TS-200, 300 500 NAD

TS-200, 300, 500 Series
TK 50773-1-OP (Rev. 5, 08/03)
Copyright© 1999 Thermo King Corp., Minneapolis, MN, USA

Printed in USA
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.
Table of Contents
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
California Emission Control System Warranty
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Your Warranty Rights And Obligations . . . . . . . . .21
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Manufacturer’s Warranty Coverage . . . . . . . . . . .22
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 11 Owner’s Warranty Responsibilities . . . . . . . . . . . .22
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Manufacturer Explanation Of Emission Control System
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 EPA Emission Control System Warranty Statement . .25
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . .26
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 13 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 13
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 14
Model 50 Units (Electric Standby) . . . . . . . . . . . . 16
3
Table of Contents
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 µP-T System Description . . . . . . . . . . . . . . . . . . . . . 47

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Microprocessor Power Switch . . . . . . . . . . . . . . . . . . 47
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 48
Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Keypad Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Understanding the Display . . . . . . . . . . . . . . . . . . 49
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . 31 Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
EMI 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Reading a Typical Display . . . . . . . . . . . . . . . . . . 50
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 The Standard Display . . . . . . . . . . . . . . . . . . . . . 50
Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ThermoGuard µP-T Controller . . . . . . . . . . . . . . . . . . . 33 Remote Indicator Lights . . . . . . . . . . . . . . . . . . . . . 51
CYCLE-SENTRY Start/Stop System . . . . . . . . . . . . . . 33
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Manual Pre-Trip Inspection
DAS - Data Acquisition System (Optional) . . . . . . . . . 34 (Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 53
Electric Standby (Model 50 Units Only) . . . . . . . . . . . . 35
Standard Model 50 Features . . . . . . . . . . . . . . . . 35
Optional Model 50 Features . . . . . . . . . . . . . . . . . 35
Engine Compartment Components . . . . . . . . . . . . . . . 36
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . 37
4
Table of Contents
Unit Operation with THERMOGUARD µP-T . . . . . . 55 Starting Unit with Full Unit Self Check . . . . . . . . . . . . .62
Operation in Confined Spaces . . . . . . . . . . . . . . . 55 After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . .63
Displaying Operating Data . . . . . . . . . . . . . . . . . . . . . 56 Restarting the Unit–Automatic Start . . . . . . . . . . . . . . .64
Entering the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . 56 Checking the Software Revision . . . . . . . . . . . . . . . . .65
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Viewing Prompt and Display Screens . . . . . . . . . . . . .66
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . 57 Locking a Display Screen on the Display . . . . . . . . . . .67
Selecting CYCLE-SENTRY or Continuous Mode . . . . 58 Viewing and Clearing Alarm Codes . . . . . . . . . . . . . . .67
Selection of Operating Modes on CYCLE-SENTRY To View Alarm Codes . . . . . . . . . . . . . . . . . . . . . .68
Equipped Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 To Clear Alarm Codes . . . . . . . . . . . . . . . . . . . . . .68
Products Requiring Continuous Run Operation for Air
Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Products Acceptable for CYCLE-SENTRY Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
µP-T Unit Self Check Test . . . . . . . . . . . . . . . . . . . . . 60 Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Starting the Unit Self Check . . . . . . . . . . . . . . . . . 60 Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Unit Self Check Report . . . . . . . . . . . . . . . . . . . . . 61 Alarm Code 84 (Restart Null) . . . . . . . . . . . . . . . . . . . .71
Alarm Code 85 (Forced Unit Operation) . . . . . . . . . . .71
Table of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . .72
5
Table of Contents
Electric Standby Operation . . . . . . . . . . . . . . . . . . . 87 Maintenance Inspection Schedule . . . . . . . . . . . . 109

Electric Power Receptacle . . . . . . . . . . . . . . . . . . . . . . 87
Starting the Unit on Electric Standby Operation . . . . . 88 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Unit Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Loading and Enroute Inspections . . . . . . . . . . . . . . 91
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . . 91 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Inspecting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Serial Number and Refrigerant Label Locations . 129
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 131

Engine Specifications for TS-200 and TS-300 . . . . . . 97
Engine Specifications for TS-500 . . . . . . . . . . . . . . . 100 Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 133
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
µP-T Controller - Factory Settings . . . . . . . . . . . . . . . 103 California Proposition 65 Warning . . . . . . . . . . . . 134
Electrical Control System . . . . . . . . . . . . . . . . . . . . . 104
Electric Standby (Model 50) . . . . . . . . . . . . . . . . . . . 105
TS-200 Electric Motor . . . . . . . . . . . . . . . . . . . . . 105
Electric Standby Power Requirements . . . . . . . . . . . 106
R-404A Refrigeration System . . . . . . . . . . . . . . . . . . 107
6
List of Figures
Figure 1:Antifreeze Caution . . . . . . . . . . . . . . . . . . . . . 14 Figure 21:Typical Display . . . . . . . . . . . . . . . . . . . . . . .50
Figure 2:ELC (Extended Life Coolant) Nameplate . . . 14 Figure 22:Standard Display . . . . . . . . . . . . . . . . . . . . .50
Figure 3:Belt Caution . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 23:Remote Indicator Light Display . . . . . . . . . .51
Figure 4:Automatic Start Caution . . . . . . . . . . . . . . . . 15 Figure 24:Entering the Setpoint . . . . . . . . . . . . . . . . . .56
Figure 5:Fan Caution . . . . . . . . . . . . . . . . . . . . . . . . . 16 Figure 25:Starting the Engine . . . . . . . . . . . . . . . . . . .57
Figure 6:Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . 16 Figure 26:Initiating a Manual Defrost . . . . . . . . . . . . . .57
Figure 7:High Voltage Caution. . . . . . . . . . . . . . . . . . . 16 Figure 27:Selecting Cycle-Sentry or
Figure 8:Emission Control Label . . . . . . . . . . . . . . . . . 18 Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Figure 9:Engine Family Name . . . . . . . . . . . . . . . . . . 18 Figure 28:Starting the Unit Self Check . . . . . . . . . . . . .60
Figure 10:Emission Control Label Location . . . . . . . . 19 Figure 29:Checking the Software Revision . . . . . . . . .65
Figure 11:Exhaust Control System Example List . . . . 20 Figure 30:Viewing Prompt and Display Screens . . . . .66
Figure 12:Front View . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Figure 31:Viewing and Clearing Alarm Codes . . . . . . .67
Figure 13:Engine Components TS-200 and TS-300 . . 40 Figure 32:Model 50 Power Receptacle Box . . . . . . . . .87
Figure 14:Engine Components TS-500 . . . . . . . . . . . 42 Figure 33:Loading Considerations . . . . . . . . . . . . . . . .92
Figure 15:Control Box . . . . . . . . . . . . . . . . . . . . . . . . . 44 Figure 34:Engine Serial Number Location . . . . . . . . .129
Figure 16:Remote Control Panel . . . . . . . . . . . . . . . . 45 Figure 35:Compressor Serial Number Location . . . . .129
Figure 17:North American Power Receptacle Box . . . 46 Figure 36:Label Locations . . . . . . . . . . . . . . . . . . . . .130
Figure 18:Microprocessor Power Switch . . . . . . . . . . . 47 Figure 37:Laminated Unit Serial Number Plate . . . . .130
Figure 19:Remote Control Panel . . . . . . . . . . . . . . . . 48 Figure 38:Refrigerant Type Label . . . . . . . . . . . . . . .130
Figure 20:Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7
List of Figures
8
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.
001 9
Introduction
10
Safety Precautions
Thermo King recommends that all services be performed by a
WARNING: Exposed coil fins can cause painful
Thermo King dealer. However, there are several general safety
lacerations. Service work on the evaporator or
practices which you should be aware of:
condenser coils is best left to a certified Thermo King
DANGER: Never operate the unit with the technician.
compressor discharge valve closed because it could
cause the compressor to explode, causing death or CAUTION: Use extreme caution when drilling holes
serious injury. in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Never drill into
WARNING: Always wear goggles or safety glasses structural components.
when working with or around the refrigeration
system or battery. Refrigerant or battery acid can
cause permanent damage if it comes in contact with
Automatic Start/Stop Operation
your eyes. This unit is capable of automatic operation and may start at any
time without prior warning.
WARNING: Keep hands and loose clothing clear of
WARNING: The unit may start at any time when the
fans and belts at all times when the unit is operating
controller is turned on. The controller display lights
or when opening or closing compressor service
up when the controller is turned on.
valves.
11
Safety Precautions
WARNING: Units equipped with electric standby may DANGER: Fluorocarbon refrigerants may produce
start at any time when the unit is connected to live toxic gases. In the presence of an open flame or
electric power and the controller is turned on. electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
WARNING: Be sure to press the OFF key to turn the
controller off before opening doors or inspecting any DANGER: Fluorocarbon refrigerants tend to
part of the unit. displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
Electrical Hazard
WARNING: Fluorocarbon refrigerants evaporate
CAUTION: Be sure to turn off the high voltage
rapidly, freezing anything they contact if accidentally
power supply, and disconnect the electric cable before
released into the atmosphere from the liquid state.
working on the unit. Units with electric standby
present a potential electrical hazard.
Refrigerant Oil
Refrigerant Observe the following precautions when working with or
around refrigerant oil:
Although fluorocarbon refrigerants are classified as safe,
observe caution when working with refrigerants or around WARNING: Always wear goggles or safety glasses to
areas where they are being used in the servicing of your unit. protect eyes from refrigerant oil contact.
12
Safety Precautions
WARNING: Protect skin and clothing from First Aid–Refrigerant Oil

prolonged or repeated contact with refrigerant oil. Eyes: Immediately flush eyes with large amounts of water for
Rubber gloves are recommended. at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
WARNING: Wash thoroughly immediately after
Skin: Remove contaminated clothing. Wash thoroughly with
handling refrigerant oil to prevent irritation.
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
First Aid necessary. Stay with victim until arrival of emergency
personnel.
First Aid–Refrigerant Ingestion: Do not induce vomiting. Immediately contact

local poison control center or physician.
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until arrival of emergency medical
personnel.
13
Safety Precautions
Safety Decals and Locations
Figure 1: Antifreeze Caution ARB108

(Attached near radiator fill cap.)
Figure 2: ELC (Extended Life Coolant) Nameplate
(Located On Expansion Tank In Units Equipped With
ELC)
14
Safety Precautions
AKA99
AKA98
Figure 4: Automatic Start Caution (Locations vary
Figure 3: Belt Caution (Locations vary depending on depending on model. Decals are located near areas
model. Decals are located near areas that contain that contain moving parts which can cause severe
belts and fans which can cause severe injuries if injuries if hands or clothing become tangled when the
hands or clothing become tangled.) unit automatically starts.)
15
Safety Precautions
Model 50 Units (Electric Standby)

CAUTION FAN
ATTENTION VENTILATEUR
91-4815
ACHTUNG VENTILATOR
ATTENZIONE VENTILATORE
CUIDADO VENTILADOR
AKB01
ARA183
Figure 6: Electrical Hazard (Locations vary
depending on model. Typically located near power
Figure 5: Fan Caution (Locations vary depending on receptacle, high voltage tray cover and interface
model. Decals are located near areas that contain board.)
fans which can cause severe injuries if hands or
clothing become tangled.)
AKB02
Figure 7: High Voltage Caution

(Located near high voltage box.)
16
Emission Control
In compliance with the California ULG (Utility, Lawn and 2-4. Fuel Oil System: Fuel oil system must remain intact
Garden) Rules, the following information is provided: and receive regular prescribed maintenance. Example: Fuel
filter replacement at required operation hour interval.
1. Selection Of Fuel Oil: Use diesel fuel only.
3. Engine Identification: With the forthcoming engine
2-1. Modification To Any Engine Component:
emission regulation worldwide, engines must be identified in a
Modifications to any engine component which many cause manner that will determine when they were built and what
engine exhaust emission output changes are not allowed. regulations they comply with. The engine must be labeled with
Any engine modification not in compliance with regulation an emission control label and the engine family name, both
will be the responsibility of the engine manufacturer, dealer or described below.
customer who made the modification.
2-2. Air Induction System: Air induction system must
remain intact and receive regular prescribed maintenance.
Example: Air cleaner element replacement at required
operation hour interval.
2-3. Exhaust System: Exhaust system must remain intact
and cannot be modified in any manner that will further restrict
exhaust flow.
17
Emission Control
a. Emission control label: a new label, shown in b. Engine Family Name, as assigned by the California
Figure 8, contains important engine information. Air Resources Board, identifies engine family group,
by largest displacement, within an engine family, and
is shown in Figure 9.
AMA04
AMA06
Figure 8: Emission Control Label Figure 9: Engine Family Name
18
Emission Control
3-1 Emission Control Labels: Emission control labels are All engine labels and supplementary labels will contain the
a requirement of the California ULG Rules. In the event the following information:
emission control label provided on the engine is inaccessible,
• Engine Family Name
there will be a supplemental label containing the same
information, provided by the equipment manufacturer, located • Displacement
in a readily accessible location, shown in Figure 10: • Manufacturer
The above information, along with the engine serial number,
will be required to obtain proper service information and
correct service repair parts. An example list which identifies
the exhaust control system is shown in Figure 11.
AMA05
Figure 10: Emission Control Label Location
19
Emission Control
AMA07
Figure 11: Exhaust Control System Example List
20
Emission Control
4. Emission Control Related Parts: The California ULG 5. Maintenance Schedule: To maintain optimum engine
Rules require a manufacturing defect warranty on all emission performance and compliance with the California ULG Rules,
control parts, including: the maintenance schedule must be adhered to.
• Fuel Injection Pump Regular scheduled maintenance is the major key to engine
• Fuel Injection Nozzle service life and emission regulation compliance. Scheduled
maintenance requirements must be performed regularly. See
• High Pressure Oil Line the Maintenance Schedule provided in this Operator’s Manual.
• Air Cleaner Element1
• Fuel Filter Element1 California Emission Control
• Air Cleaner Gasket
System Warranty Statement
• Air Intake Pipe (Manifold) Gasket
Your Warranty Rights And
• Muffler Gasket Obligations
The warranty period is two years and complete details are The California Air Resources Board and Thermo King are
included in the section of this manual titled “California pleased to explain the California emission control system
Emission Control System Warranty Statement, Your Warranty warranty on your 1996 and later utility equipment (ULG)
Rights And Obligations.” engine. In California, new utility equipment (ULG) engines
1 must be designed, built, and equipped to meet the state’s
Any warranted part which is scheduled for replacement as
stringent anti-smog standards. Thermo King must warrant the
required maintenance shall be warranted for the period of time
California emission control system on your utility equipment
up to the first scheduled replacement point for that part.
21
Emission Control
(ULG) engine for the time listed below, provided there has Owner’s Warranty Responsibilities
been no abuse, neglect or improper maintenance of your utility
As the utility equipment (ULG) engine owner, you are
equipment (ULG) engine.
responsible for the performance of the required maintenance
Your California emission control system includes parts such as listed in this Operator’s Manual. Thermo King recommends
the fuel injection pump, the fuel injection nozzle, and the that you retain all receipts covering maintenance on your utility
high-pressure fuel line. Also included are the air filter element equipment (ULG) engine, but Thermo King cannot deny
and the fuel filter element which are covered under this warranty solely for the lack of receipts or your failure to ensure
California emission control system warranty only up to the first the performance of all scheduled maintenance.
scheduled maintenance replacement.
As the utility equipment (ULG) engine owner, you should be
Where a warrantable condition exists, Thermo King will repair aware that Thermo King may deny you warranty coverage if
your utility equipment (ULG) engine with California emission your utility equipment (ULG) engine, or a part or component,
control system parts or components at no cost to you, including has failed due to abuse, neglect, improper maintenance, or
diagnosis, parts and labor. unapproved modifications.
You are responsible for presenting your utility equipment
Manufacturer’s Warranty Coverage (ULG) engine to an authorized Thermo King dealer as soon as
1996 and later utility equipment (ULG) engines: California a problem exists. The emission control system parts or
emission control system parts and components are warranted component repairs should be completed in a reasonable
for the period of two years (24 months). If any California amount of time not to exceed 30 days.
emission control system part or component on your utility If you have any questions regarding your warranty rights and
equipment (ULG) engine is defective, the part or component responsibilities, contact a Thermo King service representative
will be repaired or replaced by Thermo King. at 952-887-2337.
22
Emission Control
Manufacturer Explanation Of at a Thermo King authorized service dealer. To obtain the

phone number of your nearest Thermo King authorized
Emission Control System service dealer, call the Cold Line at: 952-887-2202.
Warranty Coverage 2. Warranty Period: Any warranted California emission
A. Warranty Commencement Date control system part or component that is not scheduled for
The California emission control system warranty period begins replacement as required maintenance, or that is scheduled
on the date the engine or equipment is delivered to the original only for regular inspection to the effect of repair or
retail purchaser. replacement as necessary, shall be warranted for the
warranty period. Any warranted part that is scheduled for
B. Length Of Coverage replacement as required maintenance shall be warranted
Thermo King warrants to the original purchaser, and each for the period of time up to the first scheduled replacement
subsequent purchaser, that the engine emission control system point for that part or component.
is free from defects in material and workmanship that cause the 3. Diagnosis: The owner shall not be charged for diagnostic
failure of the warranted California emission control system labor which leads to the determination that a California
part or component for a period of two years (24 months) emission control system warranted part or component is
beginning on the day the utility equipment (ULG) engine is defective, if the diagnostic work is performed at a Thermo
delivered to the original purchaser. King authorized service dealer.
C. What Is Covered 4. Consequential Damages: Thermo King is liable for
1. Repair or Replacement of Parts: Repair or replacement damages to other engine parts or components caused by
of any California emission control system warranted part the failure of an emission control system part or
or component will be performed at no charge to the owner component within the above stated California emission
control system warranty period.
23
Emission Control
D. What is Not Covered call the customer service representative at 888-887-2202 for
the location of the nearest Thermo King authorized service
1. Failures caused by abuse, neglect, or improper
dealer.
maintenance.
2. Add-On or Modified Parts. The use of add-on or modified G. Maintenance, Replacement and Repair of Emission
parts can be grounds for disallowing a warranty claim. Control System Related Parts
Thermo King is not liable for failures of emission control Any Thermo King approved replacement part can be used in
system parts or components caused by the use of add-on or the performance of any warranty maintenance or repairs on
modified parts. emission control system parts or components, and must be
provided without charge to the owner if the part is still under
3. Use of fuel other than the California Title 13, CCR Section
the California emission control system warranty.
2282 (g)(3), low sulfur, low aromatic, with a cetane
number of 48 minimum, will nullify this warranty. H. Emission Control System Warranty Parts List
E. How to File a Claim • Part Name
Warranty claims for California emission control system parts • Fuel Injection Pump
or components are to be filed by the Thermo King authorized
• Fuel injection Nozzle
servicing dealer on behalf of the engine owner.
• High Pressure Fuel Oil Line
F. Where to Get Warranty Service
• Air Cleaner Element
Warranty service or repairs shall be provided at all Thermo
King authorized service dealers. You can generally find dealers • Fuel Filter Element
in the Yellow Pages of your regional telephone directory, or • Air Cleaner Gasket
• Air Intake Pipe (Manifold)
24
Emission Control
• Gasket Muffler Gasket If an emission-related part or component fails during the

warranty period, it will be repaired or replaced. Any such part
I. Maintenance Statements
or component repaired or replaced under warranty is warranted
The owner is responsible for the performance of the required for the warranty period.
maintenance as defined by Thermo King within this Operator’s
Manual. During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
EPA Emission Control System replacement of any warranted part at no charge to the non-road
Warranty Statement engine owner.
In an emergency, repairs can be performed at any service
Thermo King warrants to the initial owner and each subsequent
establishment, or by the owner, using any replacement part.
owner that the certified non-road diesel engine in your unit is:
Thermo King will reimburse the owner for their expenses,
1. Designed, built and equipped so as to conform, at the time including diagnostic charges, for such emergency repair. These
of sale, with all applicable regulations adopted by the expenses shall not exceed Thermo King’s suggested retail price
United States Environmental Protection Agency (EPA). for all warranted parts replaced, and labor changes based on
2. Free from defects in materials and workmanship in Thermo King’s recommended time allowance for the warranty
specific, emission-related parts for a period of five years repair and the geographically appropriate hourly labor rate.
or 3,000 hours of operation, whichever comes first, after Any replacement part can be used for maintenance or repairs.
date of delivery to the initial owner. The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts which are not genuine
Thermo King parts.
25
Emission Control
A part not being available within 30 days or repair not being Thermo King Corporation Responsibilities
completed within 30 days constitutes an emergency.
During the emission warranty period, if a defect in material or
As a condition of reimbursement, replaced parts and received workmanship of a warranted part or component is found,
invoices must be presented at a place of business of a Thermo Thermo King will provide:
King authorized service dealer or other establishment
• New, remanufactured, or repaired parts or components
authorized by Thermo King.
required to correct the defect.
This warranty covers the following emission-related parts and
components: NOTE: Items replaced under this warranty become the
property of Thermo King.
• Fuel Injection System
• Labor, during normal working hours, required to make the
• Intake Manifold warranty repair. This includes diagnosis and labor to
• Exhaust Manifold remove and install the engine, if necessary.
• Miscellaneous hoses, clamps, connectors and sealing

devices used in the above systems. Owner Responsibilities
If failure of one of these parts or components results in failure During the emission warranty period, the owner is responsible
of another part or component, both will be covered by this for:
warranty. • The performance of all required maintenance. A warranty
claim will not be denied because the scheduled
Responsibilities maintenance was not performed. However, if the lack of
required maintenance was the reason for the repair, then
This warranty is subject to the following: the claim will be denied.
26
Emission Control
• Premium of overtime cost. Remedies under this warranty are limited to the provision of
material and services as specified herein. Thermo King is not
• Cost to investigate complaints that are not caused by
responsible for incidental or consequential damages such as
defect in Thermo King material or workmanship.
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 Operator’s Manual, or any
other manuals provided with the unit.
• Attachments, accessory items, or parts not authorized for
use by Thermo King.
• Improper off-road engine maintenance, repair, or abuse.
• Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
27
Emission Control
28
Unit Description
General Description Engine power for the unit is provided by a diesel engine.
Optional electric standby power (Model 50) is provided by an
The TS-200, TS-300 and TS-500 units are microprocessor electric motor. A clutch on the diesel engine isolates the engine
based transport temperature control systems that use the during electric standby operation.
ThermoGuard® µP-T microcontroller to manage system
functions. The continuous monitoring function of the µP-T
microprocessor optimizes the unit’s performance, thereby
The units are one-piece, front-mounted, diesel powered reducing fuel consumption and unit down time. The unit has a
cooling and heating systems designed for straight trucks. The self check feature that can be run before the daily distribution
units mount on the front of a truck with the evaporator portion route to identify possible malfunctions. The TherMax™
protruding into the box. They are designed for use with defrost/heating system increases unit heating capacity for
chlorine free R-404A refrigerant. The basic models provide the faster defrost.
following:
The built-in CYCLE-SENTRY, an exclusive Thermo King
Model 30: Cooling and hot gas heating on engine operation. feature, automatically starts and stops the unit according to
Model 50: Cooling and hot gas heating on engine operation temperature demands. In addition, a range of programmable
and electric standby operation. Electric evaporator heaters are modes allow you to tailor performance to the load you are
optional. hauling.
29
Unit Description
Design Features • Fahrenheit and Celsius Scales
• Air Cleaner, Dry Type • Fuel Filter, Spin On
• Air Switch • In-Cab Remote Display
• Alarm Code Display • Microprocessor Controller µP-T
• Alternator, 23 amp • Oil Filter, Full Flow
• Automatic Phase Correction (Model 50) • Oil Pressure Display
• Battery Voltage Display • R-404A
• Bypass Oil Filter (As of First Quarter 2001) • Scroll Compressor
• Condenser Top Screen • Smart Defrost
• Continuous System Monitoring • Stainless Steel Condenser Hardware
• Coolant Expansion Tank • Stainless Steel Evaporator Hardware
• Coolant Temperature Display • Tapered Roller Bearing Jackshaft (Model 30)
• Corrosion Resistant Protection • TherMaxTM System, Defrost/Heating
• CYCLE-SENTRY Start/Stop Controls • TK 3.74 Engine (TS-200 and TS-300)
• Diesel/Electric Autoswitching • TK 3.95 Engine (TS-500)
• Electric Hourmeter • Total Run Hourmeter
• Engine Hourmeter • Unit Self Check-pretripping
30
Unit Description
Unit Options Engine

• Bypass Oil Filter (Standard as of First Quarter 2001) Engine power for the TS-200 and TS-300 is provided by the
TK 3.74, a three-cylinder, special clean and silent diesel engine
• DAS (Data Acquisition System)
rated at 12.6 continuous horsepower (9.4 kW) at 2450 RPM. A
• Door Switch belt drive system transfers energy to the compressor, unit fans,
• Easy Read Thermometer and alternator.
• Electric Heater Strips (Model 50) Engine power for the TS-500 is provided by the TK 3.95, a
three cylinder, special clean and silent diesel engine rated at
• Electric Standby 17.0 continuous horsepower (12.7 kW) at 2425 RPM. A belt
• Engine Block Heater drive system transfers energy to the compressor, unit fans and
alternator.
• Evaporator Side Screens
• Fuel Tank
ELC (Extended Life Coolant)
• Remote Light Display
ELC (Extended Life Coolant) has been phased into these units
• Silicone Hoses as of the first quarter of 2001. The maintenance interval for
ELC is five years or 12,000 hours. A nameplate on the coolant
expansion tank identifies units with ELC (see “Safety Decals
and Locations”). The new engine coolant, Texaco Extended
Life Coolant, is Red instead of the previous Green or
Blue-Green conventional coolants.
31
Unit Description
ELC cannot be used in older units. The water pump seal EMI 2000
bellows and O-rings used in older units are not compatible with
EMI 2000 is an extended maintenance interval package. It was
ELC.
phased in as standard equipment on these units in the first
CAUTION: Do not add Red Extended Life Coolants quarter of 2001. The EMI 2000 package consists of the
to cooling systems using Green or Blue-Green following key components:
coolants. Do not add Green or Blue-Green coolants • New EMI 2000-Hour Cyclonic Air Cleaner Assembly and
to cooling systems using Red Extended Life Coolants. Air Cleaner Element (standard equipment on all TS Units)
NOTE: The use of 50/50% pre-mixed ELC is recommended • New EMI 2000-Hour Fuel Filter (black with gold
to ensure that deionized water is being used. If 100% full lettering)
strength concentrate is used, deionized or distilled water is • New EMI 2000-Hour By-Pass Oil Filter (black with gold
recommended instead of tap water to ensure the integrity of lettering)
the cooling system is maintained.
• API Rating CG-4 Mineral Oil
NOTE: Units equipped with ELC are not necessarily
• Five Year or 12,000 Hour ELC (Extended Life Coolant)
equipped with EMI 2000, but units equipped with EMI 2000
are equipped with ELC. The EMI package allows standard maintenance intervals to be
extended to 2,000 hours, or 1 year, whichever occurs first.
NOTE: Units equipped with the EMI 2000 package do
require regular inspection in accordance with Thermo King’s
maintenance recommendations.
32
Unit Description
Clutch external relays to control unit operation. When the controller is

set below 15 F (–9.4 C), the microprocessor locks out high
The centrifugal clutch engages fully at 600 ± 100 RPM on
speed heat.
engine operation, constantly turning the compressor, alternator,
and fans at both high and low speed. The clutch isolates the
engine from the belt drive system during electric standby CYCLE-SENTRY Start/Stop
operation on Model 50 units.
System
A CYCLE-SENTRY Start/Stop fuel saving system provides
Scroll Compressor optimum operating economy.
The units feature high performance TKO Scroll compressors.
WARNING: Turn the unit off by pressing the OFF key
before opening doors or inspecting any part of the
ThermoGuard µP-T Controller unit. The unit can start at any time without warning if
it has been turned on by pressing the ON key.
The µP-T is a solid-state, programmable microprocessor that
contains integrated circuits and software to control unit
The CYCLE-SENTRY system automatically starts the unit on
operation.
microprocessor demand and shuts down the unit when all
The µP-T controller uses a remote control panel and interface demands are satisfied.
relay board. The remote control panel inputs data into the
The system monitors and maintains the compartment
controller and displays operating conditions. The interface
temperature, the engine block temperature, and battery charge
relay board contains fuses to protect control circuits and
levels at a point where quick, easy starts are possible.
33
Unit Description
Defrost Air Switch: The unit is equipped with an air switch to detect
if the coil is blocked by frost.
Frost will gradually build up on the evaporator coils as a result
of normal operation. Periodically this frost must be melted to Manual Defrost: Manual Defrost allows the operator to
prevent a loss of cooling and airflow. initiate a defrost cycle by pressing the DEFROST key. See
“Initiating a Manual Defrost Cycle”.
Defrost is accomplished by passing hot refrigerant gas through
the evaporator coils, thus melting the frost (or ice). Melted
frost drains out of the unit onto the ground through the drain DAS - Data Acquisition System
tubes. The defrost damper closes during defrost to prevent (Optional)
warm air from entering the cargo area. The optional electric
heater strips are also energized in defrost during electric The DAS (Data Acquisition System) works with the µP-T to
standby operation. monitor and record the temperatures of (up to) six additional
sensors. The sensors are independent from the microprocessor
Defrost can be initiated at any time the evaporator coil and are normally located in the truck box to monitor load
temperature is below 42 F (5.5 C). temperatures. Data from the DAS sensors and the µP-T can be
There are three methods of defrost initiation: downloaded through a serial port to an IBM® PC compatible
computer. WinTrac™ 4.0 (or higher) software is used to view
µP-T Microprocessor Controller: The Microprocessor
and analyze the data. Brief reports can be printed on a
Controller is programmed to automatically initiate timed and
microprinter connected to the serial port.
forced defrost cycles. The µP-T uses temperature sensors to
determine if forced defrost is required.
34
Unit Description
Electric Standby (Model 50 Units Remote Reset Solenoid: A remote reset solenoid is
provided to reset the overload relay.
Only)
Hot Gas Heat: Hot gas heat is utilized on standard model 50
The Electric Standby option allows the unit to be operated on
units.
either the diesel engine or external electric power.
Automatic Phase Correction (Three Phase Units
DANGER: High voltage AC power is present Only): The control system features two motor contactors. This
whenever the unit is operating in the Electric mode allows correct motor rotation regardless of phase rotation on
and whenever the unit is connected to external the incoming power.
standby power. Voltages of this magnitude can be
lethal. Exercise extreme caution when working on the
unit.
Optional Model 50 Features
The following feature is available as an option on units
equipped with Electric Standby.
Standard Model 50 Features
• Electric Heat
The following features are standard equipment on units
equipped with Electric Standby.
Automatic Diesel/Electric Selection: The unit will
automatically switch to electric operation when a power cord is
connected and the standby power is switched On.
35
Unit Description
Engine Compartment CAUTION: Do not remove expansion tank cap while

Components the coolant is hot.
Air Restriction Indicator (if equipped): This is used with
the dry element only. It is not used with the oil bath filter. The
air restriction indicator is attached to the top of the air cleaner CAUTION: Do not add Red Extended Life Coolants
assembly. Visually inspect the restriction indicator periodically to cooling systems using Green or Blue-Green
to assure the air filter is not restricted. Service the air filter coolants. Do not add Green or Blue-Green coolants
when the yellow diaphragm indicates 25 in. (635 mm) of H2O. to cooling systems using Red Extended Life Coolants.
Press the button on the top of the restriction indicator after
Compressor Oil Sight Glass: The compressor oil sight
servicing the air filter. Replace the EMI 2000 air cleaner
glass is used to check the relative level of compressor oil in the
element at 2,000 hours or 1 year (whichever occurs first) if the
compressor sump.
air restriction indicator has not reached 25 in. (635 mm).
Engine Oil Dipstick: Use the engine oil dipstick to check
Coolant Expansion Tank: The coolant level and
the engine oil level.
temperature are monitored by the µP-T controller. If the
coolant temperature becomes too high or the level becomes too Receiver Tank Sight Glass: The receiver tank sight glass
low, an alarm will occur and the engine will shut down. is used to check the amount of refrigerant in the system, and
The engine must have antifreeze protection to –30 F (–34 C). the moisture content of the refrigerant.
Check and add coolant in the expansion tank as needed.
36
Unit Description
Unit Protection Devices Fuse Size Function

Battery Fuse: Late model units have a battery fuse (F1), F305 3A On/Run Relay
which protects the 2 circuit. This 60 amp fuse is located in a
F306 3A Preheat Relay
fuse holder in the 2 wire near the battery.
F037 3A Not Used
Circuit Breaker (CB1): CB1 is a 50 amp, auto reset circuit
breaker. It protects the unit’s main power circuit. F308 3A Not Used
Fuses: A number of fuses are located on the interface board. F309 15A Alternator Excitation
The sizes and functions are shown below.
F310 15A Damper Solenoid
Fuse Size Function F311 10A Motor Reset Solenoid
F200 3A 2P Power to Microprocessor F400 5A Motor Starter
F202 3A Oil Level Switch F401 10A Fuel Solenoid and Fuel Pump
F300 3A Pilot Solenoid F402 10A Throttle Solenoid
F301 3A TherMax Solenoid F403 3A Heater Contactor
F302 3A Alternator Relay
Compressor High Temperature Cutout Switch: This
F303 3A Damper Relay temperature sensitive switch open circuits to shut down the
F304 3A Starter Relay unit if the discharge temperature rises above the switch setting.
37
Unit Description
Engine Coolant Level Sensor: The coolant level is Preheat Buzzer: The preheat buzzer sounds when the
monitored by the µP-T controller. If the level becomes too low, CYCLE-SENTRY system energizes the glow plugs. This
an alarm will occur. should warn anyone near the unit that the CYCLE-SENTRY
system is about to start the diesel engine.
High Pressure Cutout: A high pressure cutout is located in
the compressor discharge manifold. This pressure sensitive Water Temperature Sensor: This sensor provides an
switch open circuits to shut down the unit if the discharge engine coolant temperature input to the microprocessor. If the
pressure rises above the switch setting. engine coolant temperature is too high, the controller stops the
unit and records an alarm.
High Pressure Relief Valve: This valve is designed to
relieve excessive pressure in the refrigeration system. Electric Motor Overload Relay (Model 50): The
overload relay protects the electric standby motor. The
Low Oil Level Switch: The low oil level switch closes if the
overload relay opens the circuit from the linestarter to the
oil drops below a certain level. If it stays closed for a specified
electric motor if the motor overloads for any reason and an
time, the microprocessor will shut the unit down and record
alarm will occur. The relay resets when the alarm code is
alarm code 66 (normal code when changing oil).
cleared.
Oil Pressure Sensor: This sensor provides an oil pressure
input to the microprocessor. If the oil pressure remains too low,
the controller stops the unit and records an alarm.
38
Unit Description
AEA2227
Figure 12: Front View
39
Unit Description
6 7
5 8
4
3
2
1 9
10
11
15
12
13
14
Figure 13: Engine Components TS-200 and TS-300
40
Unit Description
1. Engine 8. Liquid Injection Valve

2. Discharge Pressure Regulator 9. Three-way Valve
(Located Behind Accumulator)
3. Suction Pressure Regulator 10. Receiver Tank
4. Electric Motor 11. Scroll Compressor
5. Alternator 12. Accumulator
6. Pilot Solenoid 13. Coolant Expansion Tank
7. Air Switch 14. Engine Coolant Drain
15. Air Cleaner
See Figure 13: “Engine Components TS-200 and TS-300” on page 40.
41
Unit Description
4 5
3
2 6
7
1
9
15
10
11
12
14 13
Figure 14: Engine Components TS-500
42
Unit Description
1. Engine 8. Receiver Tank

2. Electric Motor 9. Discharge Pressure Regulator
3. Alternator 10. Scroll Compressor
4. Throttle Valve 11. Liquid Injection Valve
5. Air Switch 12. Accumulator
6. Three-way Valve 13. Coolant Expansion Tank
7. Pilot Solenoid 14. Engine Coolant Drain
15. Air Cleaner
See Figure 13: “Engine Components TS-500” on page 42.
43
Unit Description
AJA408
3 2
1. Microprocessor 3. Interface Board

2. High Voltage Tray Cover 4. Microprocessor Power Switch
Figure 15: Control Box
44
Unit Description
AEA43
Figure 16: Remote Control Panel
45
Unit Description
AEA102
Figure 17: North American Power Receptacle Box
46
µP-T System Description
The µP-T microprocessor controllers are self contained Microprocessor Power Switch
temperature control units designed for Smart Reefer truck
units. The microprocessor controls all unit functions to The microprocessor power switch applies power to the
maintain the cargo at the proper temperature. microprocessor and must be on to operate the unit. It is
typically located on or near the control box. Main power to the
The microprocessor continuously monitors unit operational balance of the controls is supplied by circuit breaker CB1.
information including return air, discharge air and coil
temperature sensors, unit hourmeters, oil pressure gauge, water NOTE: When the Microprocessor Power Switch is turned
temperature gauge, voltmeter, tachometer, mode indicators, “OFF,” power is still applied to the interface board and
and temperature control system controls. control circuits via CB1. To completely remove power from
the control system, disconnect the unit battery.
The Microprocessor Power Switch and the Remote Control
Panel are used to control the operation of the microprocessor.
Figure 18: Microprocessor Power Switch
47
Remote Control Panel Keypad Keys

ON Key: Turns the unit on.
OFF Key: Turns the unit off.
SELECT Key: Scrolls through the prompt and display

screens.
Figure 19: Remote Control Panel UP ARROW Key: Chooses prompt screen actions or
increases setpoint or other setting.
The remote control panel is connected to the microprocessor
and is used to operate the unit. It consists of a keypad and a DOWN ARROW Key: Chooses prompt screen actions or
display. It can be located in the truck dashboard using the decreases setpoint or other setting.
supplied DIN mounting ring, or under the dashboard using the ENTER Key: Executes prompts or loads setpoints or
supplied under dash mounting kit. An optional body mount other new settings.
enclosure kit is available to mount the remote control panel on
the truck box. DEFROST Key: Initiates a manual defrost cycle.
WHISPER Key: Disables high speed diesel mode

operation.
LOGO Key: Initiates the Unit Self Check test and
displays software revision.
48
Understanding the Display Display Icons

The display normally shows the Standard Display of return air Cool Icon: Appears when the unit is cooling.
temperature and setpoint. In addition, the icons located at the
sides of the display indicate the operating mode of the unit and
show if any alarm codes are present. Pressing the SELECT key Heat Icon: Appears when the unit is heating.
will show the prompt and display screens. The display shown
Figure 20 has all possible display features turned on. This icon appears during a remote control panel test but
is not used on truck units.
Defrost Icon: Appears when the unit is defrosting.
CYCLE-SENTRY Icon: Appears when

CYCLE-SENTRY mode has been selected.
Alarm Icon: Appears when an alarm condition has
been detected by the microprocessor.
Electric Icon: Appears when the AC power is
connected and the phases are correct.
Figure 20: Display
Setpoint Icon: Appears when the setpoint is being
shown in the lower display.
Whisper Icon: Appears when Whisper mode has been
selected.
49
ZONE
1234
These icons appear during a remote control panel test The Standard Display
but are not used on truck units.
Reading a Typical Display
ARA187
Figure 22: Standard Display
The Standard Display appears when the unit is turned on and

ARA186 no other functions have been selected. The box temperature
Figure 21: Typical Display appears in the upper display and the setpoint appears in the
lower display. This display shows a box temperature of 35.8 F
The above display shows the following information: and a setpoint of 35 F. The Standard Display is the starting
point used to reach all other prompts and displays. To return to
1. The unit is on and is cooling.
this display from any other prompts or display, wait 10 seconds
2. CYCLE-SENTRY mode and Whisper mode have been and it will return automatically.
selected.
3. The box temperature is 35.8 F and the setpoint is 35.0 F.
50
Remote Indicator Lights
Remote indicator lights are an option. The remote indicator
light display mounts on the truck to offer convenient indication
of the unit’s operating mode. The following conditions are
indicated by the respective light(s) being on:
1. Cool (White) The unit is cooling.

2. Defrost (Tan) The unit is defrosting.
3. Heat (Amber) The unit is heating.
4. High Speed
The unit is in high speed.
(Blue)
5. On (Green) The unit is turned on and may
start at any time if it is not
already running.
Figure 23: Remote Indicator Light Display
51
Remote Indicator Lights
52
Manual Pre-Trip Inspection
(Before Starting the Unit)
Pre-trip inspections are an important part of regularly Coolant: Level and temperature are monitored by the µP-T
scheduled preventive maintenance programs designed to controller. The coolant should be a 50/50 mixture of antifreeze
minimize operating problems and breakdowns before they and water and provide protection to –30 F (–34 C).
happen. Pre-trips are not intended to take the place of regular
maintenance inspections. WARNING: Do not remove the expansion tank cap
You should perform the following suggested pre-trip while the coolant is hot.
inspection before every trip involving refrigerated cargo.
Fuel: The diesel fuel supply must be adequate to guarantee the CAUTION: Do not add “RED” Extended Life
operation of the engine to at least the next check point. Coolants to cooling systems using “GREEN” or
“BLUE-GREEN” coolants. Do not add “GREEN” or
Engine Oil: The engine oil level should be at the FULL mark “BLUE-GREEN” coolants to cooling systems using
on the dipstick. Never overfill. “RED” Extended Life Coolants. See “Engine
Coolant Types” in “Specifications” for more
CAUTION: Make sure the engine is off before information.
attempting to check the engine oil level.
Battery: The terminals must be tight and free of all corrosion.
Electrolyte should be at full mark.
53
Manual Pre-Trip Inspection (Before Starting the Unit)
Belts: The belts must be in good condition and adjusted to the Coils: The condenser and evaporator coils should be clean
proper tension. Allow 0.5 in. (13 mm) deflection at the center and free of debris.
of the span between pulleys.
Cargo Box: Inspect the interior and exterior of the box for
Electrical: Check all electrical connections to make certain damage. Any damage to the walls or insulation must be
they are securely fastened. Wires and terminals should be free repaired.
of corrosion, cracks or moisture.
Defrost Drain: Check the defrost drain hoses and fittings to
Structural: Visually inspect the unit for leaks, loose or be sure they are open.
broken parts and other damage.
Doors: Be sure doors and weather seals are in good condition,
Gasket: The unit mounting gasket should be tightly the doors latch securely and weather seals fit tightly.
compressed and in good condition.
54
Unit Operation with THERMOGUARD µP-T
The µP-T controller is a programmable microprocessor that
CAUTION: The microprocessor power switch,
controls all unit functions to maintain the cargo at the proper
located on the right side of the unit next to the control
temperature. The µP-T controller continuously monitors unit
box, must be in the OFF position before disconnecting
operational information including return air, discharge air and
or connecting the unit battery.
coil temperature sensors, unit hourmeters, oil pressure switch,
water temperature gauge, voltmeter, tachometer, mode
NOTE: The microprocessor power switch must be in the ON
indicators, and temperature control system controls.
position to operate the unit.
Operation in Confined Spaces NOTE: Refer to THERMOGUARD µP-T Microprocessor

Controller Diagnosis Manual, for complete operation and
CAUTION: Operation in confined spaces. Diesel diagnosis information.
operation should be avoided in areas or
circumstances where fumes from the engine could
become trapped and cause serious injury or death.
WARNING: The unit may Start automatically AT

ANY TIME when the CYCLE-SENTRY symbol is
visible in the controller display. Make sure to press
the OFF key before opening unit doors or inspecting
any part of the unit.
55
Displaying Operating Data

Unit operational information appears on liquid crystal display
(LCD). During normal operation, the Standard Display appears
on the screen. The Standard Display is the return air
temperature (upper display) and setpoint temperature (lower
display). Check the symbols (icons) that appear on the display.
These symbols identify the operating information that
currently appears (see “Display Icons”). Figure 24: Entering the Setpoint
The keypad allows the operator to select information to display 3. Press the ENTER key to load the new setpoint into the
and program unit features including the setpoint temperature. If microprocessor. The display will show [Lod]
no key is pressed for about 10 seconds, the display will return (abbreviation for Load) for a few seconds and then the
to the Standard Display. new setpoint will reappear in the display.
IMPORTANT: You must press the ENTER key or the setpoint
Entering the Setpoint WILL NOT be changed. The display will return to the
Standard Display and the setpoint will return to the old
1. Press the ON key to turn the unit on.
setpoint in about 10 seconds if the ENTER key is not pressed.
2. Press the UP or DOWN ARROW keys to select the desired
setpoint.
56
Starting the Engine Initiating a Manual Defrost Cycle
Figure 25: Starting the Engine Figure 26: Initiating a Manual Defrost
CAUTION: This unit will start automatically in The unit must be running in either CYCLE-SENTRY or
either CYCLE-SENTRY or Continuous mode after Continuous mode and the coil temperature must be below
the ON key is pressed. 45 F (7 C). Press the DEFROST key to start a manual defrost
cycle. The defrost prompt will appear in the display when the
Press the ON key to turn the unit on. If no other key is pressed, unit starts a defrost cycle. The defrost cycle will terminate
the engine will automatically preheat and start in about 10 automatically. If the unit is not running or the coil temperature
seconds in either CYCLE-SENTRY or Continuous mode. If is not below 45 F (7 C), the request will be ignored.
other keys are pressed (for example: to change the setpoint or
view display screens), the engine will automatically preheat
and start about 10 seconds after the last key is pressed.
57
Selecting CYCLE-SENTRY or IMPORTANT: You must press the ENTER key or the
operating mode will not be changed. The display will return
Continuous Mode to the Standard Display and the operating mode will return to
the old operating mode in about 10 seconds if the ENTER key
is not pressed.
Figure 27: Selecting Cycle-Sentry or Continuous

Mode

2. Press the SELECT key to display [CYCLS] and [YES] or
[no].
3. Press the UP or DOWN Arrow keys to select the desired
mode:
[YES] = CYCLE-SENTRY mode
[no] = Continuous mode.
4. Press the ENTER key to load the new operating mode
selection into the microprocessor.
58
Selection of Operating Modes on Products Requiring Continuous Run

CYCLE-SENTRY Equipped Units Operation for Air Flow
The Thermo King CYCLE-SENTRY system is designed to • Fresh fruits and vegetables, especially asparagus, bananas,
save refrigeration fuel costs. The savings vary with the broccoli, carrots, citrus, green peas, lettuce, peaches,
commodity, ambient temperatures and trailer insulation. spinach, strawberries, sweet corn, etc.
CYCLE-SENTRY is designed for use only with products • Non-processed meat products (unless pre-cooled to
which do not require tight temperature control or continuous recommended temperature)
airflow, such as all deep frozen products and non-perishable • Fresh flowers and foliage.
non-frozen products.
The start/stop nature of CYCLE-SENTRY does not satisfy the Products Acceptable for
temperature control or airflow requirements for perishable or CYCLE-SENTRY Operation
temperature sensitive products. Thermo King therefore does
• Frozen foods (in adequately insulated trucks)
NOT recommend the use of CYCLE-SENTRY control for
these products. • Boxed or processed meats
Your selection of the operating mode for the proper protection • Poultry
of a particular commodity should use the following guidelines:
• Fish
• Dairy products
• Candy
• Chemicals
59
• Film 1. Disconnect the electric standby power cord if present.

• All non-edible products. 2. Press the ON key to turn the unit on.
NOTE: The above listings are not all inclusive. Consult your 3. Clear any alarms.
grower or shipper if you have any questions about the
4. Press and hold the TK LOGO key for at least 3 seconds
operating mode selection of your type of load.
until the Unit Self Check [USC] prompt screen appears.
5. Press the ENTER key. The display will briefly show [Lod]
µP-T Unit Self Check Test and the unit will then start the Unit Self Check.
The Unit Self Check is a functional test of the unit’s operating NOTE: The Unit Self Check can also be started if the unit is
capability. Once the test is started by the operator, it is fully already running by starting at step 3.
automatic and requires no operator attendance.
If any alarms were not cleared before starting the Unit Self
Check, they will be displayed at this time. They can be cleared
Starting the Unit Self Check by pressing the ENTER key.
The balance of the Unit Self Check is fully automatic and
requires no operator attendance. The following tests are
performed:
Preheat and Start: The controller will automatically preheat
and start the diesel engine.
Display Check: All segments of the display will be lighted at
ARA188 the same time.
Figure 28: Starting the Unit Self Check
60
Show Programmable Settings: All programmable [CHEC]—Stored or check alarm conditions were detected
settings will be sequentially displayed. These settings may be during the Unit Self Check. These alarms will be preceded by a
verified by the operator if necessary. dash (-) to indicate that they were detected during a Unit Self
Check.
Defrost Check: The operation of the damper door is
checked. [FAIL]—Shutdown alarm conditions were detected during the
Unit Self Check and the unit has been shut down to prevent
RPM Check: The diesel engine RPM is checked in both high
possible damage. This will occur as soon as a shutdown
and low speed.
condition is detected. The Unit Self Check will not be
Cooling Check: The ability of the unit to cool is checked. completed.
Heating Check: Checks unit’s heating performance. If check or shutdown alarms are detected during a Unit Self
Check the condition(s) should be corrected and the check
Cooling Check: Second cooling test ensures the unit can repeated before releasing the unit for service. See the Alarm
switch from cool to heat and back to cool. Codes chapter of this manual, and the µP-T Microprocessor
Diagnosis Manual, for details.
Unit Self Check Report
At the completion of the Unit Self Check, the check results will
appear on the display. They will remain until any key on the
controller is pressed. Check results are shown as either [PASS],
[CHEC] or [FAIL].
[PASS]—The unit has passed the Unit Self Check.
61
Starting Unit with Full Unit Self 5. When the Unit Self Check is complete, [PASS], [CHEC],
or [FAIL] will appear on the display until a function key
Check (e.g., SELECT or ENTER) is pressed. Continue as follows:
The procedure is used for a complete checkout of the unit and PASS—The unit is running and no alarms have been
unit control circuits. It should be used when first starting the recorded. The unit has passed the Unit Self Check. Go to
unit for a trip before the cargo is loaded. A full Unit Self Check step 7.
procedure may take up to 30 minutes and the unit will run
unattended. CHEC—The unit is running but Check Alarms have been
recorded. Go to step 6.
1. Perform a Manual Pretrip Inspection (see the Manual
Pretrip Inspection chapter). FAIL—The unit has shut down, recorded Alarm Code 28,
and possibly recorded other Shutdown Alarms. Go to
2. Adjust the setpoint to the desired load temperature (see step 6.
“Entering the Setpoint” on page 56).
3. Select CYCLE-SENTRY or Continuous Mode (see
“Selecting CYCLE-SENTRY or Continuous Mode” on
page 58).
4. Initiate a Unit Self Check (see “mP-T Unit Self Check
Test” on page 60). This procedure is automatic and can be
performed on the way to the loading area or while waiting
to load.
62
6. View the Alarms (see “Viewing and Clearing Alarm After Start Inspection
Codes” on page 67).
After the unit is running, check the following items to confirm
a. Correct the alarm conditions. See the Alarm Codes that the unit is running properly.
chapter of this manual, and the µP-T Microprocessor
Diagnosis Manual, for details about Alarm Codes. Oil Pressure: Engine oil pressure is automatically checked
by the controller. If oil pressure is within the acceptable
b. Clear the alarms (see “Viewing and Clearing Alarm
operating range, the engine will continue to run. If oil pressure
Codes” on page 67).
is not within the the acceptable operating range, the controller
c. Repeat the Unit Self Check test until [PASS] appears will shut off the engine and display alarm code 19.
(the unit passes the Unit Self Check).
Compressor Oil: The compressor oil level should be visible
7. Recheck the setpoint. in the sight glass after 15 minutes of operation.
8. Complete the After Start Inspection (see “After Start Pre-cooling: Make sure that the setpoint is at the desired
Inspection” on page 63). temperature and allow the unit to run for a minimum of 30
minutes (longer if possible) before loading the trailer.
This provides a good test of the refrigeration system while
removing residual heat and the moisture from the trailer
interior to prepare it for a refrigerated load.
63
Defrost: When the unit has finished pre-cooling the truck Restarting the Unit–Automatic
interior, manually initiate a defrost cycle (see “Initiating a
Manual Defrost Cycle” on page 57). This will remove the frost Start
that builds up while running the unit to pre-cool the truck. This procedure is used when starting a unit that has been shut
The defrost cycle should end automatically. off for a short time. When a unit that has been shut off for a
long time is first started, it should be started and put through a
NOTE: The unit will not defrost unless the evaporator coil full Unit Self Check (see “Starting Unit with Full Unit Self
temperature is below 45 F (7 C). Check” on page 62).
1. Push the ON key.
2. After a 10 second delay, the unit should preheat an start
automatically.
NOTE: When the CYCLE-SENTRY icon is active, the unit
may not start if the compartment temperature is near the
setpoint, the engine is warm, and the battery is fully charged.
64
If cooling or heating is required and the engine temperature is Checking the Software Revision
below approximately 120 F (96 C), but the engine fails to start
automatically:
1. Push the OFF key.
2. Check for and correct any alarm conditions and clear the
alarm codes. View the alarms with the SELECT key, clear
the alarms with the ENTER key, and the repeat the auto
start procedure. See the Alarm Codes chapter of this
manual, and the µP-T Microprocessor Diagnosis Manual, Figure 29: Checking the Software Revision
for detailed information about alarms.
3. If the engine will still not start, push the OFF key, 1. Press the ON key to turn the unit on.
determine and correct the cause of the failure. 2. Press and hold the TK LOGO key to display [USC].
3. Press the SELECT key to display [rEU] and the software
revision.
4. The software revision shown here is Revision 1520.
65
Viewing Prompt and Display [ALr]: Alarm codes. Only appears if alarm codes exist.
Screens [Pnt]: Print DAS report. Only appears with revision 154x or
later software, DAS module installed and the [Pnt - YES - nO]
screen in Super Guarded Access set to [YES]. Also, the unit
must be on for about 15 seconds with no key pressed for the
unit microprocessor to confirm the presence of the DAS
module and sensors.
[CYCLS]: CYCLE-SENTRY or Continuous mode prompt
screen. [YES] = CYCLE-SENTRY; [no] = Continuous
Figure 30: Viewing Prompt and Display Screens [dIS]: Discharge air temperature as measured by the discharge
temperature sensor.
[coL]: Evaporator coil temperate as measured by the
2. Press the SELECT key repeatedly to show the prompt and evaporator coil temperature sensor.
display screens.
[ds.1 - ds.6]: DAS sensor temperature (up to six sensors).
Each prompt or display screen will remain on the display for Only appears for the sensors that are connected with revision
about 10 seconds. The display will then return to the Standard 154x or later software and DAS module installed. Also, the
Display of box temperature and setpoint if no other key is unit must be on for about 15 seconds with no key pressed for
pressed. The prompt and display screens will appear in the the unit microprocessor to confirm the presence of the DAS
order shown following: module and sensors.
[tLH]: Total amount of time in hours the unit has been turned
on with the keypad On key.
66
[EnH]: Total amount of time in hours the diesel engine has Locking a Display Screen on the
run.
Display
[ELH]: Total amount of time in hours the electric motor has
The display screens in the preceding list that are underlined can
run (on units equipped with Electric Standby).
be locked on the display. Select the desired display screen by
[Hr4]: Total accumulated hours on hour meter 4 (only appears pressing the SELECT key and then press the ENTER key. The
if this hour meter is set to Type 1, 2 or 3). display will now remain on the screen until any other key is
pressed.
[Hr5]: Total accumulated hours on hour meter 5 (only appears
if this hour meter is set to Type 1, 2 or 3).
[Hr6]: Total accumulated hours on hour meter 6 (only appears Viewing and Clearing Alarm
if this hour meter is set to Type 1, 2 or 3). Codes
[oIL]: Diesel engine oil pressure.
[Ent]: Diesel engine coolant temperature.
[rPn]: Diesel engine RPM.
[bAt]: Battery voltage of the unit battery.
[bLIt]: Backlight select (allows the driver to select high or low
backlight illumination level).
Figure 31: Viewing and Clearing Alarm Codes
[dFI]: Initial defrost interval.
[ddr]: Defrost duration.
67

2. If the Alarm icon is present, one or more alarms have been
detected.
To View Alarm Codes

Press the SELECT key to show the Alarm display screen.
If more than one code exists, they will “cycle” through the
display, with each alarm appearing for several seconds.
The alarm code shown here is Alarm Code 66 — Low Engine
Oil Level.
To Clear Alarm Codes

1. Correct the cause of the alarm code. See Alarm Codes
chapter.
2. Press the SELECT key to display the alarm code.
3. Press the ENTER key to clear the alarm code.
If more than one alarm code is present, press the ENTER key to
clear each alarm code individually.
68
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.
004 69
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.
70
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. When the alarm that caused 85 is no longer active,
condition continues to occur, the alarm that caused the Alarm Code 85 will be reset.
shutdown will appear on the display and the unit will shut
down until the alarm is cleared. Code 84 will automatically
clear after the final attempt at restarting has occurred.
71
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
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
72
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
Sensor temp, repair as required X
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
15 Glow Plug Check Repair after delivery X
73
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
19* Low Engine Oil Pressure Check engine oil level, add oil as needed, repair as required X
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
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
74
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
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
75
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
Check high speed operation, monitor box temp, repair as
40 High Speed Circuit X
required
76
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
Temporary overheat condition, if condition persists repair as
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
Multi-temp zone sensor failed, zone shut down, monitor
47 Remote Sensor Shutdown X
temp and repair as required
77
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
50 Reset Clock Unit will operate normally, set date and time to clear alarm X
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
A diagnostic mode timed out, does not affect unit
54 Test Mode Time-out X
performance
78
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
Unit operating without boost capacitors, repair as required
60 Boost Circuit X
(RC units only)
79
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
65 Unassigned
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
68 µP 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
80
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
72 Hourmeter 5 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 µP Reverted to Default Settings X
repair immediately
75 µP Internal Fault Code Controller may be defective, repair immediately X
81
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Data logger missed logging one event, no action required,
Data Log Overflow X
79 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
Temporary shutdown resulting from other alarm codes.
84 Restart Null X
Refer to detailed explanation at start of chapter
82
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
90-
Unassigned
92
83
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
Suction pressure drops less than specified when Loader
95 Loader Valve #2 X
Valve #2 is energized during unit start up, repair as required
96-
Unassigned
98
Compression ratio of discharge to suction pressure has
99 High Compressor Pressure Ratio X
risen above specification, repair as required
100-
Unassigned
104
84
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
Receiver Tank Press Solenoid Unit operating with reduced heat performance, monitor box
105 X
Circuit temp, repair as required
Unit operating with reduced heat performance, monitor box
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
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
85
Alarm Codes

Level Of
Action
Check
Ok To
Down
Shut
Run
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
115-
Unassigned
120
121 Liquid Injection Valve X
repair as required
86
Electric Standby Operation
Model 50 units are equipped with Electric Standby. This Electric Power Receptacle
feature allows the unit to operate on electric power as well as
be powered by the standard diesel engine. The electric power receptacle is used to connect the unit to an
appropriate electric power source for electric standby
During Electric Standby operation, power to the unit is operation. Press the unit OFF key before connecting or
supplied by an electric motor connected to a high voltage disconnecting the power cord.
power source. Check the unit for proper power source ratings.
WARNING: Units equipped with electric standby can

start at any time when the unit is connected to live
electric power and the controller is turned on.
CAUTION: Always turn the electric power supply off

when handling, connecting, or disconnecting high
voltage power cords.
Figure 32: Model 50 Power Receptacle Box
87
NOTE: The Model 50 control system automatically NOTE: In Continuous mode, the unit will operate in both
determines if diesel or electric power is desired. Diesel and Electric operation. In CYCLE-SENTRY mode, the
unit will operate in both Diesel and Electric operation.
If power is supplied to the receptacle (the unit is plugged in),
the microprocessor power switch is turned on, and the ON key
is pressed, the unit will automatically run in the electric Starting the Unit on Electric
standby mode.
Standby Operation
If the power is removed or interrupted at the receptacle, the
controller will display [StArt Eng] (start engine) on the display. Use this procedure to start a unit that has been shut off for a
If the ENTER key is pressed, the unit will start and run in diesel. short time. When a unit that has been shut off for a long time is
You can program this feature so the diesel engine restarts on first started, put it through a full Unit Self Check (see “µP-T
electric standby power failure are fully automatic. Unit Self Check Test” on page 60).
1. Perform a Manual Pretrip Inspection (see Manual Pretrip
CAUTION: The Electric Power Icon will not appear Inspection chapter).
in the display if electric power is not present (the unit 2. Press the OFF key to make sure the unit is turned off.
is not plugged in), or if there are electrical voltage or
3. Connect the electric power receptacle to an appropriate
phase problems while the power cord is connected to
electric power supply (see “Electric Standby” in the
a power outlet. Under these conditions, when the
Specifications chapter).
microprocessor power switch is turned on and the ON
key is pressed, the unit will start and run on diesel CAUTION: Always turn the electric power supply off
automatically. when handling, connecting, or disconnecting high
voltage power cords.
88
4. Turn the high voltage power supply on. The Automatic Unit Fails to Start
Phase Correction system adjusts the phase sequence of the
power supply to correspond to the wiring of the electric If cooling or heating is required by the controller and the
motor. electric motor fails to start (Alarm Codes 36 or 38): -
5. Press the ON key. If the controller determines the unit 1. Press the OFF key to turn the unit off.
should cool or heat, the appropriate icons will appear and 2. Determine and correct the cause for not starting.
the electric motor will start. It may not start if the return air
3. Clear the alarm codes. Clearing the codes will reset the
sensor is within a few degrees of setpoint.
electric motor overload.
6. Complete an After Start Inspection (see “After Start
Inspection” on page 63).
7.
CAUTION: Electric operation mode is not stored in
the controller if the microprocessor power switch is
turned OFF. Turning the switch back ON again, even
with the power cord connected, will not assure start
up in Electric Standby. If the voltage is low or an
electric phase is missing, the Electric icon will not be
present in the display and the unit will start in diesel.
89
90
Loading and Enroute Inspections
Thermo King refrigeration units are designed to maintain the 4. Pre-cool the cargo compartment. Adjust the setpoint to the
required temperature for the product being carried during its desired cargo temperature and allow the unit to run a
time in transit. Because of the unit’s unique design, special care minimum of 30 to 60 minutes (longer if possible) before
is required during loading to prevent cargo spoilage. loading. Check to be certain the setpoint temperature is
correct for the cargo.
Pre-Loading Inspection Pre-cooling before loading will remove residual heat and
moisture from the cargo compartment and prepare it to
1. Inspect all door seals, including vent doors, for condition receive the refrigerated load. Pre-cooling also provides a
and a tight seal with no air leakage. good test of the refrigeration system.
2. Inspect the cargo compartment inside and out for damaged 5. Make sure products are pre-cooled to the proper
or loose skin and insulation. temperature before loading. Any variance should be noted
3. Inspect the inside of the cargo compartment for damaged on the manifest.
walls, air ducts, floor channels or “T” flooring, clogged 6. Supervise product loading to make sure that there is
defrost drain tubes, and clogged or damaged floor sufficient air space around and through the load so air flow
channels which could block the air return, creating is not restricted.
isolated areas in the load that are warmer than the desired
temperature.
001 91
1. Unit Inspection
2. Good Outside Air Circulation
3. Gaskets Equally Compressed
4. Clear Defrost Drains
5. Tight Doors
Good Air Circulation Around
6.
Load
Interior and Exterior Walls and
7.
Insulation in Good Condition
Cargo at Proper Temperature
8.
Prior to Loading
Figure 33: Loading Considerations
92
Inspecting the Load 3. While inspecting to see that the cargo is loaded properly,
make sure the evaporator inlets and outlets are not
Never assume that the product has been loaded properly. Watch blocked.
for and perform the following tasks. It takes only a few
minutes and could save you or your employer considerable 4. Close or supervise the closing of the cargo compartment
time and money later on. doors. Make sure they are securely locked.
1. Make sure the unit is off before opening the cargo 5. Check to make sure the unit setpoint is set at the desired
compartment doors. During operation, the unit blows out temperature as listed on the manifest.
refrigerated air, and draws in outside air. 6. If the unit was stopped, restart using the appropriate
NOTE: The unit can be run with the doors open if the starting procedure outlined in this manual.
truck is backed into a refrigerated warehouse with tight 7. Repeat the after-start inspection.
door seals.
8. Defrost the unit 30 minutes after loading by starting a
2. Perform a final check of the load temperature. If the load manual defrost cycle.
is too hot or too cold, make a final notation on the
manifest.
CAUTION: Make sure cargo is pre-cooled to the

proper temperature before loading. The unit is
designed to maintain temperature, not cool an
above-temperature load.
93
Enroute Inspections c. The evaporator is plugged with frost. Initiate a manual

defrost cycle. The defrost cycle will be automatically
NOTE: Enroute inspections are recommended every four terminated.
hours for the prevention of damage to the cargo.
d. Improper air circulation within the cargo
1. Note the setpoint to make certain no one has altered the compartment. Inspect the cargo compartment (if
setting since picking up the load. possible) to determine if the evaporator fans are
2. Note the return air temperature reading. It should be working and properly circulating the air. Poor air
within the desired temperature range. If the return air circulation can be due to improper loading of the
temperature reading is not within the desired temperature cargo or shifting of the load, or the fan belt slipping.
range, it indicates one of the following: You can check the fan belt tension by depressing the
belt with your thumb. A 0.5 in. (13 mm) deflection is
a. The unit has not had sufficient time to pull down the
normal.
temperature. Refer to log, if possible, for history of
load (for example, above temperature load, properly WARNING: The unit may START automatically AT
pre-cooled cargo compartment, length of time on ANY TIME while it is turned ON. Make sure to turn
road). the unit OFF before opening unit doors or inspecting
b. The unit is in defrost or has just completed defrost. any part of the unit.
NOTE: You can cancel defrost by turning the unit off, e. The unit did not start automatically. If the unit
then restarting the unit. cranked without starting, determine and correct the
cause for not starting.
94
f. The unit may have a low refrigerant charge. If liquid

CAUTION: Stop the unit if the compartment
is not showing in the unit receiver tank sight glass, the
temperature remains outside the desired temperature
refrigerant charge may be low. Adding refrigerant or
range from the setpoint on two consecutive 30 minute
repairing the refrigeration system requires a
inspections. Contact the nearest Thermo King
competent mechanic. Refer such problems to the
Service Center or your company office immediately.
nearest Thermo King dealer or authorized Service
Take all necessary steps to protect and maintain
Center, or call the Thermo King Cold Line telephone
proper load temperature.
number shown on the inside back cover of this
manual for referral. 3. Initiate a Manual Defrost cycle after each Enroute
NOTE: If the temperature in the compartment is not Inspection.
within the desired temperature range, repeat the Enroute
Inspection every 30 minutes until the compartment
temperature comes within the desired temperature range.
95
96
Specifications
Engine Specifications for TS-200 and TS-300
Engine Thermo King TK 3.74
Fuel Type Use Diesel Fuel only.
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity Crankcase and filter: 9.1 quarts (8.6 liters)
With bypass oil filter: 10.1 quarts (9.5 liters)
Fill to full mark on dipstick
Oil Type: Mineral Oil API Classification CG-4 (or better)
Synthetic Oil* (After First 500 Hours) API Classification CG-4 (or better)
* Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an
emergency requires addition of petroleum oil. Mixing is not recommended, however, since it will dilute the superior
performance properties of the synthetic oil.
97
Specifications
Engine Specifications for TS-200 and TS-300 (Continued)

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 20 to 50 psig (138 to 345 kPa) in low speed
40 to 60 psig (276 to 414 kPa) in high speed
Engine RPM: Low Speed Operation 1625 ± 25 RPM
High Speed Operation 2450 ± 50 RPM
Cooling System Capacity 5.5 quarts (5.2 liters) with overflow tank
Engine Coolant Type: Conventional Conventional coolant (antifreeze) is green or blue-green. Units
equipped with conventional coolant do not have an ELC nameplate
on the expansion tank.
CAUTION: Make sure you know what type of coolant is in your unit. Do
not mix conventional coolant and ELC.
98
Specifications
Engine Specifications for TS-200 and TS-300 (Continued)

Engine Coolant Type (continued):
ELC (Extended Life Coolant) ELC is red. Units equipped with ELC have an ELC nameplate on the
expansion tank (see “Safety Decals and Locations”).
Use a 50/50 concentration of any of the following equivalents:
Texaco ELC (16445, 16447)
Havoline Dex-Cool® (7994, 7995, 7997, 7998)
Havoline XLC for Europe (30379, 33013)
Shell Dexcool® (94040)
Shell Rotella (94041)
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
Engine Thermostat 180 F (82 C)
Radiator Cap Pressure 10 psig (69 kPa)
99
Specifications
Engine Specifications for TS-500

Engine Thermo King TK 3.95
Fuel Type Use Diesel Fuel only.
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity Crankcase and filter: 11.8 quarts (11.2 liters)
With bypass oil filter: 12.8 quarts (12.1 liters)
Fill to full mark on dipstick
Oil Type: Mineral Oil API Classification CG-4 (or better)
Synthetic Oil* (After First 500 Hours) API Classification CG-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 20 to 50 psig (138 to 345 kPa) in low speed
40 to 60 psig (276 to 414 kPa) in high speed
* Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an
emergency requires addition of petroleum oil. Mixing is not recommended, however, since it will dilute the superior
performance properties of the synthetic oil.
100
Specifications
Engine Specifications for TS-500 (Continued)

Engine RPM: Low Speed Operation 1625 ± 25 RPM
High Speed Operation 2425 ± 25 RPM
Cooling System Capacity 4.0 quarts (3.8 liters) with overflow tank
Engine Coolant Type: Conventional Conventional coolant (antifreeze) is green or blue-green. Units
equipped with conventional coolant do not have an ELC nameplate
on the expansion tank.
CAUTION: Make sure you know what type of coolant is in your unit. Do
not mix conventional coolant and ELC.
ELC (Extended Life Coolant) ELC is red. Units equipped with ELC have an ELC nameplate on the
expansion tank (see “Safety Decals and Locations”).
Use a 50/50 concentration of any of the following equivalents:
Texaco ELC (16445, 16447)
Havoline Dex-Cool® (7994, 7995, 7997, 7998)
Havoline XLC for Europe (30379, 33013)
Shell Dexcool® (94040)
Shell Rotella (94041)
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
101
Specifications
Engine Specifications for TS-500 (Continued)

Engine Thermostat 180 F (82 C)
Radiator Cap Pressure 10 psig (69 kPa)
Belt Tension
NOTE: Use belt tension gauge (see Tool Catalog) whenever possible to check belt tension. New belts should be tensioned cold,
and then tensioned cold again after 10 hours of unit operation.
Engine/Jackshaft or Electric Motor 55 to 60 on bottom span between engine and jackshaft or electric motor
Jackshaft or Electric 55 to 60 between alternator and jackshaft or electric motor (or 1/4 in. [6 mm]
Motor/Compressor deflection with 10 lb. [4.5 kg] pressure)
102
Specifications
µP-T Controller - Factory

Settings
tLH = Total Hours Protection Time
EnH = Diesel Engine Hours Diesel Run Time
ELH = Electric Motor Hours Electric Run Time
oIL = Engine Oil Pressure Switch
dFI = Defrost Interval 4 hours
ddr = Defrost Duration 45 minutes
103
Specifications
Electrical Control System

Voltage 12.5 Vdc (nominal)
Circuit Breaker (CB1), Main 50 amp auto reset
Fusible Link (early models) P/N 44-8244
Battery Fuse (later models) 60 amp
Battery Charging System 12 Volt, 23 amp, brush type integral alternator
Voltage Regulator Setting 14.1 Vdc at 70 F (21 C)
Fuses See “Fuses” on page 37.
104
Specifications
Electric Standby (Model 50)

TS-200 Electric Motor
Voltage/Phase/Frequency Horsepower Kilowatts RPM Full Load Amps
230/3/60 6.0 4.5 1765 16.2
460/3/60 6.0 4.5 1765 8.1
220/3/50 5.0 3.7 1465 14.0
380/3/50 5.0 3.7 1465 8.1
230/3/60 7.2 5.4 1765 19.2
460/3/60 7.2 5.4 1765 9.7
220/3/50 6.0 4.5 1460 17.0
380/3/50 6.0 4.5 1460 9.8
105
Specifications
Electric Standby (Model 50) (Continued)

230/3/60 10.0 7.5 1750 24.4
460/3/60 10.0 7.5 1750 12.2
220/3/50 8.0 6.0 1455 20.3
380/3/50 8.0 6.0 1455 11.7
Electric Standby Power Requirements

Supply Circuit Breaker 50 amp for 220-230 Volt (TS-500)
30 amp for 220-230 Volt (TS-200 and TS-300)
20 amp for 380-460 Volt (all units)
Extension Cord Size 380-460 Volt up to 25 ft–12 gauge, up to 75 ft–10 gauge
220-230 Volt up to 25 ft–10 gauge, up to 75 ft–8 gauge
NOTE: Electrical wiring must conform to all local and

national electrical codes.
106
Specifications
R-404A Refrigeration System

Compressor Model: TS-200 and TS-300 TKO 4 hp Scroll
TS-500 TKO 6 hp Scroll
Refrigerant Charge: TS-200 7.0 lb. (4 kg) R-404A
TS-300 7.2 lb. (4 kg) R-404A
TS-500 9.0 lb. (4 kg) R-404A
Compressor Oil Charge* 1.6 quarts (1.5 liters)
Ester Base type oil TK 203-433 (Required for scroll compressor)
Suction Pressure Regulator Setting: TS-200 28 to 30 psig (193 to 207 kPa)
TS-300 36 to 38 psig (248 to 262 kPa)
Throttling Valve Setting: TS-500 28 to 30 psig (193 to 207 kPa)
Heat/Defrost Method Engine Operation: Hot gas
Electric Operation: Hot gas (and optional electric heater strips)
High Pressure Cutout Switch Opens at 470 psig (3241 kPa) or higher (shutdown)
Automatic reset at 375 psig (2586 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be
measured so that the same amount of oil can be added before placing the replacement compressor in the unit.
107
Specifications
R-404A Refrigeration System (Continued)

Defrost Time Interval Programmable in 2, 4 or 6 hour increments.
Factory preset at 4 hours.
Air Switch Setting: TS-200 and TS-300 0.9 in. (22.8 mm) H2O
TS-500 1.5 in. (38 mm) H2O
WARNING: Use ONLY ester based refrigeration WARNING: When servicing Thermo King R404A
compressor oil in this unit’s R404A refrigeration refrigeration systems, use only those service tools
system. certified for and dedicated to R404A refrigerant and
DO NOT use ester based oil in other Thermo King ester based compressor oils. Residual non-HFC
units. refrigerants and non-ester based oils will
DO NOT mix ester based oil with PAG or standard contaminate this unit’s refrigeration system.
synthetic compressor oils.
Keep ester based compressor oil in tightly sealed
containers. If ester based oil becomes contaminated
with moisture or standard oils, dispose of properly -
DO NOT USE!
108
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep After first week of operation:
your Thermo King unit in top operating condition. The
• Check belt tension.
following general schedule is provided to assist in monitoring
that maintenance. • Tighten unit mounting bolts.
The schedule covers units with conventional coolant and units • Check coolant level.
with ELC. See “ELC (Extended Life Coolant)” on page 31 for • Check refrigerant oil level.
more information about coolants.
• Check refrigerant level.
The schedule also covers units with and without EMI 2000.
See “EMI 2000” on page 32 for more information about EMI
2000.
For more specific detail, see the maintenance manual for your
unit and to the PreTrip Inspection chapter in this manual.
109
Pretrip 1,200 2,000 Annual Inspect/Service These Items

Hours Hours 3,000
NOTE: The 1,200 hour maintenance interval may be extended to 2,000 hours or
Hours
1 year (whichever occurs first) when equipped with EMI fuel filter and EMI bypass
oil filter.
Engine
NOTE: These service intervals require the use of either CG-4 mineral oil or synthetic
oil.
• Check fuel supply.
• • Check engine oil level.
• • Inspect belts for condition and proper tension.
• • Check engine oil pressure; hot, high speed. Minimum 40 psig (276 kPa,
2.8 bar).
• • • Listen for unusual noises, vibrations, etc.
110

Hours Hours 3,000
Hours
oil filter.
Engine (continued)
• • Dry air cleaner. Check air restriction indicator (if so equipped). Change air
cleaner element when indicator reaches 25 in. Replace air cleaner element at
2,000 hours or 1 year (whichever occurs first) if air restriction indicator has not
reached 25 in.
If not equipped with an air restriction incicator, replace air cleaner element at
2,000 hours or 1 year (whichever occurs first).
• Clean and service crankcase breather and check air cleaner hose for damage.
• Change standard (white) fuel filter.
• Change EMI 2000 (black) fuel filter.
• Inspect and clean fuel prefilter and electric fuel pump filter.
• Drain water from fuel tank and check vent.
• Check and adjust engine speeds (high and low speed).
111

Hours Hours 3,000
Hours
oil filter.
Engine (continued)
• Check condition of engine mounts.
• Maintain year around antifreeze protection at –30 F (–34 C).
— Change green engine coolant every 2 years.
— Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank (see “Safety
Decals and Locations”).
Engine Oil Change Intervals (see below)
NOTE: Change engine oil and filters (hot).
• Oil change interval with API classification CG-4 (or better) mineral oil or
synthetic oil.
• Oil change interval with API classification CG-4 (or better) mineral oil or
synthetic oil, and EMI 2000 bypass oil filter.
112

Hours Hours 3,000
Hours
oil filter.
Electrical
• Check controller for alarms.
• Run Unit Self Check Test. See “µP-T Unit Self Check Test.”
• • Check battery voltage screen.
• Inspect battery terminals and electrolyte level.
• Inspect electrical contacts for pitting or corrosion.
• Inspect wire harness for damaged wires or connections.
• Check calibration of return and discharge air sensors, and optional temperature
sensors, in 32 F (0 C) ice water.
• Check air switch setting.
• Inspect alternator bearings* and brushes.
• Inspect electric motor bearings* (Model 50).
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
113

Hours Hours 3,000
Hours
oil filter.
Refrigeration
• • Check refrigerant level.
• • Check compressor oil level.
• • Check suction pressure regulator or throttling valve setting on defrost or heat.
• Check discharge and suction pressures.
• Check compressor efficiency.
— Replace dehydrator and compressor oil filter every two years.
114

Hours Hours 3,000
Hours
oil filter.
Structural
• • Visually inspect unit for fluid leaks (coolant, oil, refrigerant).
• • Visually inspect unit for damaged, loose or broken parts (includes air ducts and
bulkheads, if so equipped).
• • Inspect clutch for shoe and anchor bushing wear with a mirror. Check
bearings.*
• Inspect idlers, fan shafts and jackshaft for leakage and bearing wear.*
• Clean entire unit including condenser and evaporator coils and defrost drains.
• Check defrost damper operation.
• Check all unit, fuel tank, engine and electric motor mounting bolts, brackets,
lines, hoses, etc.
* With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
115
116
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50047 for the Thermo King
Self-Powered Truck Unit Warranty.
117
Warranty
118
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.
001 119
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 earth’s
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.
120
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.
121
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 earth’s
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.”
122
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.
123
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.
124
Index
Symbols C
µP-T Controller - Factory Settings 103 Checking the Software Revision 65
µP-T System Description 47 Clutch 33
µP-T Unit Self Check Test 60 Compressor High Temperature Cutout Switch 37
Compressor Oil Sight Glass 36
A Compressor, TKO Scroll 33
After Start Inspection 63 COOL Icon 49
Air Restriction Indicator 36 Coolant ExpansionTank 36
alarm codes Coolant Type, Engine 98, 101
Code 84 (restart null) 71 CYCLE-SENTRY Icon 49
Code 85 (forced unit operation) 71
corrective action 70 D
repair 69 DAS - Data Acquisition System 34
types 70 Defrost 34
ALARM Icon 49 DEFROST Icon 49
Automatic Start/Stop Operation 11 DEFROST Key 48
Design Features 30
B Display Icons 49
Belt Tension Specifications 102 Displaying Operating Data 56
DOWN ARROW Key 48
125
Index
E F
ELC (Extended Life Coolant) 31 First Aid - Refrigerant Oil 13
ELECTRIC Icon 49 forced unit operation alarm code 71
Electric Motor Overload Relay 38 Fuses 37
Electric Standby 35
Electric Standby Operation 87 H
Starting the Unit 88 HEAT Icon 49
Electric Standby Specifications 105 High Pressure Cutout 38
Electrical Control System 104 High Pressure Relief Valve 38
Electrical Control System Specifications 104
Electrical Hazard 12 I
Emergency Cold Line 131 Initiating a Manual Defrost Cycle 57
EMI 2000 32 inspecting load 93
Engine Compartment Components 36 introduction 9
Engine Components 40, 42
Engine Coolant Level Sensor 38 K
Engine Oil Dipstick 36 Keypad Keys 48
Engine, TK 3.74 Specifications 97
Engine, TK 3.95 Specifications 100 L
enroute inspections 91, 94 loading inspections 91
ENTER Key 48 loading procedures
Entering the Setpoint 56 pre-loading inspection 91
LOGO Key 48
Low Oil Level Switch 38
126
Index
M Remote Light Indicator Box 51

Maintenance 109 restart null alarm code 71
Maintenance Inspection Schedule 109 Restarting the Unit 64
Manual Pre-Trip Inspection 53
Microprocessor Power Switch 47 S
Safety Decals and Locations 14
O Safety Precautions 11
OFF Key 48 SELECT Key 48
Oil Pressure Sensor 38 Selecting CYCLE-SENTRY or Continuous Mode 58
Oil Type, Compressor 107 Selection of Operating Modes on CYCLE-SENTRY
Oil Type, Engine 97, 100 Equipped Units 59
ON Key 48 Serial Number Locations 129
SETPOINT Icon 49
P Specifications 97
Power Receptacle Box, Model 50 87 Starting the Engine 57
Preheat Buzzer 38
pre-loading inspection 91 U
Understanding The Display 49
R Unit Description 29
Receiver Tank Sight Glass 36 Unit Operation, Thermoguard uPT 55
Refrigerant 12 Unit Options 31
Refrigerant Oil 12 Unit Protection Devices 37
Refrigeration System Specifications 107 UP ARROW Key 48
Remote Control Panel 48
127
Index
V
Viewing and Clearing Alarm Codes 67
Viewing Prompt and Display Screens 66
W
warranty 117
Water Temperature Sensor 38
WHISPER Icon 49
WHISPER Key 48
128
Serial Number and Refrigerant Label
Locations
Write the unit model and unit serial number in the spaces
provided in the following Emergency Cold Line chapter. This
information is needed to service the unit.
Figure 35: Compressor Serial Number Location
Figure 34: Engine Serial Number Location
129
Serial Number and Refrigerant Label Locations
1
2
Figure 37: Laminated Unit Serial Number Plate
• Nameplate on inside of top right side of unit frame near

three-way valve.
1. Refrigerant Type Figure 38: Refrigerant Type Label

2. Unit Serial Plate
• This label identifies the type of refrigerant in the unit.
Figure 36: Label Locations
130
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. Have the
following information available when you call:
Name ________________Title _________________
Company _____________Phone No. _____________
Address ___________________________________
Location ______________Destination ____________
Product _______________Required Temp. ________
AKB12
Present Temp. __________Time Out Of Service _____
Unit Model _______________Problem ___________
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any Serial Number_______________________________
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
131
132
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.
133 001
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
001 134

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TS-200, 300, 500 Series

TK 50773-1-OP (Rev. 5, 08/03)

Copyright© 1999 Thermo King Corp., Minneapolis, MN, USA

Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 µP-T System Description . . . . . . . . . . . . . . . . . . . . . 47

Electric Standby Operation . . . . . . . . . . . . . . . . . . . 87 Maintenance Inspection Schedule . . . . . . . . . . . . 109

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 131

WARNING: Protect skin and clothing from First Aid–Refrigerant Oil

First Aid–Refrigerant Ingestion: Do not induce vomiting. Immediately contact

Safety Decals and Locations

Figure 1: Antifreeze Caution ARB108

Model 50 Units (Electric Standby)

Figure 7: High Voltage Caution

Figure 8: Emission Control Label Figure 9: Engine Family Name

Figure 10: Emission Control Label Location

Manufacturer Explanation Of at a Thermo King authorized service dealer. To obtain the

• Gasket Muffler Gasket If an emission-related part or component fails during the

• Miscellaneous hoses, clamps, connectors and sealing

Design Features • Fahrenheit and Celsius Scales

• Air Cleaner, Dry Type • Fuel Filter, Spin On

• Air Switch • In-Cab Remote Display

• Alarm Code Display • Microprocessor Controller µP-T

• Alternator, 23 amp • Oil Filter, Full Flow

• Automatic Phase Correction (Model 50) • Oil Pressure Display

• Battery Voltage Display • R-404A

• Bypass Oil Filter (As of First Quarter 2001) • Scroll Compressor

• Condenser Top Screen • Smart Defrost

• Continuous System Monitoring • Stainless Steel Condenser Hardware

• Coolant Expansion Tank • Stainless Steel Evaporator Hardware

• Coolant Temperature Display • Tapered Roller Bearing Jackshaft (Model 30)

• Corrosion Resistant Protection • TherMaxTM System, Defrost/Heating

• CYCLE-SENTRY Start/Stop Controls • TK 3.74 Engine (TS-200 and TS-300)

• Diesel/Electric Autoswitching • TK 3.95 Engine (TS-500)

• Electric Hourmeter • Total Run Hourmeter

• Engine Hourmeter • Unit Self Check-pretripping

Unit Options Engine

Clutch external relays to control unit operation. When the controller is

Engine Compartment CAUTION: Do not remove expansion tank cap while

Unit Protection Devices Fuse Size Function

Figure 12: Front View

1. Engine 8. Liquid Injection Valve

1. Engine 8. Receiver Tank

See Figure 13: “Engine Components TS-500” on page 42.

1. Microprocessor 3. Interface Board

Figure 15: Control Box

Figure 16: Remote Control Panel

Figure 17: North American Power Receptacle Box

Figure 18: Microprocessor Power Switch

Remote Control Panel Keypad Keys

OFF Key: Turns the unit off.

SELECT Key: Scrolls through the prompt and display

WHISPER Key: Disables high speed diesel mode

Understanding the Display Display Icons

CYCLE-SENTRY Icon: Appears when

Reading a Typical Display

Figure 22: Standard Display

The Standard Display appears when the unit is turned on and

1. Cool (White) The unit is cooling.

Figure 23: Remote Indicator Light Display

Operation in Confined Spaces NOTE: Refer to THERMOGUARD µP-T Microprocessor

WARNING: The unit may Start automatically AT