverses direction at regularly recurring intervals.
rpm: Revolutions per minute. Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box volts: The basic measuring unit of electrical potential.
temperature.
watt: The basic measuring unit of electrical power.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
TLE: Thin-line evaporator. A Thermo King remote evaporator
designed to be compact (thin) while supplying superior air
flow. See ECT and EW.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
108

repair 63 CYCLE-SENTRY
types 64 start-stop controls 27
alarm icon 38 CYCLE-SENTRY icon 38
amber status light 43 CYCLE-SENTRY mode 55
automatic start/stop safety precautions 12
D
B damper inspection 46
battery inspection 46 DAS (Data Acquisition System) 28
belt tension 95 defrost 27
belts inspection 46 control 25
defrost drain inspection 46
defrost icon 38
109
Index
A C
air cleaner restriction indicator 31 changing setpoint 53
alarm 25 coils inspection 46
alarm codes compressor 24
Code 84 (restart null) 65 compressor oil sight glass 31
Code 85 (forced unit operation) 65 continuous mode 55
corrective action 64 control panel 48
displaying and clearing 61 cool icon 38
repair 63 CYCLE-SENTRY
types 64 start-stop controls 27
alarm icon 38 CYCLE-SENTRY icon 38
amber status light 43 CYCLE-SENTRY mode 55
automatic start/stop safety precautions 12
D
B damper inspection 46
battery inspection 46 DAS (Data Acquisition System) 28
belt tension 95 defrost 27
belts inspection 46 control 25
defrost drain inspection 46
defrost icon 38
109

closing 30
E opening 29
ELC (extended life coolant) 23 fuel level 45
electric standby icon 38 fuse link 32
electrical control system specifications 95 fuses 33
electrical hazards 12
electrical inspection 46 G
Emergency Cold Line 117 green status light 43
EMI 3000 24
engine compartment components 31 H
engine coolant level 45 heat icon 38
engine oil dipstick 31 high pressure cutout switch 32
110
Index
display 36 engine oil level 45

alarm icon 38 engine specifications 93
cool icon 38 enroute inspections 86
CYCLE-SENTRY 38 enter key 41
defrost icon 38 extended life coolant (ELC) 23
electric standby 38
heat icon 38 F
icons 38 first aid for refrigerant 13
setpoint 38 first aid for refrigerant oil 13
displaying operating data during normal operation 52 flashing amber status light 43
door inspection 46 forced unit operation alarm code 65
down key 41 front doors
closing 30
E opening 29
ELC (extended life coolant) 23 fuel level 45
electric standby icon 38 fuse link 32
electrical control system specifications 95 fuses 33
electrical hazards 12
electrical inspection 46 G
Emergency Cold Line 117 green status light 43
EMI 3000 24
engine compartment components 31 H
engine coolant level 45 heat icon 38
engine oil dipstick 31 high pressure cutout switch 32
110

enter 41 P
select 40 post-loading inspection 85
TK logo 41 preheat buzzer 32
up key 41 pre-loading inspection 83
pretrip inspection, manual 45
L printing a trip report 58
loading procedures protection devices 32
enroute inspections 86
post-loading inspection 85 R
pre-loading inspection 83 receiver tank sight glass 32
low oil level switch 32 refrigerant oil safety 13
low oil pressure switch 32 refrigerant safety 12
111
Index
high pressure relief valve 32 M

maintenance inspection schedule 97
I manual defrost cycle, initiating 56
icons 38 manual pretrip inspection 45
introduction 9 microprocessor controller TG-VI 25
J O
jump starting 89 oil type
compressor 96
K engine 93
keypad 40 On/Off switch 48
down key 41
enter 41 P
select 40 post-loading inspection 85
TK logo 41 preheat buzzer 32
up key 41 pre-loading inspection 83
pretrip inspection, manual 45
L printing a trip report 58
loading procedures protection devices 32
enroute inspections 86
post-loading inspection 85 R
pre-loading inspection 83 receiver tank sight glass 32
low oil level switch 32 refrigerant oil safety 13
low oil pressure switch 32 refrigerant safety 12
111

refrigerant 12
refrigerant oil 13 U
select key 40 unit description 21
selecting CYCLE-SENTRY or continuous mode 55 unit self check test 50
selection of operating modes 54 up key 41
serial number locations 113
setpoint icon 38 W
setpoint, changing 53 warranty 101
software revision, checking 57
specifications 93
standard display 39
starting diesel engine 49
112
Index
refrigeration system specifications 96 starting unit with unit self check test 50
remote status light 43 status light, remote 43
restart null alarm code 65 structural inspection 46
switch panel and controls 25
S
safety precautions 11 T
automatic start/stop operation 12 TG-VI
decal locations 14 controller 25, 35
electrical hazards 12 thermometer 25
first aid for refrigerant 13 thermostat 25
first aid for refrigerant oil 13 TK logo key 41
general safety practices 11 trip report, printing 58
refrigerant 12
refrigerant oil 13 U
select key 40 unit description 21
selecting CYCLE-SENTRY or continuous mode 55 unit self check test 50
selection of operating modes 54 up key 41
serial number locations 113
setpoint icon 38 W
setpoint, changing 53 warranty 101
software revision, checking 57
specifications 93
standard display 39
starting diesel engine 49
112

Figure 35: Compressor Serial Number Location
113
Serial Number Locations

Compressor: Stamped between the cylinders on the front
end above the oil pump.
Engine: See the engine identification plate located on the
engine valve cover.
Unit: Nameplates on the bulkhead above the compressor
inside the curbside door and on the roadside of the evaporator.
Figure 35: Compressor Serial Number Location
113

Figure 36: Engine Serial Number Location Figure 37: Unit Serial Number Plate Locations
(on the bulkhead above compressor inside
curbside door and on roadside of evaporator)
114
Figure 36: Engine Serial Number Location Figure 37: Unit Serial Number Plate Locations
(on the bulkhead above compressor inside
curbside door and on roadside of evaporator)
114

Figure 38: Unit Serial Number Plate
115
Figure 38: Unit Serial Number Plate
115

116
116

AKB12
If you cant get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
117
Emergency Cold Line

The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AKB12
If you cant get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
117

the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local THERMO KING dealer.
118
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits

the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local THERMO KING dealer.
118

the State of California to cause cancer.
001 119
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
001 119

Ingersoll Rands Climate Solutions sector delivers energy-efcient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efcient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
2011 Ingersoll-Rand Company

Printed in U.S.A.

Sb200tg Thermo King

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Operators Manual

Copyright 2007 Thermo King Corp., Minneapolis, MN, USA

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TG-VI Microprocessor Controller . . . . . . . . . . . . . . . . . 25 Unit Operation with TG-VI Controller . . . . . . . . . . . 47

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Loading and Enroute Inspections . . . . . . . . . . . . . . 83 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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CAUTION: Use extreme caution when drilling holes Electrical Hazard

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WARNING: Fluorocarbon refrigerants evaporate First Aid

WARNING: Protect skin and clothing from First AidRefrigerant Oil

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Figure 2: Belt Replacement Caution

Figure 1: Belt Warning

Figure 2: Belt Replacement Caution

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Figure 3: Automatic Start Caution

Figure 3: Automatic Start Caution

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Figure 5: Door Latch Warning

Figure 5: Door Latch Warning

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EPA Emission Control System Warranty

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Fuel Injection System New, remanufactured, or repaired parts or components

EPA Emission Control System Warranty Statement

As a condition of reimbursement, replaced parts and received

Fuel Injection System New, remanufactured, or repaired parts or components

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EPA Emission Control System Warranty Statement

Owner Responsibilities Attachments, accessory items, or parts not authorized for

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EPA Emission Control System Warranty Statement

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Figure 6: Front View

Figure 6: Front View

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Design Features Key Features & Options SB-200TG

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Figure 7: TK486V (Tier 2)

Diesel Engine ELC (Extended Life Coolant)

CAUTION: Do not add GREEN or

Figure 7: TK486V (Tier 2)

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EMI 3000 Thermo King X430L Compressor

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TG-VI Microprocessor Controller

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In CYCLE-SENTRY Operation Mode:

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CYCLE-SENTRY Start-Stop Controls Defrost

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Opening the Front Doors Opening the Secondary Door Latch

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Closing the Front Doors