Thermo King SB-190 30 User manual

SB-190 30
TK 51245-2-MM (Rev. 2, 12/03)
Copyright© 2001 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

The maintenance information in this manual covers unit model SB-190 30 (002006)
For further information, refer to…
SB-190 30 Operator’s Manual TK 51246
SB-190 30 Parts Manual TK 51214
THERMOGUARD µP-VI Microprocessor Control System Diagnosis
Manual TK 50566
X214, X418, X426 and X430 Compressor Overhaul Manual TK 6875
Diagnosing TK Refrigeration System TK 5984
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
ElectroStatic Discharge (ESD) Training Guide TK 40282
The information in this manual is provided to assist owners, operators and service people in the proper
upkeep and maintenance of Thermo King units.
This manual is published for informational purposes only and the information so provided should not be considered
as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be
consulted.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to,
the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manu-
facturer’s plants as, in the manufacturer's judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantabil-
ity, or warranties arising from course of dealing or usage of trade, are made regarding the information, rec-
ommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held
liable in contract or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the installation of any
Thermo King product or its mechanical failure.

Recover Refrigerant
At Thermo King, we recognize the need to preserve the environ-
ment 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 regula-
tions concerning the use of refrigerants and the certification of
technicians. For additional information on regulations and tech-
nician certification programs, contact your local THERMO KING
dealer.

Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Unit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Unit Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Manual Pretrip Inspection (Before Starting Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Starting Unit with Electronic Full Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Selection of Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Restarting Unit—Diesel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
After Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Loading Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Australian Bosch Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Battery (Dealer Supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fuse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Thermoguard µP-VI Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Table of Contents (continued)
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Antifreeze Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Bleeding Air From the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Draining Water From Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuel Filter/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Injection Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjusting Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Positive Crankcase Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine Air Cleaner (Filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Model 30 Belt Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Model 30 Fan Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Refrigeration Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Refrigerant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
High Pressure Cutout Switch (HPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Three-Way Valve Condenser Pressure Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Electronic Throttling Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Pressure Transducers (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hot Gas Solenoid (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Refrigeration Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor Coupling Removal (Model 30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Compressor Coupling Installation (Model 30) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Discharge Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
In-line Condenser Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Condenser Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Bypass Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Table of Contents (continued)
Refrigeration Service Operations (continued)
Three-Way Valve Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Three-Way Valve Condenser Pressure Bypass Check Valve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Pilot Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Suction Vibrasorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Discharge Pressure Transducer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Suction Pressure Transducer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Electronic Throttling Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Compressor Oil Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hot Gas Solenoid Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Condenser, Evaporator, and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Condenser and Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Fan Shaft Assembly Overhaul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Idler Assembly Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Defrost and Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Cool Cycle with Electronic Throttling Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Heat/Defrost Cycle with Electronic Throttling Valve (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wiring Diagrams and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

i
Safety Precautions
GENERAL PRACTICES
1. ALWAYS WEAR GOGGLES OR SAFETY
GLASSES. Refrigerant liquid and battery acid can per-
manently damage the eyes (see First Aid under Refrig-
eration Oil).
2. Never operate the unit with the compressor discharge
valve closed.
3. Keep your hands clear of the fans and belts when the
unit is running. This should also be considered when
opening and closing the compressor service valves.
4. Make sure the gauge manifold hoses are in good condi-
tion. Never let them come in contact with a belt, fan
motor pulley, or any hot surface.
5. Never apply heat to a sealed refrigeration system or
container.
6. Fluorocarbon refrigerants, in the presence of an open
flame or electrical short, produce toxic gases that are
severe respiratory irritants capable of causing death.
7. Make sure all mounting bolts are tight and are the cor-
rect length for their particular application.
8. Use extreme caution when drilling holes in the unit.
The holes may weaken structural components. Holes
drilled into electrical wiring can cause fire or explosion.
9. Use caution when working around exposed coil fins.
The fins can cause painful lacerations.
10. Use caution when working with a refrigerant or refrig-
eration system in any enclosed or confined area with a
limited air supply (for example, a bus or garage).
Refrigerant tends to displace air and can cause oxygen
depletion, resulting in suffocation.
11. EPA Section 608 Certification is needed to work on
refrigeration systems.
REFRIGERANT
Although fluorocarbon refrigerants are classified as safe
refrigerants, certain precautions must be observed when
handling them or servicing a unit in which they are used.
When exposed to the atmosphere in the liquid state, fluoro-
carbon refrigerants evaporate rapidly, freezing anything
they contact.
First Aid
In the event of frost bite, the objectives of First Aid are to
protect the frozen area from further injury, to warm the
affected area rapidly, and to maintain respiration.
• EYES: For contact with liquid, immediately flush eyes
with large amounts of water and get prompt medical
attention.
• SKIN: Flush area with large amounts of lukewarm
water. Do not apply heat. Remove contaminated cloth-
ing and shoes. Wrap burns with dry, sterile, bulky
dressing to protect from infection/injury. Get medical
attention. Wash contaminated clothing before reuse.
• INHALATION: Move victim to fresh air and use CPR
or mouth-to-mouth ventilation, if necessary. Stay with
victim until arrival of emergency medical personnel.
REFRIGERANT OIL
Avoid refrigeration oil contact with the eyes. Avoid pro-
longed or repeated contact of refrigeration oil with skin or
clothing. Wash thoroughly after handling refrigeration oil to
prevent irritation.
First Aid
In case of eye contact, immediately flush with plenty of
water for at least 15 minutes. CALL A PHYSICIAN. Wash
skin with soap and water.

Safety Precautions (Rev. 02/03)
ii
ELECTRICAL HAZARDS
High Voltage
When servicing or repairing a refrigeration unit, the possi-
bility of serious or even fatal injury from electrical shock
exists. Extreme care must be used when working with an
operating refrigeration unit. Lethal voltage potentials can
exist on connections in the high voltage tray of the control
box.
Precautions
1. When working on high voltage circuits on the refrigera-
tion unit, do not make any rapid moves. If a tool drops,
do not grab for it. People do not contact high voltage
wires on purpose. It occurs from an unplanned move-
ment.
2. Use tools with insulated handles that are in good condi-
tion. Never hold metal tools in your hand if exposed,
energized conductors are within reach.
3. Treat all wires and connections as high voltage until a
meter and wiring diagram show otherwise.
4. Never work alone on high voltage circuits on the refrig-
eration unit, another person should always be standing
by in the event of an accident to shut off the refrigera-
tion unit and to aid a victim.
5. Have electrically insulated gloves, cable cutters and
safety glasses available in the immediate vicinity in the
event of an accident.
First Aid
IMMEDIATE action must be initiated after a person has
received an electrical shock. Obtain immediate medical
assistance if available.
The source of shock must be immediately removed by
either shutting down the power or removing the victim from
the source. If it is not possible to shut off the power, the wire
should be cut with either an insulated instrument (e.g., a
wooden handled axe or cable cutters with heavy insulated
handles) or by a rescuer wearing electrically insulated
gloves and safety glasses. Whichever method is used do not
look at the wire while it is being cut. The ensuing flash can
cause burns and blindness.
If the victim has to be removed from a live circuit, pull the
victim off with a non-conductive material. Use the victim’s
coat, a rope, wood, or loop your belt around the victim’s leg
or arm and pull the victim off. DO NOT TOUCH the victim.
You can receive a shock from current flowing through the
victim’s body. After separating the victim from power
source, check immediately for the presence of a pulse and
respiration. If a pulse is not present, start CPR (Cardio Pul-
monary Resuscitation) and call for emergency medical
assistance. If a pulse is present, respiration may be restored
by using mouth-to-mouth resuscitation, but call for emer-
gency medical assistance.
Low Voltage
Control circuits used in the refrigeration unit are low volt-
age (12 volts dc). This voltage potential is not considered
dangerous, but the large amount of current available (over
30 amperes) can cause severe burns if shorted or ground.
Do not wear jewelry, a watch or rings. These items can short
out electrical circuits and cause severe burns to the wearer.

1
Specifications
ENGINE
Model Thermo King se 2.2
Number of Cylinders 4
Cylinder Arrangement In-line vertical, number 1 on pulley end
Firing Order 1-3-4-2
Direction of Rotation Counterclockwise viewed from flywheel end
Fuel Type No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity: Crankcase 14.2 liters (15 quarts) crankcase
Fill to full mark on dipstick
Oil Type: Mineral Oil API Classification CF-4 or CG-4
Synthetic Oil (After First 500 Hours) API Classification CF-4 or CG-4
Oil Viscosity -15 to 40 C (5 to 104 F): SAE 15W-40
-20 to 40 C (-4 to 104 F): SAE 10W-40
-20 to 30 C (-4 to 86 F): SAE 10W-30
-30 to 30 C (-22 to 86 F): SAE 5W-30
Engine rpm: Low Speed Operation 1425 to 1475 rpm
High Speed Operation 2175 to 2225 rpm
Engine Oil Pressure 276 to 448 kPa (40 to 65 psi, 2.76 to 4.48 bar,
2.814 to 4.568 Kg/cm2)
Intake Valve Clearance 0.40 mm (0.016 in.)
Exhaust Valve Clearance 0.40 mm (0.016 in.)
Valve Setting Temperature 21 C (70 F)
Fuel Injection Timing 0.5 mm (0.02 in.) at 14°BTDC (timed on No. 1
cylinder)
Low Oil Pressure Switch (Normally Closed) 117 ± 21 kPa (17 ±3 psi, 1.17 ± 0.21 bar,
1.19 ± 0.214 Kg/cm2)
Engine Coolant Thermostat 82 C (180 F)
Coolant System Capacity 9.5 liters (10 quarts)
Radiator Cap Pressure 48 kPa (7 psi, 0.48 bar, 0.489 Kg/cm2)
Drive Direct to compressor; belts to fans, alternator and
water pump
BELT TENSION Tension No. on TK Gauge P/N 204-427
Model 30:
Alternator Belt 35
Lower Fan Belt (Engine to Idler) 67
Upper Fan Belt (Fan to Idler) 74

Specifications (Rev. 12/03)
2
REFRIGERATION SYSTEM
Compressor Thermo King X430L
Refrigerant Charge—Type: 13 lb (5.9 kg)—R-404A
Compressor Oil Charge 4.3 qt (4.1 liters)*
Compressor Oil Type Polyol Ester type P/N 203-413
Throttling Valve Setting 27 to 29 psi (187 to 200 kPa) Standard with non-ETV
units
Heat/Defrost Method: Engine Operation Hot gas
High Pressure Cutout 470 ± 7 psi (3241 ± 48 kPa)
Automatic reset @ 375 ± 38 psi (2586 ± 262 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.
ELECTRICAL CONTROL SYSTEM
Voltage 12.5 Vdc
Battery One, group C31, 12 volt battery
Fuse Link Rating 110 amps @ 72 F (22 C)
Fuse F3—Power to Defrost Relay/Damper 15 amp
Fuse F9—Main Control Power 40 amp
Fuse F18—Power to High Speed Solenoid 15 amp
Fuse F21—Power to On/Off Switch 25 amp
Other Fuses 2 or 5 amp
Battery Charging: Model 30 12 volt, 37 amp, brush type alternator
Voltage Regulator Setting 13.8 to 14.3 volts @ 77 F (25 C)
NOTE: Fuse F15 (Bypass resistor for Prestolite Alternator) must be removed for the Bosch Alternator.

Specifications (Rev. 12/03)
3
ELECTRICAL COMPONENTS
NOTE: Disconnect components from unit circuit to check resistance.
Current Draw (Amps) Resistance—Cold
at 12.5 Vdc (Ohms)
Fuel Solenoid 1.4 8.8
Damper Solenoid 5.7 2.2
Throttle Solenoid 2.9 4.3
Glow Plug 7.1 1.8
Pilot Solenoid 0.7 17.0
Starter Motor—Gear Reduction Type 250-375*
Modulation Valve (Optional) 1.7** 7.6
Hot Gas Bypass Valve (Optional) 1.1 11.1
* On-the-engine cranking check. Bench test is approximately 100 amps on the direct drive starter and
approximately 80 amps on the gear reduction starter.
**Test at 12.5 Vdc
SMART REEFER µP-VI MICROPROCESSOR TEMPERATURE CONTROLLER
Temperature Controller:
Type Electronic THERMOGUARD µP-VI Microprocessor with digital thermostat, thermometer and fault indicator monitor
Setpoint Range -20 to 80 F (-29 to 27 C)
Programmable setpoint range to -25 to 90 F (-32 to 32 C)
Digital Temperature Display -40 to 99.9 F (-40 to 40 C)
Internal Defrost Timer:
Temperature Pulldown 2, 4, 6, 8 or 12 hours (selectable, standard setting 4)
Temperature In-range 4, 6, 8 or 12 hours (selectable, standard setting 6)
Defrost Initiation: Coil Sensor Coil must be below 45 F (7 C)
Defrost Termination: Coil Sensor Terminates defrost with coil temperature above 58 F (13 C)
Interval Timer Terminates defrost 30 to 45 minutes (programmable) after initiation
if coil sensor has not terminated defrost

4

5
Maintenance Inspection Schedule
Fuel
Island
Pre-trip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
Engine
•Check fuel supply and engine oil level.
•Inspect belts for condition and proper tension
(belt tension tool No. 204-427).
••••Check engine oil pressure hot, on high speed (should display “OK”).
••••Listen for unusual noises, vibrations, etc.
*3,000 hours or two years, whichever occurs first.

Maintenance Inspection Schedule (Rev. 12/03)
6
Engine (Continued)
• • • Check air cleaner restriction indicator (change when indicator reaches 22 in.).
Replace EMI 3000 air cleaner element at 3,000 hours or two years (whichever
occurs first) if air cleaner restriction indicator has not reached 22 in. The EMI
3000 air cleaner element has a nameplate that reads “EMI 3000.”
• • • Drain water from fuel tank and check vent.
• • • Inspect/clean fuel transfer pump inlet strainer (pre-filter).
• • • Replace standard (silver) fuel filter/water separator.
• Replace EMI 3000 (black) fuel filter/water separator.
• • • Check and adjust engine speeds (high and low speed).
• Check condition of engine mounts.
• Check condition of drive coupling bushings per Service Bulletin T&T 171.
••••Checkenginecoolantlevelandantifreeze protection (-30 F [-34 C]).
Fuel
Island
Pre-trip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
*3,000 hours or two years, whichever occurs first.

Maintenance Inspection Schedule (Rev. 12/03)
7
Engine (Continued)
ENGINE OIL CHANGE INTERVALS (see below)
NOTE: Change engine oil and filter (hot).
• • • Standard blue (or silver) oil filter.
• EMI 3000 (black) oil filter. Requires oil with API Rating CG-4 or better.
NOTE: The engine oil change interval is extended to 3,000 hours or two years when equipped with the optional EMI 3000
oil filter and oil with API Rating CG-4 or better. EMI 3000 filters are black with gold lettering.
— Change green or blue-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”).
— Test fuel injection nozzles at least every 10,000 hours
per TK Service Bulletin T&T 052.
Fuel
Island
Pre-trip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
*3,000 hours or two years, whichever occurs first.

Maintenance Inspection Schedule (Rev. 12/03)
8
Structural
••••Visuallyinspectunitforfluidleaks.
••••Visuallyinspectunitfordamaged,looseorbrokenparts(includesairducts).
• • • Inspect tapered roller bearing fanshaft and idler for leakage and bearing wear.
• • • Clean entire unit including condenser and evaporator coils and defrost drains.
• • • Check all unit, fuel tank and electric motor mounting bolts, brackets, lines,
hoses, etc.
• • • Check evaporator damper door adjustment and operation.
Refrigeration
••••Checkrefrigerantlevel.
• • • Check compressor oil level.
• • • Check throttling valve regulating pressure on defrost.
• Check compressor efficiency and pump down refrigeration system.
Replace dehydrator and check discharge and suction pressure every 2 years.
Electrical
• • • Inspect battery terminals and electrolyte level.
• • • Inspect wire harness for damaged wires or connections.
••••Checkdamperdooroperation
(closes on defrost initiation, opens defrost termination).
• Inspect alternator.
Microprocessor
• Run Pretrip Test (refer to Pretrip Test in this manual)
Fuel
Island
Pre-trip
Every
1,500
Hours
Every
3,000
Hours*
Annual
4,500
Hours
Inspect/Service These Items
*3,000 hours or two years, whichever occurs first.

9
Unit Description
The unit is a one-piece, self-contained, diesel powered
refrigeration-heating unit. The unit mounts on the front of
the trailer with the evaporator portion extending into the
trailer. There is one basic model: Model 30: Cool, hot gas
heat and defrost on engine operation.
During engine operation power is provided by the se 2.2; a
four-cylinder, water-cooled, direct injection diesel engine
with a continuous power rating of 20.7 kW (34.8 hp) @
2200 rpm. The engine uses a spin-on, duel element, full
flow/bypass oil filter and “CF-4/CG-4” rated petroleum
engine oil for extended 1,500 hours maintenance intervals.
The compressor is connected directly to the engine.
SMART REEFER µP-VI Microprocessor
The SMART REEFER µP-VI is a microprocessor control
system designed for a transport refrigeration system. The
µP-VI integrates the following functions: thermostat, digital
thermometer, hourmeters, oil pressure condition, water tem-
perature, ammeter, voltmeter, tachometer, mode indicator,
refrigeration system controller, discharge and suction pres-
sure sensors, and diagnostic system.
The CYCLE-SENTRY system and integral defrost timer,
are standard features. Remote controls, data logging, and
remote status lights are optional features.
The microprocessor mounts inside a weather tight control
box. The LCD display is visible through a transparent cover.
Opening the keypad door provides quick access to the
microprocessor keypad. The keypad is used to control the
operation of the microprocessor.
CYCLE-SENTRY Start-Stop Controls
A CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy. Selecting Continuous or
CYCLE-SENTRY operation (on units equipped with
CYCLE-SENTRY) is accomplished using the microproces-
sor keypad.
WARNING: With the unit On/Off switch in the ON
position, the unit may start at anytime without prior
warning.
NOTE: A buzzer sounds when the unit is automatically
preheating.
NOTE: The microprocessor has an OptiSet™feature that
can lockout CYCLE-SENTRY operation and force Con-
tinuous Run within a programmable range of setpoints. If
this feature is active and the setpoint is within the pro-
grammed lockout range, the CYCLE-SENTRY symbol will
not appear while the unit is automatically starting. The
unit will operate in Continuous Run as long as the set-
point is within the programmed lockout range. Refer to the
appropriate THERMOGUARD Microprocessor Controller
Operation & Diagnostic Manual for specific information
about the OptiSet™ feature.
The CYCLE-SENTRY system automatically starts the unit
on microprocessor demand, and shuts down the unit when
all demands are satisfied. As well as maintaining the box
temperature, engine block temperature and battery charge
levels are monitored and maintained. If the block tempera-
ture falls below 30 F (-1 C), the engine will start and run
until the block temperature is above 90 F (32 C). If the bat-
tery voltage falls to the programmed limit selected by
CYCLE-SENTRY Battery Voltage (typically 12.2 volts)
and Diesel CYCLE-SENTRY mode is selected, the engine
will start and run until the charge rate falls below that pro-
grammed by CYCLE-SENTRY Amps (typically 5
amperes).

Unit Description (Rev. 12/03)
10
Features of the CYCLE-SENTRY system are:
• Offers either CYCLE-SENTRY or Continuous Run
operation.
• Controller regulated all season temperature control.
• Maintains minimum engine temperature in low ambient
conditions.
• Battery Sentry keeps batteries fully charged during unit
operation.
• Variable preheat time.
• Preheat indicator buzzer.
Data Logger- DAS (Optional)
The DAS (Data Acquisition System) is an independent data
logger that logs information from dedicated external DAS
sensors and inputs. The DAS features up to six directly con-
nected sensors. The DAS is also connected through a serial
port to the unit microprocessor. This allows unit operating
information, operating information, alarm codes and com-
partment temperatures to be logged as well. The data can be
retrieved using an IBM®PC compatible laptop or desktop
computer and Thermo King WinTrac 4.1 (or higher) soft-
ware. The computer is connected to the Computer Port on
the front of the control box. Detailed graph or table trip
reports can then be created.
Thermo King X430L Compressor
The unit is equipped with a Thermo King X430L, four-
cylinder compressor with 30 cu. in. (492 cm3) displacement.