Trane Technologies THERMO KING E-200 Series User manual

Revision C
June 2023 TTKK 6611771177--1188--MMMM--EENN
Truck Edition
E-200 Series
Maintenance Manual

©2023 Trane Technologies TK 61717-18-MM-EN
Introduction
This manual is published or in ormational purposes only. Thermo King®makes no representations warranties express
or implied, with respect to the in ormation recommendations and descriptions contained herein. In ormation provided
should not be regarded as all-inclusive or covering all contingencies. I urther in ormation is required, Thermo King
Service Department should be consulted.
TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
oorr aalltteerreedd aass,, iinn tthhee mmaannuu aaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo aa eecctt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
Revision History
Revision A (01/20) Original release
Revision B (11/20) TK Holdover Battery Recycling information
Revision C (06/23) Removed DVDT Filter
General Information
The maintenance information in this manual covers unit models:
E–Series System Numbers TKE200
For further information, refer to:
E-200 Parts Manual TK 61702
E-200 Operator’s Manual TK 61652
E-200 Installation Manual TK 61694
Lithium Ion Battery Safety Manual TK 61900
Direct Smart Reefer IV Microprocessor Control System Diagnostic Manual TK 61714
Direct Smart Reefer IV Microprocessor Control System Diagnostic Manual TK 61714
Direct Smart Reefer III Microprocessor Control System Diagnostic Manual TK 61096
Vehicle Powered Truck Installation Standards and Procedures TK 61588
Diagnosing Thermo King Truck and Trailer Refrigeration Systems TK 5984
Evacuation Station Operation and Field Application TK 40612
Silver Brazing & Soft Soldering TK 7949
Tool Catalog TK 5955
The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo
King units.
Recover Refrigerant
NNoottee In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas
Regulations must be observed when working on refrigeration systems.
At Thermo King®, we recognize the need to preserve the environment and limit the potential harm to the ozone layer
that can result rom allowing re rigerant to escape into the atmosphere.

TK 61717-18-MM-EN 3
We strictly adhere to a policy that promotes the recovery and limits the loss o re rigerant into the atmosphere.
When working on transport temperature control systems, a recovery process that prevents or minimizes re rigerant
loss to the atmosphere is required by law. In addition, service personnel must be aware o the applicable European
Union, National, Federal, State, and/or Local regulations governing the use o re rigerants and certi ication o
technicians. For additional in ormation on regulations and technician programs, contact your local THERMO KING
dealer.
SSeerrvviiccee TToooollss - Use the proper service tools. Gauge mani old sets should include appropriate shuto valves or
disconnects near the end o each service line.
RReeccoovveerryy EEqquuiippmmeenntt - Recovery equipment must be used. Proper recovering, storing and recycling o re rigerants is
an important part o all service work.
SSeerrvviiccee PPrroocceedduurreess - Recommended procedures must be used to minimize re rigerant loss.
CCoommppoonneennttss mmaayy bbee iissoollaatteedd by closing service valves and per orming system pump-downs.
CCoommppoonneennttss uunnaabbllee ttoo bbee iissoollaatteedd or service must be repaired only a ter re rigerant is properly recovered.
R-1 4a/R-404A/R-452A
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUnnlliikkee ootthheerr TThheerrmmoo KKiinngg uunniittss,, PPoollyyvviinnyyll eetthheerr ((PPVVEE)) iiss tthhee oonnllyy ooiill aapppprroovveedd oorr uussee iinn TTHHIISS TThheerrmmoo KKiinngg
uunniitt.. IItt sshhoouulldd nnoott bbee mmiixxeedd wwiitthh aannyy ootthheerr ttyyppee..
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
DDoo nnoott mmiixx PPoollyyvviinnyyll eetthheerr ((PPVVEE)) aanndd ssttaannddaarrdd ssyynntthheettiicc ccoommpprreessssoorr ooiillss.. BBeeiinngg eetthheerr--bbaasseedd,, PPVVEE ddooeess nnoott
hhyyddrroollyyzzee,, ssoo tthhee uussuuaall pprreeccaauuttiioonnss ddoo nnoott aappppllyy oorr mmooiissttuurree ccoonnttaammiinnaattiioonn,, hhoowweevveerr iitt iiss ssttiillll ggoooodd pprraaccttiiccee
ttoo kkeeeepp PPoollyyvviinnyyll eetthheerr ccoommpprreessssoorr ooiill iinn ttiigghhttllyy sseeaalleedd ccoonnttaaiinneerrss.. II PPoollyyvviinnyyll eetthheerr ooiill bbeeccoommeess
ccoonnttaammiinnaatteedd wwiitthh ssttaannddaarrdd ooiillss,, ddiissppoossee oo pprrooppeerrllyy––DDOO NNOOTT UUSSEE..
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
WWhheenn sseerrvviicciinngg TThheerrmmoo KKiinngg RR--113344aa,, RR--440044AA oorr RR--445522AA uunniittss,, uussee oonnllyy tthhoossee sseerrvviiccee ttoooollss cceerrttii iieedd oorr aanndd
ddeeddiiccaatteedd ttoo RR--113344aa//RR--440044AA//RR--445522AA rree rriiggeerraanntt aanndd PPoollyyvviinnyyll eetthheerr ccoommpprreessssoorr ooiillss.. RReessiidduuaall nnoonn--HHFFCC
rree rriiggeerraannttss oorr ooiillss wwiillll ccoonnttaammiinnaattee RR--113344aa//RR--440044AA//RR--445522AA ssyysstteemmss..
IInnttrroodduuccttiioonn

4TK 61717-18-MM-EN
SSaa eettyy PPrreeccaauuttiioonnss ............................................................................................................................................................ 88
Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Auto Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TK Lithium Ion Battery Sa ety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Re rigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Re rigerant Oil Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LowVoltage............................................................................... 13
Controller/Microprocessor Service Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FirstAid....................................................................................... 13
SSppeeccii iiccaattiioonnss .. .. .... .. .... .. .... .. .......... .... .. .... .. .... .. .......... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .... .. .. 1155
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electric Standby Power Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Re rigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressors.................................................................................. 17
Solder Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
UUnniitt DDeessccrriippttiioonn .... .... .. .... .. .... ...... .... .... .. .... .. .... ...... .... .. .... .......... .... ...... .... .. .... .......... .... ...... .... .. .... .......... .... ...... .... .. .... ........ 1199
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Standard Unit Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Options....................................................................................... 19
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Compressor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Condenser................................................................................. 20
Evaporator ................................................................................ 20
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Re rigerant ................................................................................ 20
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Evaporator Drain Line Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electric Standby Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TK Lithium Ion Batteries (i equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
StandardFeatures ......................................................................... 21
OptionalFeatures.......................................................................... 21
Protection Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DSR Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
ControlBox............................................................................... 22
Description............................................................................... 22
UnitControls.............................................................................. 23
Table of Contents

TK 61717-18-MM-EN 5
Standby Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Re rigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Solenoids and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HotGasSolenoid(HGS) .................................................................... 26
Liquid Injection Solenoid (LIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Condenser Inlet Solenoid (CIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Suction Pressure Regulator Valve (SPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Discharge Pressure Regulator Valve (DPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LiquidLineCheckValve..................................................................... 26
Switches and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation ................................................................................. 28
CoolMode................................................................................ 28
NullMode................................................................................ 33
HeatMode................................................................................ 33
DerostMode ............................................................................. 33
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MMaaiinntteennaannccee IInnssppeeccttiioonn SScchheedduullee .... .. .......... .... .. .......... .... ...... .... .. .... .. ...... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... 3399
EElleeccttrriiccaall MMaaiinntteennaannccee.. .. .......... .... .. .... .. .... .. .......... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .... .. .. 4400
Auto Start Hard Stop / Disable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
De rost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
De rost Termination Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
De rost Termination Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Removal ................................................................................. 41
Installation ............................................................................... 41
Liquid Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Condenser Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Condenser Fan Motor Removal and Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal ................................................................................. 42
Installation ............................................................................... 42
Evaporator Fan Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Evaporator Fan Motor Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal ................................................................................. 43
Installation ............................................................................... 43
Drain Line Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drain Line Heater Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal ................................................................................. 43
Installation ............................................................................... 43
Fuses......................................................................................... 45
Fuses: Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Harness Fuses: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TTaabbllee oo CCoonntteennttss

6TK 61717-18-MM-EN
Relays ........................................................................................ 47
Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
AC Components Model 20 and Model 50 Units Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
PowerSupply.............................................................................. 50
Removal ................................................................................. 50
Installation ............................................................................... 51
Compressor Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Testing 115/1/60 and 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
TK Lithium Ion Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
RRee rriiggeerraattiioonn MMaaiinntteennaannccee .. .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .... .. .... .. .......... .... .. .......... .... .. .... ...... .... .. ...... .... .. .......... 5533
Evacuating and Charging the Re rigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checking the Re rigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Testing the Re rigerant Charge with an Empty Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Testing the Re rigerant Charge with a Loaded Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Suction (Low Side) Bump Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Re rigeration System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cleanup Procedure or Small Truck Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Tools Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Clean-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Putting the Unit Back Into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Putting the Unit Back Into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
RRee rriiggeerraattiioonn SSeerrvviiccee OOppeerraattiioonnss .. .... .. ........ .. .... .. .......... .... .. .......... .... .. .... .. .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. ........ 5577
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal................................................................................... 57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Drier.......................................................................................... 58
Removal................................................................................... 58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Discharge Pressure Transducer (DPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removal................................................................................... 59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Condenser Inlet Solenoid (CIS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
OilSeparator.................................................................................. 60
Removal................................................................................... 60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Expansion Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Checking Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Expansion Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal ................................................................................. 62
Low Pressure Cutout Switch (LPCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Low Pressure Cutout Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
TTaabbllee oo CCoonntteennttss

TK 61717-18-MM-EN 7
Low Pressure Cutout Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal ................................................................................. 63
Installation ............................................................................... 63
Suction Pressure Regulator Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Suction Pressure Regulator Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Suction Pressure Regulator Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removal ................................................................................. 64
Installation ............................................................................... 64
Liquid Line Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Liquid Line Check Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Liquid Line Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removal ................................................................................. 64
Installation ............................................................................... 64
Replacing Re rigerant Hoses (Speedy Clip System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CCoommpprreessssoorr MMaaiinntteennaannccee .... .. .... .. ...... .... .. .... .. .... .. .... .. ...... .... .. .......... .... ...... .... .. .... .. ...... .... .. .......... .... .. .... ...... .... .. ........ 6666
Electric Standby Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal................................................................................... 66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
CCoommpprreessssoorr DDrriivvee MMoodduullee .. .... .. .... .. ...... .... .. .... .. .... .. .... .. ...... .... .. .......... .... .. .... .. .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .... .. .. 6699
Compressor Drive Module Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Removal................................................................................... 69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
SSttrruuccttuurraall MMaaiinntteennaannccee .. .......... .... .. .... .. .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .......... .... .. .... .. .... .. .......... .... .. .... .. .... .. .... .. ...... 7711
Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Unit Mounting Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
OOvveerr--tthhee--RRooaadd MMeecchhaanniiccaall DDiiaaggnnoossiiss.. .......... .... .. ...... .... .. .... .. .... .. .... .. ...... .... .. .... .. .... .. .... .. ...... .... .. .... .. .... .. .... .. ...... 7744
EElleeccttrriicc SSttaannddbbyy MMeecchhaanniiccaall DDiiaaggnnoossiiss .... ...... .... .. .... .. .... .. .......... .... .. .... .. .... .. .......... .... .. .......... .... .. .... .. .... .. .......... 7755
RRee rriiggeerraattiioonn DDiiaaggnnoossiiss.... ...... .... ...... .... .. .... .. .......... .... .. ...... .... .. .... ...... .... .. .......... .... .. ...... .... .. .... .. .... .. .... .. ...... .... .. .... .. .... 7766
RRee rriiggeerraattiioonn DDiiaaggnnoossiiss CChhaarrtt .... .. ...... .... .. .......... .... ...... .... .. .... .. ...... .... .. .......... .... .. .... .. .... .. .......... .... .. .... .. .... .. .... .. ...... 7788
DDiiaaggrraamm IInnddeexx.... .... .. ...... .... .. .......... .... .. .... .. .... .. .......... .... .. .... .. .... .. .... .. ...... .... .. .......... .... ...... .... .. .... .. ...... .... .. .......... .... .. .... .... 8800
TTaabbllee oo CCoonntteennttss

8TK 61717-18-MM-EN
Safety Precautions
Danger, Warning, Caution, and Notice
Thermo King®recommends that all service be per ormed by a Thermo King dealer and to be aware o several general
sa ety practices.
Sa ety advisories appear throughout this manual as required. Your personal sa ety and the proper operation o this unit
depend upon the strict observance o these precautions. The our types o advisories are de ined as ollows:
DDAANNGGEERR
HHaazzaarrdd!!
IInnddiiccaatteess aann iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, ii nnoott aavvooiiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
WWAARRNNIINNGG
HHaazzaarrdd!!
IInnddiiccaatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, ii nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
CCAAUUTTIIOONN
HHaazzaarrdd!!
IInnddiiccaatteess aa ppootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, ii nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn mmiinnoorr oorr mmooddeerraattee iinnjjuurryy aanndd
uunnssaa ee pprraaccttiicceess..
NNOOTTIICCEE
HHaazzaarrdd!!
IInnddiiccaatteess aa ssiittuuaattiioonn tthhaatt ccoouulldd rreessuulltt iinn eeqquuiippmmeenntt oorr pprrooppeerrttyy--ddaammaaggee oonnllyy aacccciiddeennttss..
Auto Start/Stop
CCAAUUTTIIOONN
RRiisskk oo IInnjjuurryy!!
TThhee uunniitt ccaann ssttaarrtt aanndd rruunn aauuttoommaattiiccaallllyy aannyy ttiimmee tthhee uunniitt iiss ttuurrnneedd oonn.. TTuurrnn tthhee uunniitt OOnn//OO sswwiittcchh OO aanndd
ddiissccoonnnneecctt tthhee AAuuttoo SSttaarrtt DDiissaabbllee sswwiittcchh oonn ttoopp oo tthhee eelleeccttrriiccaall ccaabbiinneett bbee oorree ddooiinngg iinnssppeeccttiioonnss oorr wwoorrkkiinngg
oonn aannyy ppaarrtt oo tthhee uunniitt.. PPlleeaassee nnoottee tthhaatt oonnllyy QQuuaallii iieedd aanndd CCeerrttii iieedd ppeerrssoonnnneell sshhoouulldd aatttteemmpptt ttoo sseerrvviiccee yyoouurr
TThheerrmmoo KKiinngg uunniitt..
CCAAUUTTIIOONN
RRiisskk oo IInnjjuurryy!!
TThhee vveehhiiccllee''ss eennggiinnee mmaayy bbee eeqquuiippppeedd wwiitthh AAuuttoo SSttaarrtt//SSttoopp.. TThhee vveehhiiccllee mmuusstt bbee ttuurrnneedd oo bbee oorree sseerrvviicciinngg
tthhee uunniitt..
CCAAUUTTIIOONN
RRiisskk oo IInnjjuurryy!!
TThhee uunniitt ccaann ssttaarrtt aanndd rruunn aauuttoommaattiiccaallllyy aannyy ttiimmee tthhee uunniitt iiss ttuurrnneedd oonn.. TTuurrnn tthhee uunniitt OOnn//OO sswwiittcchh OO bbee oorree
ddooiinngg iinnssppeeccttiioonnss oorr wwoorrkkiinngg oonn aannyy ppaarrtt oo tthhee uunniitt.. PPlleeaassee nnoottee tthhaatt oonnllyy QQuuaallii iieedd aanndd CCeerrttii iieedd ppeerrssoonnnneell
sshhoouulldd aatttteemmpptt ttoo sseerrvviiccee yyoouurr TThheerrmmoo KKiinngg uunniitt..
CCAAUUTTIIOONN
RRiisskk oo IInnjjuurryy!!
TThhee vveehhiiccllee''ss eennggiinnee mmaayy bbee eeqquuiippppeedd wwiitthh AAuuttoo SSttaarrtt//SSttoopp.. TThhee vveehhiiccllee mmuusstt bbee ttuurrnneedd oo bbee oorree sseerrvviicciinngg
tthhee uunniitt..

TK 61717-18-MM-EN 9
Battery Installation and Cable Routing
WWAARRNNIINNGG
HHaazzaarrdd oo EExxpplloossiioonn!!
AAnn iimmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccoouulldd rreessuulltt iinn aa iirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. AA TThheerrmmoo KKiinngg aapppprroovveedd bbaatttteerryy
mmuusstt bbee iinnssttaalllleedd aanndd pprrooppeerrllyy sseeccuurreedd ttoo tthhee bbaatttteerryy ttrraayy..
WWAARRNNIINNGG
HHaazzaarrdd oo EExxpplloossiioonn!!
IImmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccaabblleess ccoouulldd rreessuulltt iinn aa iirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy ccaabblleess mmuusstt bbee iinnssttaalllleedd,,
rroouutteedd,, aanndd sseeccuurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheemm rroomm rruubbbbiinngg,, cchhaa iinngg,, oorr mmaakkiinngg ccoonnttaacctt wwiitthh hhoott,, sshhaarrpp,, oorr
rroottaattiinngg ccoommppoonneennttss..
WWAARRNNIINNGG
FFiirree HHaazzaarrdd!!
DDoo nnoott aattttaacchh uueell lliinneess ttoo bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo ccaauussee aa iirree aanndd
ccoouulldd ccaauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AA bbaatttteerryy ccaann bbee ddaannggeerroouuss.. LLiitthhiiuumm--iioonn bbaatttteerriieess aarree ppootteennttiiaallllyy hhaazzaarrddoouuss.. TThhee ccoommbbuussttiioonn ggaass rroomm tthheessee
bbaatttteerriieess iiss ttooxxiicc aanndd ccaann pprreesseenntt aa sseerriioouuss FFIIRREE HHAAZZAARRDD ii ddaammaaggeedd,, ddee eeccttiivvee,, oorr iimmpprrooppeerrllyy uusseedd.. AA bbaatttteerryy
ssttoorreess eennoouugghh eelleeccttrriicciittyy ttoo bbuurrnn yyoouu ii iitt ddiisscchhaarrggeess qquuiicckkllyy.. AAllwwaayyss wweeaarr ggoogggglleess oorr ssaa eettyy ggllaasssseess aanndd
ppeerrssoonnaall pprrootteeccttiivvee eeqquuiippmmeenntt wwhheenn wwoorrkkiinngg wwiitthh aa bbaatttteerryy.. DDoo nnoott rreeppllaaccee tthhee bbaatttteerryy wwiitthh aannyy ttyyppee ootthheerr
tthhaann tthhee oonnee aapppprroovveedd bbyy TThheerrmmoo KKiinngg oorr tthhiiss uunniitt..
WWAARRNNIINNGG
HHaazzaarrdd oo EExxpplloossiioonn!!
AAllwwaayyss ccoovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm rroomm mmaakkiinngg ccoonnttaacctt wwiitthh mmeettaall ccoommppoonneennttss dduurriinngg bbaatttteerryy
iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall ccoouulldd ccaauussee tthhee bbaatttteerryy ttoo eexxppllooddee..
CCAAUUTTIIOONN
HHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!
SSeett aallll uunniitt eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbee oorree ccoonnnneeccttiinngg bbaatttteerryy ccaabblleess ttoo tthhee bbaatttteerryy ttoo pprreevveenntt tthhee
uunniitt rroomm ssttaarrttiinngg uunneexxppeecctteeddllyy aanndd ccaauussiinngg ppeerrssoonnaall iinnjjuurryy..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott ccoonnnneecctt ootthheerr mmaannuu aaccttuurreerrss eeqquuiippmmeenntt oorr aacccceessssoorriieess ttoo tthhee uunniitt oorr ttoo tthhee TThheerrmmoo KKiinngg BBaatttteerriieess
uunnlleessss aapppprroovveedd bbyy TThheerrmmoo KKiinngg.. FFaaiilluurree ttoo ddoo ssoo ccaann rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt aanndd vvooiidd tthhee
wwaarrrraannttyy..
TK Lithium Ion Battery Safety
This product is sa e with normal use. Exposure to the ingredients contained within and/or their combustion products
could be harm ul. Risk o exposure occurs only i the battery is mechanically, thermally, or electrically abused to the
point o compromising the enclosure. I this occurs, exposure to the electrolyte solution contained within can occur by
inhalation, ingestion, eye contact, and skin contact. The battery should not be opened or burned.
SSaa eettyy PPrreeccaauuttiioonnss

10 TK 61717-18-MM-EN
WWAARRNNIINNGG
RRiisskk oo IInnjjuurryy!!
VVaappoorrss oorr mmiissttss rroomm aa ccoommpprroommiisseedd bbaatttteerryy//cceellll mmaayy ccaauussee rreessppiirraattoorryy iirrrriittaattiioonn..
WWAARRNNIINNGG
RRiisskk oo IInnjjuurryy!!
SSwwaalllloowwiinngg tthhee ccoonntteennttss oo aa ccoommpprroommiisseedd cceellll mmaayy ccaauussee sseerriioouuss cchheemmiiccaall bbuurrnnss oo tthhee mmoouutthh,, ooeessoopphhaagguuss,,
aanndd ggaassttrrooiinntteessttiinnaall ttrraacctt..
WWAARRNNIINNGG
RRiisskk oo IInnjjuurryy!!
CCoonnttaacctt wwiitthh tthhee ccoonntteennttss oo aa ccoommpprroommiisseedd cceellll//bbaatttteerryy ccaann ccaauussee sseevveerree iirrrriittaattiioonn oorr bbuurrnnss ttoo tthhee sskkiinn..
WWAARRNNIINNGG
RRiisskk oo IInnjjuurryy!!
CCoonnttaacctt wwiitthh tthhee ccoonntteennttss oo aa ccoommpprroommiisseedd cceellll//bbaatttteerryy ccaann ccaauussee sseevveerree iirrrriittaattiioonn oorr bbuurrnnss ttoo tthhee eeyyee..
Refrigerant Hazards
DDAANNGGEERR
HHaazzaarrddoouuss PPrreessssuurreess!!
AAllwwaayyss ssttoorree rree rriiggeerraanntt iinn pprrooppeerr ccoonnttaaiinneerrss,, oouutt oo ddiirreecctt ssuunnlliigghhtt aanndd aawwaayy rroomm iinntteennssee hheeaatt.. HHeeaatt
iinnccrreeaasseess pprreessssuurree iinnssiiddee ssttoorraaggee ccoonnttaaiinneerrss,, wwhhiicchh ccaann ccaauussee tthheemm ttoo bbuurrsstt aanndd ccoouulldd rreessuulltt iinn sseevveerree
ppeerrssoonnaall iinnjjuurryy..
DDAANNGGEERR
CCoommbbuussttiibbllee HHaazzaarrdd!!
DDoo nnoott uussee ooxxyyggeenn ((OO22 )) oorr ccoommpprreesssseedd aaiirr oorr lleeaakk tteessttiinngg.. OOxxyyggeenn mmiixxeedd wwiitthh rree rriiggeerraanntt iiss ccoommbbuussttiibbllee..
WWAARRNNIINNGG
HHaazzaarrddoouuss GGaasseess!!
DDoo nnoott uussee aa HHaalliiddee ttoorrcchh.. WWhheenn aa llaammee ccoommeess iinn ccoonnttaacctt wwiitthh rree rriiggeerraanntt,, ttooxxiicc ggaasseess aarree pprroodduucceedd.. TThheessee
ggaasseess ccaann ccaauussee ssuu ooccaattiioonn,, eevveenn ddeeaatthh..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
RRee rriiggeerraanntt iinn aa lliiqquuiidd ssttaattee eevvaappoorraatteess rraappiiddllyy wwhheenn eexxppoosseedd ttoo tthhee aattmmoosspphheerree,, rreeeezziinngg aannyytthhiinngg iitt ccoonnttaaccttss..
WWeeaarr bbuuttyyll lliinneedd gglloovveess aanndd ootthheerr ccllootthhiinngg aanndd eeyyee wweeaarr wwhheenn hhaannddlliinngg rree rriiggeerraanntt ttoo hheellpp pprreevveenntt rroossttbbiittee..
WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss cchheemmiiccaallss,, AALLWWAAYYSS rree eerr ttoo tthhee aapppplliiccaabbllee MMaatteerriiaall DDaattaa SSaa eettyy
SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm oo CCllaassssii iiccaattiioonn aanndd LLaabbeelllliinngg oo CChheemmiiccaallss))
gguuiiddeelliinneess oorr iinn oorrmmaattiioonn oonn aalllloowwaabbllee ppeerrssoonnaall eexxppoossuurree lleevveellss,, pprrooppeerr rreessppiirraattoorryy pprrootteeccttiioonn,, aanndd hhaannddlliinngg
iinnssttrruuccttiioonnss..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
WWhheenn bbeeiinngg ttrraannss eerrrreedd,, rree rriiggeerraanntt mmuusstt bbee iinn lliiqquuiidd ssttaattee ttoo aavvooiidd ppoossssiibbllee eeqquuiippmmeenntt ddaammaaggee..
SSaa eettyy PPrreeccaauuttiioonnss

TK 61717-18-MM-EN 11
Refrigerant Oil Hazards
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
PPrrootteecctt yyoouurr eeyyeess rroomm ccoonnttaacctt wwiitthh rree rriiggeerraanntt ooiill.. TThhee ooiill ccaann ccaauussee sseerriioouuss eeyyee iinnjjuurriieess.. PPrrootteecctt sskkiinn aanndd
ccllootthhiinngg rroomm pprroolloonnggeedd oorr rreeppeeaatteedd ccoonnttaacctt wwiitthh rree rriiggeerraanntt ooiill.. TToo pprreevveenntt iirrrriittaattiioonn,, wwaasshh yyoouurr hhaannddss aanndd
ccllootthhiinngg tthhoorroouugghhllyy aa tteerr hhaannddlliinngg tthhee ooiill.. RRuubbbbeerr gglloovveess aarree rreeccoommmmeennddeedd.. WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd
hhaazzaarrddoouuss cchheemmiiccaallss,, AALLWWAAYYSS rree eerr ttoo tthhee aapppplliiccaabbllee MMaatteerriiaall DDaattaa SSaa eettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS
((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm oo CCllaassssii iiccaattiioonn aanndd LLaabbeelllliinngg oo CChheemmiiccaallss)) gguuiiddeelliinneess oorr iinn oorrmmaattiioonn oonn
aalllloowwaabbllee ppeerrssoonnaall eexxppoossuurree lleevveellss,, pprrooppeerr rreessppiirraattoorryy pprrootteeccttiioonn,, aanndd hhaannddlliinngg iinnssttrruuccttiioonnss..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee tthhee ccoorrrreecctt ooiill iinn TThheerrmmoo KKiinngg ssyysstteemmss ttoo aavvooiidd ddaammaaggiinngg eeqquuiippmmeenntt aanndd nnuullllii yyiinngg iittss wwaarrrraannttyy..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott mmiixx rree rriiggeerraanntt ooiillss.. MMiixxiinngg iinnccoommppaattiibbllee ooiillss wwiillll ddaammaaggee tthhee ssyysstteemm..
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee ddeeddiiccaatteedd rree rriiggeerraattiioonn eeqquuiippmmeenntt ttoo pprreevveenntt ccoonnttaammiinnaattiinngg rree rriiggeerraattiioonn ssyysstteemmss wwiitthh tthhee wwrroonngg ttyyppee oo
ooiill oorr rree rriiggeerraanntt..
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
DDoo nnoott eexxppoossee tthhee rree rriiggeerraanntt ooiill ttoo tthhee aaiirr aannyy lloonnggeerr tthhaann nneecceessssaarryy.. SSttoorree rree rriiggeerraanntt ooiill iinn aann aapppprroovveedd
sseeaalleedd ccoonnttaaiinneerr ttoo aavvooiidd mmooiissttuurree ccoonnttaammiinnaattiioonn.. TThhee ooiill wwiillll aabbssoorrbb mmooiissttuurree,, wwhhiicchh rreessuullttss iinn mmuucchh lloonnggeerr
eevvaaccuuaattiioonn ttiimmeess aanndd ppoossssiibbllee ssyysstteemm ccoonnttaammiinnaattiioonn..
NNOOTTIICCEE
MMaatteerriiaall DDaammaaggee!!
WWiippee uupp ssppiillllss iimmmmeeddiiaatteellyy.. RRee rriiggeerraanntt ooiill ccaann ddaammaaggee ppaaiinnttss aanndd rruubbbbeerr mmaatteerriiaallss..
Electrical Hazards
High Voltage
IImmppoorrttaanntt Do not move the vehicle if the power cable or the electric standby icon is illuminated.
DDAANNGGEERR
HHaazzaarrddoouuss VVoollttaaggee!!
LLeetthhaall aammoouunnttss oo vvoollttaaggee aarree pprreesseenntt iinn ssoommee eelleeccttrriiccaall cciirrccuuiittss.. UUssee eexxttrreemmee ccaarree wwhheenn wwoorrkkiinngg oonn aann
ooppeerraattiinngg rree rriiggeerraattiioonn uunniitt.. II tthheerree iiss aa rriisskk oo eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr llaasshh,, tteecchhnniicciiaannss MMUUSSTT ppuutt
oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ssppeeccii iicc rreeqquuiirreemmeennttss oorr aarrcc
llaasshh pprrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR
VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL
MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
SSaa eettyy PPrreeccaauuttiioonnss

12 TK 61717-18-MM-EN
DDAANNGGEERR
HHaazzaarrddoouuss VVoollttaaggee!!
DDaannggeerroouuss tthhrreeee pphhaassee AACC eelleeccttrriicc ppoowweerr iiss pprreesseenntt wwhheenneevveerr tthhee uunniitt iiss ooppeerraattiinngg iinn eeiitthheerr DDiieesseell MMooddee,,
EElleeccttrriicc MMooddee oorr HHoollddoovveerr MMooddee aanndd wwhheenneevveerr tthhee uunniitt iiss ccoonnnneecctteedd ttoo aa ssoouurrccee oo eexxtteerrnnaall ssttaannddbbyy ppoowweerr..
VVoollttaaggeess oo tthhiiss mmaaggnniittuuddee ccaann bbee lleetthhaall.. EExxeerrcciissee eexxttrreemmee ccaauuttiioonn wwhheenn wwoorrkkiinngg oonn tthhee uunniitt..
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
TTrreeaatt aallll wwiirreess aanndd ccoonnnneeccttiioonnss aass ii tthheeyy wweerree hhiigghh vvoollttaaggee uunnttiill aa mmeetteerr aanndd wwiirriinngg ddiiaaggrraamm iinnddiiccaattee
ootthheerrwwiissee.. OOnnllyy uussee ttoooollss wwiitthh iinnssuullaatteedd hhaannddlleess.. NNeevveerr hhoolldd uunniinnssuullaatteedd mmeettaall ttoooollss nneeaarr eexxppoosseedd,, eenneerrggiizzeedd
ccoonndduuccttoorrss.. II tthheerree iiss aa rriisskk oo eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr llaasshh,, tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE iinn
aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ssppeeccii iicc rreeqquuiirreemmeennttss oorr aarrcc llaasshh
pprrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE
TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD
EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
NNeevveerr wwoorrkk aalloonnee oonn hhiigghh vvoollttaaggee cciirrccuuiittss iinn tthhee rree rriiggeerraattiioonn uunniitt.. AAnnootthheerr ppeerrssoonn sshhoouulldd bbee nneeaarrbbyy ttoo sshhuutt
oo tthhee uunniitt aanndd pprroovviiddee aaiidd iinn tthhee eevveenntt oo aann aacccciiddeenntt.. II tthheerree iiss aa rriisskk oo eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr
llaasshh,, tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--
ssppeeccii iicc rreeqquuiirreemmeennttss oorr aarrcc llaasshh pprrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,,
DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG
CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
IInn tthhee eevveenntt oo aann eelleeccttrriiccaall aacccciiddeenntt,, aallll rreeqquuiirreedd PPPPEE sshhoouulldd bbee nneeaarr tthhee wwoorrkk aarreeaa iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,,
NNFFPPEE 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ssppeeccii iicc rreeqquuiirreemmeennttss oorr aa CCaatteeggoorryy 33 rriisskk..
WWAARRNNIINNGG
RRiisskk oo IInnjjuurryy!!
DDoo nnoott mmaakkee rraappiidd mmoovveess wwhheenn wwoorrkkiinngg oonn hhiigghh vvoollttaaggee cciirrccuuiittss iinn rree rriiggeerraattiioonn uunniittss.. DDoo nnoott ggrraabb oorr aalllliinngg
ttoooollss bbeeccaauussee yyoouu mmiigghhtt aacccciiddeennttaallllyy ttoouucchh aa hhiigghh vvoollttaaggee ssoouurrccee..
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee ww//CCaappaacciittoorrss!!
BBee ccaarree uull wwhheenn wwoorrkkiinngg wwiitthh eelleeccttrriiccaall cciirrccuuiittss tthhaatt ccoonnttaaiinn ccaappaacciittoorrss.. SSoommee ccaappaacciittoorrss hhoolldd aa ssiiggnnii iiccaanntt
eelleeccttrriiccaall cchhaarrggee tthhaatt mmiigghhtt ccaauussee bbuurrnnss oorr sshhoocckkss ii aacccciiddeennttaallllyy ddiisscchhaarrggeedd.. CCaappaacciittoorrss mmuusstt bbee ddiisscchhaarrggeedd
bbee oorree wwoorrkkiinngg oonn eelleeccttrriiccaall cciirrccuuiittss.. II tthheerree iiss aa rriisskk oo eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr llaasshh,, tteecchhnniicciiaannss
MMUUSSTT ppuutt oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ssppeeccii iicc
rreeqquuiirreemmeennttss oorr aarrcc llaasshh pprrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,,
DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG
CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
SSaa eettyy PPrreeccaauuttiioonnss

TK 61717-18-MM-EN 13
Low Voltage
WWAARRNNIINNGG
LLiivvee EElleeccttrriiccaall CCoommppoonneennttss!!
CCoonnttrrooll cciirrccuuiittss uusseedd iinn rree rriiggeerraattiioonn uunniittss aarree llooww vvoollttaaggee ((1122 ttoo 4488 VVddcc)).. HHoowweevveerr,, tthhee llaarrggee aammoouunntt oo
aammppeerraaggee aavvaaiillaabbllee ccaann ccaauussee sseevveerree bbuurrnnss ii aacccciiddeennttaallllyy sshhoorrtteedd ttoo ggrroouunndd wwiitthh mmeettaall oobbjjeeccttss,, ssuucchh aass ttoooollss..
DDoo nnoott wweeaarr jjeewweellrryy,, wwaattcchheess,, oorr rriinnggss bbeeccaauussee tthheeyy iinnccrreeaassee tthhee rriisskk oo sshhoorrttiinngg oouutt eelleeccttrriiccaall cciirrccuuiittss aanndd
ddaammaaggiinngg eeqquuiippmmeenntt oorr ccaauussiinngg sseevveerree bbuurrnnss.. II tthheerree iiss aa rriisskk oo eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr llaasshh,,
tteecchhnniicciiaannss MMUUSSTT ppuutt oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ssppeeccii iicc
rreeqquuiirreemmeennttss oorr aarrcc llaasshh pprrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,,
DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG
CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
Controller/Microprocessor Service Precautions
Take precautions to prevent electrostatic discharge when servicing the controller or microprocessor and its related
components. Even tiny amounts o current can severely damage or destroy electronic components.
Observe the ollowing precautions when servicing a controller or microprocessor control system to avoid damaging
electronic components. Re er to the applicable unit, controller, or microprocessor diagnostic manual or more
in ormation.
• I the unit has a service or microprocessor ON/OFF switch, turn it OFF be ore connecting or disconnecting the
battery.
• Disconnect power to the unit.
• Avoid wearing clothing that generates static electricity (wool, nylon, polyester, etc.).
• Wear a wrist strap (P/N 204-622 or equivalent) with the lead end connected to the microprocessor or unit ground
terminal (i equipped). These straps are available rom most electronic equipment distributors. DO NOT wear these
straps with power applied to the unit.
• Avoid unnecessary contact with the electronic components.
• Store and ship electronic components in antistatic bags and protective packaging.
• Leave electronic components in their antistatic packing materials until you’re ready to use them.
• A ter servicing any electronic components, check the wiring or possible errors be ore restoring power to the unit.
• Never use a battery and a light bulb to test circuits on any controller or microprocessor-based equipment.
Welding Precautions
Take precautions be ore electrically welding any portion o the unit or the vehicle to which it is attached. Veri y that
welding currents are not allowed to low through the unit’s electronic circuits.
Observe the ollowing precautions when welding to avoid damaging electronic components.
• I the unit has a service switch, or microprocessor ON/OFF, turn it OFF be ore connecting or disconnecting the
battery.
• Disconnect power to the unit.
• Disconnect all wire harnesses rom the microprocessor. Disconnect the ECU and the battery charger i so equipped.
• I there are any electrical circuit breakers in the control box, switch them OFF.
• Close the control box.
• Components that could be damaged by welding sparks should be removed rom the unit.
• Use normal welding procedures, but keep the ground return electrode as close to the area being welded as
practical. This will reduce the likelihood o stray welding currents passing through any electronic circuits.
First Aid
RREEFFRRIIGGEERRAANNTT
SSaa eettyy PPrreeccaauuttiioonnss

14 TK 61717-18-MM-EN
•EEyyeess:: For contact with liquid, immediately lush eyes with large amounts o water and get prompt medical
attention.
•SSkkiinn:: Flush area with large amounts o warm water. Do not apply heat. Remove contaminated clothing and shoes.
Wrap burns with dry, sterile, bulky dressing to protect rom in ection. Get prompt medical attention. Wash
contaminated clothing be ore reuse.
•IInnhhaallaattiioonn:: Move victim to resh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth
resuscitation to restore breathing, i necessary. Stay with victim until emergency personnel arrive.
•FFrroosstt BBiittee:: In the event o rost bite , the objectives o First Aid are to protect the rozen area rom urther injury,
warm the a ected area rapidly, and to maintain respiration.
RREEFFRRIIGGEERRAANNTT OOIILL
•EEyyeess:: Immediately lush with large amounts o water or at least 15 minutes. Get prompt medical attention.
•SSkkiinn:: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention i irritation
persists.
•IInnhhaallaattiioonn:: Move victim to resh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth
resuscitation to restore breathing, i necessary. Stay with victim until emergency personnel arrive.
•IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local poison control center or physician.
EENNGGIINNEE CCOOOOLLAANNTT
•EEyyeess:: Immediately lush with large amounts o water or at least 15 minutes. Get prompt medical attention.
•SSkkiinn:: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention i irritation
persists.
•IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local poison control center or physician.
BBAATTTTEERRYY AACCIIDD
•EEyyeess:: Immediately lush with large amounts o water or at least 15 minutes. Get prompt medical attention. Wash
skin with soap and water.
•SSkkiinn:: Immediately remove contaminated clothing. Wash skin with large volumes o water, or at least 15 minutes.
Wash skin with soap and water. Do not apply atty compounds. Seek immediate medical assistance.
•IInnhhaallaattiioonn:: Provide resh air. Rinse mouth and nose with water. Seek immediate medical assistance.
•IInnggeessttiioonn:: I the injured person is ully conscious: make the person drink extensive amounts o milk. Do not induce
vomiting. Take the injured person immediately to a hospital.
EELLEECCTTRRIICCAALL SSHHOOCCKK
Take IMMEDIATE action a ter a person has received an electrical shock. Get quick medical assistance, i possible.
The source o the shock must be quickly stopped, by either shutting o the power or removing the victim. I the power
cannot be shut o , the wire should be cut with an non-conductive tool, such as a wood-handle axe or thickly insulated
cable cutters. Rescuers should wear insulated gloves and sa ety glasses, and avoid looking at wires being cut. The
ensuing lash can cause burns and blindness.
I the victim must be removed rom a live circuit, pull the victim away with a non-conductive material. Use wood, rope,
a belt or coat to pull or push the victim away rom the current. DO NOT TOUCH the victim. You will receive a shock rom
current lowing through the victim’s body. A ter separating the victim rom power source, immediately check or signs
o a pulse and respiration. I no pulse is present, start Cardio Pulmonary Resuscitation (CPR). I a pulse is present,
respiration might be restored by using mouth-to-mouth resuscitation. Call or emergency medical assistance.
AASSPPHHYYXXIIAATTIIOONN
Move victim to resh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore
breathing, i necessary. Stay with victim until emergency personnel arrive.
SSaa eettyy PPrreeccaauuttiioonnss

TK 61717-18-MM-EN 15
Specifications
Electrical System
12 Vdc
Fuses
E-200
Fuse 1: Main Fuse 150 amps
Fuse 3: Evaporator Fan 15 amps
Fuse 4: Evaporator second Fan 15 amps
Fuse 5: Distribution fuse 20 amps
Fuse 6: Drain Heaters 2 amps
Fuse 9: Evaporator Fan second compartment 15 amps
Fuse 11: Drain Heaters second compartment 2 amps
Fuse 14: ACC1 Ignition Fuse 5 amps
Fuse 25: Vehicle Battery 5 amps
Fuse 63:
TK Battery
1 Battery 150 amps
Fuse 83: 2 Battery 80 amps
Fuse 71: SCM Fuse 60 amps
Fuse 72: SCM Fuse 60 amps
Fuse 8:
BMS Fuses 10 amps
Fuse 84:
Condenser Fan Motor
Voltage 13 Vdc
Full Load Current 10 Amps
Power Rating 130 W
RPM with Full Load 2,800
Condenser Fan Motor
Voltage 13 Vdc
Full Load Current 11 Amps
Power Rating 145 W
RPM with Full Load 2,670
Evaporator Fan Motors (Each)
Voltage 13 Vdc
Full Load Current 7.5 Amps
Power Rating 97.5 W
RPM with Full Load 2,800

16 TK 61717-18-MM-EN
Compressor driver module
Battery Input 11.5 to 14.5 VDC
Isolated, balanced three-phase output: 240 VAC Maximum
30–300 Hz (speed
controlled)
Electrical output power: 1150 W continuous, 1400
W for 30 sec
Smart Charger module
Bidirectional battery Charger / Discharger
Voltage 13 Vdc
Maximum Charge Current 40 A dc
Maximum Discharge Current 40 A dc
Electric Standby Power Supply Requirements
Power Cord Length
Power Cord Size (AWG)
Voltage Phase Hz Power Supply Circuit Breaker 25 ft 50 ft 75 ft
230 Vac 1 50/60 16 amp AWG16/
1.5mm2
AWG16/
1.5mm2
AWG16/
1.5mm2
115 Vac 1 50/60 20 amp AWG14/
2.5mm2
AWG14/
2.5mm2
AWG14/
2.5mm2
Refrigeration System
NNoottee Units are available with R-404A, R-452A or R-134A Refrigerants. All of which comply with F-Gas legislation
revision 2014 (Regulation (EC) No 517/2014)
Refrigerant GWP
R-404A 3922
R-452A 2140
R-134A 1430
CCAAUUTTIIOONN
SSeerrvviiccee PPrroocceedduurree!!
FFlluuoorriinnaatteedd RRee rriiggeerraanntt ggaasseess sshhoouulldd nnoott bbee vveennttiillaatteedd ttoo aattmmoosspphheerree.. TTaakkee nnoottee oo tthhee rree rriiggeerraanntt ttyyppee ((llaabbeell
oonn oouuttssiiddee oo uunniitt)) aanndd ddoo nnoott ccrroossss--ccoonnttaammiinnaattee..
Re er to the Vehicle Powered Truck Installation Standards and Procedures TK 61588 (Section 10 – System Evacuation
Procedures) and Section 12 – System Charging Procedures) or service in ormation about evacuating and charging the
re rigeration system.
NNoottee *Final refrigerant charge will vary based on each unique installation
R-1 4a Refrigeration System E-Series
Refrigerant Charge: E-200 20 1.3kg (2.8lb) (including 1.5m (60") hoses
supplied as standard) R134a
Defrost Method Hot Gas
SSppeeccii iiccaattiioonnss

TK 61717-18-MM-EN 17
Defrost Termination Switch: Opens
Closes
48.0 ± 5.0 F (8.9 ± 2.8 C)
36.0 ± 5.0 F (2.2 ± 2.8 C)
Low Pressure Cutout Switch (LPCO): Opens
Closes
5 to 11 in. Hg vacuum (-17 to -37 kPa)
4 to 7 psig (28 to 48 kPa)
R-452A Refrigeration System E-Series MAX
Refrigerant Charge: E-200 MAX 50
E-200 MAX 50 Spectrum
1.3kg (2.8lb) (including 1.5(60") hoses
supplied as standard) R452A/R404A
1.6kg (3.5lb) (including 6m(237") hoses
supplied as standard) R452A/R404A
Important:
1. For each additional meter
(39") of hose extension, add
80g (0.17lb) of refrigerant.
2. It is a good idea to utilise
the WINTRAC tool to set
compressor speed at an
intermediate level (for
example - 60Hz) during
refrigeration charge. If the
unit is charged with the
compressor at full speed,
overcurrent protection may
trip.
3. DO NOT overcharge the
system. Checking the sight
glass is free from bubbles
may be misleading if the
evaporator box is warm.
Decrease the temperature
of the box to 5ºC or below
before checking the sight
glass.
Defrost Method Hot Gas
Defrost Termination Switch: Opens
Closes
48.0 ± 5.0 F (8.9 ± 2.8 C)
36.0 ± 5.0 F (2.2 ± 2.8 C)
Liquid Injection Switch (LISW): Refer to (“Liquid Injection System,” p. 42) for
operation description
Low Pressure Cutout Switch (LPCO): Opens
Closes
5 to 11 in. Hg vacuum (-17 to -37 kPa)
4 to 7 psig (28 to 48 kPa)
SPR (Suction Pressure Regulator) Valve Setting 24 psig (165 kPa/3bar) or below
DPR (Discharge Pressure Regulator) Valve Setting Factory setting 87 ± 2 psig (6 ± 0.14 bar)
Important: Do not exceed 145 psi (10 bar)
to avoid tripping the compressor
motor current protection.
Compressors
NNOOTTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee tthhee ccoorrrreecctt ooiill iinn TThheerrmmoo KKiinngg ssyysstteemmss ttoo aavvooiidd ddaammaaggiinngg eeqquuiippmmeenntt aanndd nnuullllii yyiinngg iittss wwaarrrraannttyy..
NNoottee Once the oil has been extracted from the compressor, note the oil level in order to be able to maintain the same
level in the replacement compressor. Polyol Ester (POE) or Polyvinyl Ether (PVE) compressor oil must be used in
conventional Thermo King units. Mineral oils or PAG oils must not be added to systems.
E-200 Rotary hermetic (variable speed)
System Oil Capacity - hermetic Compressor: 14 oz. (0.41 liter)
SSppeeccii iiccaattiioonnss

18 TK 61717-18-MM-EN
Compressor Oil Type: PVE
Motor Voltage: Variable Frequency 230V/3/80Hz PWS V/ph/Hz
Defrost Method Hot Gas
Defrost Timer Initiation Interval Adjustable, 1 minute to 8 hours, default is 4 hours
Defrost Termination Interval Defrost is terminated by Klixon switch, or by Defrost
Termination Timer [dtt] adjustable, 5 to 50 minutes, default is
30 minutes.
Solder Applications
Refrigeration Components
For general refrigeration tubing connections:
copper to copper or copper to brass
Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
Use: Solder Type 15% Silver TK No. 203-364 Use: Flux Type TK
No. 203-365
For refrigeration tubing connections of dissimilar metals:
copper to stainless steel or brass to stainless steel
Joint Clearances: 0.003 to 0.005 in. (0.076 to 0.127 mm)
Use: Solder Type 35% Silver TK No. 203-366 Use: Flux Type TK
No. 203-365
NOTE: Some units may be equipped with compressor pressure regulator (CPR) valve and/or suction pressure regulator (SPR)
valve and/or discharge pressure regulator (DPR) valve. To reduce the chance of overheating the CPR/SPR/DPR valve, 95-5
solder or equivalent may be used.
Use 95-5 TK No. 204-167
Use Flux TK No. 204-417
Thermostatic expansion valve (TXV) Use tin welding
SSppeeccii iiccaattiioonnss

TK 61717-18-MM-EN 19
Unit Description
Unit Description
Thermo King Vehicle Powered Truck Units are two-piece units comprised o a condenser and evaporator designed or
resh, rozen, and deep rozen applications on small trucks and vans.
Operated by a variable speed hermetic compressor. During road operation, energy is provided by the vehicle (i
available) or by TK batteries (See “Options,” p. 19). Standby mode is powered rom the mains supply through AC/DC
converters included in the condenser section. De rost is accomplished by hot gas. Heat is provided by the hot gas
system and by the orced-convection air- low created by the ans.
The user riendly Direct Smart Ree er (DSR) controller makes operating your unit simple, while its modular design
allows or ease o service.
E-Series Units Include:
•EE--220000:: or resh temperature applications above or close to 0°C (32°F).
•EE--220000 MMAAXX:: or rozen temperature applications below 0°C (32°F) and down to -25°C (-13°F).
There are three basic models :
•MMooddeell 2200:: Cool and De rost with both vehicle and electric standby compressor operation.
•MMooddeell 5500:: Hot gas heat, Cool and De rost with both vehicle and electric standby compressor operation.
•MMAAXX SSppeeccttrruumm:: Multi-Temperature versions o the models above with the cargo area split into zones o di erent
temperature combination settings.
Standard Unit Features
•CCoonnddeennsseerr - Lightweight design, easy to service with automotive grade polypropylene cover.
•EEvvaappoorraattoorr - Ultra slim design, aluminum construction automotive grade Acrylonitrile Butadiene Styrene (AABBSS)
cover.
•CCoonnttrroollss - User riendly Direct Smart Ree er (DSR) In-Cab controller.
•RRee rriiggeerraanntt - R-134a, R-452A or R-404A (depending on unit model).
•EElleeccttrriicc SSttaannddbbyy
•SSttaarrtt//SSttoopp aanndd IInnccrreeaasseedd IIddllee SSppeeeedd FFuunnccttiioonnaalliittyy - improves the re rigeration per ormance during long periods
o engine stops due to vehicle START/STOP activation/vehicle running in idle (eg. Tra ic jam, urban distribution
with high density o tra ic lights,…). Needs Dealer activation and installation according to each chassis OEM's
conversion manual.
Options
• Hot Gas
• Door Switch Kit
NNoottee Installing door switch(es) is strongly recommended if the application will use holdover mode.
• Snow Covers
• Re rigeration Hose / Harness Covers
• Roo Top Mounting Kit
• TracKing®
•HHoolldd--oovveerr uunnccttiioonnaalliittyy - using extended vehicle battery to allow the user to maintain the temperature control o
the compartment or a certain period when there is no alternator or stand-by power sources available. Needs Dealer
activation.
•TTKK BBaatttteerriieess - This option allows to get up to 2 x 1.8kWh Li-ion batteries mounted in the driver’s cabin. This will
keep the re rigeration unit in operation while the vehicle is stopped and cannot be connected to shore power. This is
use ul to hold the cargo box temperature during the ollowing circumstances or example: deliveries to customers,
lunch breaks etc. without the need to return to base. Each battery can support the re rigeration unit operating more
than 1 hour in standard conditions. This option is not compatible with using extended vehicle battery or short
holdover times.

20 TK 61717-18-MM-EN
• Electric Standby Plug (230V single phase 50Hz/60Hz or 115V single phase 60Hz options)
NNoottee Some options are available factory installed or as a retrofit option to suit individual customer needs.
System Components
The system consists o the ollowing main components:
Compressor(s)
With E-Series units, mobile operation and electric standby modes operate with a compressor driven by an DC/AC
inverter. Power is taken rom vehicle battery or auxiliary batteries in mobile operation or rom shore power in electric
standby.
Condenser
The condenser is located on the roo o the vehicle or on the ront o the cargo box. The cover can easily be removed to
access the uses or service the unit.
Figure 1. Condenser
Evaporator
The evaporator is mounted on the ceiling inside the cargo box. The cover can easily be removed or service.
Figure 2. Evaporator
Oil Separator
An oil separator is a standard eature. The oil separator separates compressor oil rom re rigerant vapor and returns the
oil to the compressor through the suction line. The oil separator helps provide positive oil return at high compressor
speeds and low operating temperatures. This eature enhances compressor lubrication and extends compressor li e.
Refrigerant
• E-Series units use R-134a re rigerant.
• E-Series MAX units use R-452A or R-404A re rigerant.
Liquid Injection System
MAX units use R-404A or R-452A. These units have a liquid injection system to limit discharge temperature o the
engine driven compressor.
Unlike other units, the E-200 liquid injection system works in the ollowing way:
•HHeeaattiinngg mmooddee:: The liquid injection will be open during the irst ew minutes (as de ined by a parameter) ollowing a
compressor start. In this case, the unction is to drain the compressor battery rom liquid re rigerant, especially
when the ambient temperature is very low.
•CCoooolliinngg mmooddee:: The liquid injection will become active when the ambient temperature is very high while the box is
deep- rozen. In this way, the re rigerant discharge temperature is limited. Again, the parameters that are set in the
controller de ine this behavior.
UUnniitt DDeessccrriippttiioonn