Installation Manual-A

Trailer Edition
Super II 100, Super II 190 Single Temperature Systems
Spectrum Super II Multi-Temperature Systems
TK 51286-2-IM

(Rev. 3, 02/06)

Copyright© 2001 Thermo King Corp., Minneapolis, MN,

U.S.A.Printed in U.S.A.
Release History
Released (08/01)
Rev. 1 (10/04) Art and text changes.
Rev. 2 (05/05) Added new door switch installation instructions.
Rev. 3 (02/06) Page 36, Added “Thermo King recommends the fuel tank be mounted 203.2 mm (8.00 in.) inside of the trailer
frame. Otherwise, the OEM or installer is responsible to ensure the fuel tank position meets or exceeds DOT or Federal
Highway regulations, when applicable”.

2
 Installation Manual for Super II 100,
Super II 190 and Spectrum Super II Systems

AAZ38

3
 Introduction

Installation Manual-A was written to assist with the installation of the

Thermo King Super II 100 and Super II 190 Single Temperature and
Spectrum Super II Multi-Temperature refrigeration systems onto
trailers specifically designed and built for refrigerated applications.
Due to its complexity, you should not attempt this installation unless you:
• Are an experienced mechanic
• Can safely lift 34 kilos (75 lbs.)
• Are certified or trained in the repair and maintenance of diesel powered
refrigeration systems
• Have a basic understanding of electricity and electrical wiring
• Have the necessary tools and equipment to complete the installation.
Installation Manual-B was written to complete the installation of the
Multi-Temperature systems with Spectrum remote evaporators.

This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the
manufacturer’s judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or
descriptions contained herein.

4
 Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Uncrating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installing the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Trailer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installing the Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Evaporator Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installing the Rear Remote Controller (OPTION) . . . . . . . . . . . . . . . . . . . . . 40
Mounting Bolt Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installing the Door Switch (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installing the Status Light (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bulkhead Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Installing the Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rear Remote Controller Dimensions (OPTION) . . . . . . . . . . . . . . . . . . . . . . 24 Installing the Bottom Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Status Light Dimensions (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5
 Safety Precautions

The symbol appears next to a point that is particularly important: WARNING: Always wear goggles or safety glasses. Refrigerant
liquid, refrigeration oil, and battery acid can permanently damage
DANGER: Addresses a circumstance that, if encountered, will the eyes (see First Aid under Refrigeration Oil).
lead to death or serious injury.
WARNING: Keep your hands away from fans and belts when the
unit is running. This should also be considered when opening and
WARNING: Addresses a circumstance that, if encountered, might
closing the compressor service valves.
lead to death or serious injury.
WARNING: Make sure gauge manifold hoses are in good
CAUTION: Addresses a circumstance that, if encountered, may condition. Never let them come in contact with a belt, fan motor
cause damage to equipment or minor injury. pulley, or any hot surface.

DANGER: Never operate the unit with the discharge valve closed WARNING: Make sure all mounting bolts are tight and are of
because it could cause the compressor to explode, causing death correct length for their particular application.
or serious injury.
WARNING: Never drill holes in the unit unless absolutely
DANGER: Never apply heat to a sealed refrigeration system or necessary. Holes drilled into the unit may weaken structural
container because it could explode, causing death or serious components. Holes drilled into electrical wiring can cause fire or
injury. explosion.

DANGER: Fluorocarbon refrigerants, in the presence of an open WARNING: When using ladders to install or service refrigeration
flame or electrical short, produce toxic gases that are severe systems, always observe the ladder manufacturer’s safety labels
respiratory irritants capable of causing death. and warnings. A work platform is the recommended method for
installations.
DANGER: Be careful when working with a refrigerant or
refrigeration system in any enclosed or confined area with a WARNING: Exposed coil fins are very sharp and can cause
limited air supply (i.e., a trailer, container or the hold of a ship). painful lacerations.
Refrigerant tends to displace air and can cause oxygen depletion
which may result in death by suffocation.

6
 Safety Precautions (continued)

Refrigerant Refrigeration Oil

WARNING: Although fluorocarbon refrigerants are classified as WARNING: Avoid refrigeration oil contact with the eyes. Avoid
safe refrigerants, certain precautions must be observed when prolonged or repeated contact of refrigeration oil with skin or
handling them or servicing a unit in which they are used. When clothing. Wash thoroughly after handling refrigeration oil to
released to the atmosphere in the liquid state, fluorocarbon prevent irritation.
refrigerants evaporate rapidly, freezing anything they contact.
First Aid
First Aid In case of eye contact, immediately flush with plenty of water for at least
FROST BITE: In the event of frost bite, the objectives of First Aid are to 15 minutes. CALL A PHYSICIAN. Wash skin with soap and water.
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 clothing 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.

7
 Required Tools
1. Safety Glasses
2. Drill
3. Drill Bits
4. Tape Measure
5. Mechanics Tools
6. Lifting Bar
7. Work Platform (Recommended)
8. Torque Wrench
9. Forged Eyebolts
NOTE: Equipment such as scales, gauges, refrigerant leak detectors, and
torque wrenches should be in good working condition and routinely
calibrated to assure accurate readings.

8
Required Tools

ABN21

9
 Installation Components
1. Screws, Flatwashers, 13. Drain Hose Check Valves
Lockwashers
14. Bottom Panels
1/4 in.
15. Vinyl Taper Strips
2. Locking Nuts
16. Fuel Tank
1/2 in. x 13
17. Fuel Tank Hanger
3. Washers
18. Fuel Tank Support Channel
1/4 in.
19. Fuel Tank Mounting Strap
4. Captive Nuts
20. Fuel Tank Mounting Brackets
1/4 in.
21. Fuel Tank Nameplate
5. Grommets
22. Fuel Tank Backing Plates
6. Screws-Self Tapping
23. Bulkhead (option)
7. Clamps
8. Cable Ties
9. Fuel Line
1/4 in. OD
3/8 in. OD
10. Fuel Line Fittings
1/4 in.
3/8 in.
11. Fuel Line Connector
12. PVC Hose

10
Installation Components

11
 Trailer Requirements

DANGER: The front trailer must be structurally strong enough to support the weight of the refrigeration unit!

Approximate Weight
Super II 100, Super II 190 and Spectrum Super II 667 kg (1468 lbs.) to 758 kg (1667 lbs.)
CAUTION: The minimum distance from the king pin to the front of the trailer must be 914.4 mm (36.00 in.) or severe damage to the equipment
will result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

CAUTION: The minimum clearance required for the swing radius must be 1549.4 mm (61.00 in.) or severe damage to the equipment will result.
VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

12
Trailer Requirements

AGA807

13
 Evaporator Opening Dimensions

Evaporator Opening Vinyl Taper Strip Installation Instructions

DANGER: The front trailer wall must be structurally strong • Clean trailer surface area of overlap seams above opening.
enough to support the weight of the refrigeration unit! • Peel off paper backing from vinyl taper strip.

The location of the unit mounting bolts and evaporator opening in the front • Apply vinyl taper strip to trailer seams, positioning thicker side along
wall is critical. VERIFY ALL DIMENSIONS BEFORE INSTALLING edge of seam (Detail I).
UNIT!
NOTE: It may be necessary to relocate the front corner clearance lights
to the corner radius of the trailer to prevent damage.
1. The evaporator opening must be square. The diagonal measurements
must be within ± 3.0 mm (0.12 in.).
2. The gasket surface around the opening must be at least 76.2 mm (3.00
in.) wide, be flat ± 3.2 mm (0.05 in.) and free of rivets, seams or bolt
heads.
3. Trailers often have overlap vertical seams above the unit opening
which cause poor gasket sealing and adversely affect the performance
of your Thermo King unit (Detail I).
4. To provide proper sealing surface at these seams, install the vinyl taper
strips supplied in the installation kit (Detail I).

14
Evaporator Opening Dimensions

AGA808

15
 Mounting Bolt Dimensions
Mounting Bolts Mounting Bolts Specifications
DANGER: Eight mounting bolts must be installed to properly DANGER: The use of mounting bolts other than those specified
secure the unit to the trailer front wall! Failure to do so could could result in severe damage to equipment, void the warranty or
result in severe damage to equipment, void the warranty or cause cause personal injury or death!
personal injury or death!
Use Metric M12 x 1.75 pitch class 8.8 (1/2 in.-13 UNC - 28 Rolled thread
NOTE: The location of the unit mounting bolts in the trailer front wall is grade 5), medium carbon steel bolts and locking nuts. All hardware must
critical to proper unit installation. be zinc plated with dichromate finish.
All mounting bolts must be square with the front wall and securely
fastened to the trailer wall in such a manner to allow the mounting nuts to
be torqued to 82 N•m (60 ft. lbs.) from outside the trailer.
1. Six top mounting bolts are to extend 44.4 mm (1.75 in.) beyond the
front wall (Detail I).
2. Two bottom mounting bolts are to extend 57.2 mm (2.25 in.) beyond
the front wall (Detail II).

16
Mounting Bolt Dimensions

17
 Unit Dimensions
I. Front View
II. Side View
III. Top View
IV. Overall area required for servicing the unit.

18
Unit Dimensions

215.8 mm
(8.5 in.)
129.5 mm
(5.10 in.)

914.6 mm
(36.01 in.)

693.4
(27.3 in.)

AGA810

19
 Bulkhead Dimensions

Thermo King Recommends Using A Bulkhead

Bulkheads are available from authorized Thermo King dealers.
Return Airflow Typical Bulkhead Shown (Dimensions are approximate)
Restrictions of the return airflow adversely affects the performance of the I. Front View
unit. The area directly behind the evaporator return air inlet must not be
II. Side View
restricted.

Bulkhead Function
A bulkhead is used to keep the return airflow from being restricted if the
load shifts. The bulkhead also prevents the load from shifting into the
return airflow passageway on the front wall of the trailer.

20
Bulkhead Dimensions

21
 Battery Dimensions
NOTE: The specified battery, electrical wiring and electronic controls
SAE Ratings
were designed to operate and maintain only the Thermo King
refrigeration system and factory authorized Thermo King options. Thermo King Cold Cranking Amps Reserve Capacity
Service Part Number
30 Seconds
CAUTION: Do not connect other manufacturer’s equipment or @0F
accessories to the Thermo King unit! This could result in severe 203-600 750 180 minutes minimum
damage to equipment and void the warranty! (3/8-16 NC connections) @ 25 amps
Units are designed for one 12 volt, Group C31 battery supplied by the 203-601 750 180 minutes minimum
installer. (lug connections) @ 25 amps
203-724 950
• 750 CCA recommended for ambients above -15 F (-26 C). (lug connections)
• 950 CCA recommended for ambients below -15 F (-26 C). 203-725 950
(3/8-16 NC connections)
The battery must be suitable for deep cycling, heavy duty and rated with a
minimum of 95 amp/hr. 203-726 700
(3/8-16 NC connections)
NOTE: See chart for Thermo King approved batteries.
NOTE: Batteries are available with either lugs or threaded studs.

22
Battery Dimensions

23
 Rear Remote Controller Dimensions
(OPTION)
Controller and Mounting Box Dimensions
I. Front View
II. End View
III. Side View

24
Rear Remote Controller Dimensions
(OPTION)

25
 Status Light Dimensions
(OPTION)
I. Front View
II. Side View

26
Status Light Dimensions
(OPTION)

27
 Lifting Bar Dimensions
I. Front View.
WARNING: Do not use a fork lift to install unit!
II. Side View.
III. Complete welded lifting bar.
WARNING: Thermo King requires a 2 point lifting bar to safely
lift and install units. A lifting bar can be made from the drawings
provided. 1. Forged Clevis Pin.
2. Forged Chain Links.
WARNING: All hardware used to assemble the lifting bar must be
DIN 931 class 10.9 (SAE grade 8). The use of hardware other 3. Locking Master Chain Link.
than specified may cause personal injury, severe damage to the
equipment and void the warranty.

WARNING: The lifting bar and lifting device combined must be

able to support minimum weight of 1360.8 kilos (1 1/2 tons).

28
Lifting Bar Dimensions

AGA806

29
 Uncrating the Unit

DANGER: Do not use a forklift to install the unit! This could

Disposable Wood Crate
result in severe damage to the equipment, void the warranty or • Remove top wood crate member.
cause personal injury or death!
• Attach forged eyebolts and 2 point lifting bar to unit.

WARNING: Thermo King requires a 2 point lifting bar to safely • Remove hardware holding unit to crate uprights.
lift and install units. A lifting bar can be made from the drawings • Remove installation kit boxes and any other loose components from
provided (see Lifting Bar Dimensions). rear of unit.
Super II 100, Super II 190 and Spectrum Super II units are shipped in a • Remove hardware holding unit to crate base.
disposable wood crate.
• Disassemble crate.
NOTE: To avoid unnecessary damage to your unit, place the crated unit
near the trailer prior to its removal • Unit is now ready for installation.

30
Uncrating the Unit

31
 Installing the Unit

WARNING: Do not use a forklift to install the unit! This could

Unit Installation
result in severe damage to equipment, void the warranty or cause 9. Trailers often have overlap seams above the unit opening which cause
personal injury or death! poor gasket sealing and adversely affect the performance of your
Thermo King unit.
WARNING: Use only locking hooks to safely lift the unit! Failure 10. To provide proper sealing surface at these seams, install the vinyl taper
to use locking hooks could result in severe damage to the strips supplied in the installation kit.
equipment, void the warranty or cause personal injury or death!
(Detail I). Vinyl Taper Strip Installation Instructions
WARNING: Thermo King requires a 2 point lifting bar to safely • Clean trailer surface area of overlap seams above opening.
lift and install units. A lifting bar can be made from the drawings • Peel off paper backing from vinyl taper strip.
provided (see Lifting Bar Dimensions).
• Apply vinyl taper strip to trailer seams positioning thicker side along
edge of seam.
Access to Mounting Holes (Detail II).
11. Install two 5/8-11 forged lifting eyebolts into threaded holes located on
1. Through the opening on the top of the unit.
the top of the unit (Detail I).
2. By opening the left side door.
12. Use the lifting bar to lift unit up to the trailer opening.
3. By opening the lift side door.
13. Attach washer and elastic stop nuts provided in the installation kit.
4. By opening the control box door. Torque to 82 N•m (60 ft. lbs.).
5. By opening the right side door. NOTE: All nuts that hold the unit to the trailer should be elastic stop nuts
(Nylock Type) provided in the installation kit.
6. By opening the right side door.
7. By opening the right side door.
8. Through the opening on the top of the unit.

32
Installing the Unit

AGA811

33
 Installing the Drain Hoses
1. Drain Hoses should run straight down the trailer wall from the unit with
no kinks or bends.
2. Secure with screws and clamps provided in installation kit.
3. Cut off excess hose and attach drain hose check valves provided in
installation kit.

34
 Installing the Drain Hoses

AGA812

35
 Installing the Fuel Tank

DANGER: An improperly installed fuel tank could lead to serious

Installation Recommendations
injury or death! Consult your trailer manufacturer for specific 1. Channel must be used with every tank installation.
details on proper fuel tank installation and recommendations. NOTE: This drawing shows a typical installation with 12 inch
NOTE: Thermo King supplies the Fuel Tank, Fuel Tank Hangers, Fuel crossmember spacing. For other crossmember spacing, refer to TK
Tank Channels and Fuel Tank Straps. Due to differences in trailer drawing 5937C22.
manufacturers, additional support channels may be required to safely 2. Torque 1/2 in. hardware to 81 - 88 N•m (60 - 65 ft. lb).
support the overall weight of the fuel tank components including the full
capacity of diesel fuel. Consult your trailer manufacturer for specific 3. Torque 3/8 in. hardware to 34 N•m (25 ft. lb).
details on proper fuel tank installation and recommendations. 4. Torque band clamping hardware to 48 N•m (35 ft. lb).
5. Route fuel lines from fuel tank, through conduit and connect to unit.
Clamp every 609.6 mm (24.0 in.).
6. Thermo King recommends the fuel tank be mounted 203.2 mm
(8.00 in.) inside of the trailer frame. Otherwise, the OEM or installer is
responsible to ensure the fuel tank position meets or exceeds DOT or
Federal Highway regulations, when applicable.
7. Position fuel line 228.6 mm (9.00 in.) from center line of trailer.

36
Installing the Fuel Tank

37
 Installing the Fuel Lines
4. Secure all fuel lines with provided clamps (Detail II).
DANGER: Leaking fuel lines could cause a fire resulting in death
or serious injury! All fuel line fittings must be tight and leak free! 5. Route fuel supply line from the bracket to the fuel pickup on the fuel
tank. Install fuel line connector (provided in installation kit), cut end of
fuel line at a 45 degree angle and insert into fuel pickup tube until it is
DANGER: Do not route fuel lines with battery cables or electrical
25.4 mm (1.00 in.) from bottom of tank and tighten securely.
wires, as this could cause a fire!
6. Route fuel return line from the bracket to the fuel tank return fitting.
1. Install the fuel line bracket to the predrilled holes in the frame or any Attach fuel line connectors and tighten securely.
convenient location on the trailer.
7. Remove plastic cap from the fuel vent and point the outlet to the rear of
2. Fuel lines should be routed in a protective housing with no kinks or the trailer.
sharp bends (Detail I). NOTE: Add a sufficient amount of fuel (1/4 tank) to allow the unit to run
3. Rubber grommets must be used when routing fuel lines through holes for 8 to 12 hours during engine break-in and pre-delivery procedures.
in metal (Detail I).

38
Installing the Fuel Lines

AGA815

39
 Installing the Rear Remote Controller
(OPTION)

Foamed-In-Place Installation
NOTE: Verify mounting location and all dimensions before installing the NOTE: Coupling should not protrude more than 6.4 mm (.25 in.)
remote controller. inside the controller box.

DANGER: Do not route electrical harness together with fuel lines 5. Install cap in bottom of controller box before foaming trailer wall.
as this could cause a fire resulting in death or serious injury! 6. Apply chalking to controller box and install securely into trailer wall.
7. Apply Superlube (or equivalent) to interface harness connector and
CAUTION: Do not drill holes into refrigeration, electrical or attach securely to back of controller. Route interface harness through
mechanical components or severe damage to the equipment will chase. Secure controller to controller box with screws.
result!
8. Route chase and interface harness from controller to host unit. Secure
Preferred Wire Routing (Steps 1,2, 6-10) with clamps.

NOTE: The preferred routing of the electrical harness chase and 9. Cut off excess harness and strip wire ends. Crimp onto existing splice
interface harness is from the bottom of the controller box. and use heat shrink covering.

1. Connect the harness chase to the bottom of controller while providing a 10. Apply Superlube (or equivalent) and secure connect remote interface
drip loop. harness connector to evaporator harness connector.

2. Install and route a 1/2 in. CPVC drain hose from the bottom of the A. 69.8 mm (2.75 in.)
controller box out of trailer floor. B. 196.8 mm (7.75 in.)

Alternative Wire Routing (Steps 3-10)

NOTE: The alternative routing of the electrical harness chase and
interface harness is from the side of the controller box.
3. Drill an appropriate size hole in the controller box for the harness chase
coupling.
4. Install harness chase coupling.

40
Installing the Rear Remote Controller
(OPTION)

41
 Installing the Rear Remote Controller
(OPTION)

Retro-Fit Installation
NOTE: Verify mounting location and all dimensions before installing the 3. Apply caulking to controller box and install securely in trailer wall.
remote controller.
NOTE: Make sure the drain hose and harness chase are connected
DANGER: Do not route electrical harness together with fuel lines properly.
as this could cause a fire resulting in death or serious injury! 4. Apply caulking to remote controller with interface connector harness,
route harness down chase and forward to unit.
CAUTION: Do not drill holes into refrigeration, electrical or 5. Route harness under trailer through chase in floor or I-beam cross
mechanical components or severe damage to the equipment will members towards the unit.
result!
6. From inside the trailer, measure and drill an appropriate size hole and
route the harness up into the trailer towards the unit.
CAUTION: Rubber grommets must be used when routing
electrical harnesses through metal holes! NOTE: Ensure hole is properly sealed after routing harness.
7. Secure harness to the backside of the unit with clamps.
1. Cut opening in trailer wall per dimensions shown.
8. Measure the length of harness required to connect to host unit
A. 203 mm (8.0 in.)
evaporator harness connector, cut off excess harness and strip wire
B. 107.9 mm (4.25 in.) ends. Crimp into existing splice and use heat shrink covering.
C. 38 x 12.7 mm (1.5 x .5 in.) 9. Securely connect the remote interface harness to the evaporator harness
connector.
2. Install and route a 1/2 in. CPVC drain hose and 0.88 O.D. harness
chase from the bottom of the controller box out of the trailer.

42
 Installing the Rear Remote Controller
(OPTION)

7
C

A
6

3
4

2
9

AAB76

8 5 3

43
 Installing the Door Switch
(OPTION)
NOTE: These instructions are intended as reference guide only to assist with a typical door switch installation. Your installation may be different
depending on the trailer, the amount and types of doors and the customers particular requirements.
Door Switch Components • The door switch and magnet must be installed parallel to each other,
The door switch consists of a magnet, a switch, non-magnetic mounting not perpendicular. Long cross hair aligns to long cross hair.
hardware and a interface harness to connect to the host unit. • It is important that a maximum gap of 19 mm (0.75 in.) is maintained
• The magnet is always mounted on the door. between the door switch and the magnet. Shims may be required and
must be a non-magnetic material (aluminum, wood, plastic, etc.) or the
• The switch (with harness) is always mounted to a stationary location.
door switch will not operate properly.
• Two short interface harnesses are available depending on your
particular kit. One allows a single door switch in a single zone to (Detail A) Ceiling Mounted
activate a unit shutdown. The other allows two door switches in the 1. Mount the magnet flush with the top edge of the door and secure with
same zone to each activate a unit shutdown. supplied hardware.
Non-magnetic mounting hardware is included to install the switches. If 2. Close the door and mount the switch to the door sill parallel with the
alternate hardware is used it must also be non-magnetic or the door switch magnet, being sure the “cross hairs” are aligned and that the maximum
will not operate properly. gap of 19 mm (0.75 in.) is maintained.
Installer is to supply and fabricate the harness connecting the interface (Detail B) Floor Mounted
harness to the door switch per the table below. The harness should be 18
AWG or better, 3 wires, color coded RED, BLACK and WHITE. 1. Mount the magnet flush with the bottom edge of the door and secure
Interface Harness Wiring Door Switch Wiring
with supplied hardware.
RED = (12 Vdc) POWER RED = (12 Vdc) POWER 2. Close the door and mount the switch to the floor parallel with the
BLACK = (CH) GROUND BLACK = (CH) GROUND
magnet, being sure the “cross hairs” are aligned and that the maximum
gap of 19 mm (0.75 in.) is maintained.
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT
Mounting Locations (Detail C) Outside Door Installation
The door switch can be mounted on the inside or outside of either swing 1. Mount the magnet flush with the top edge of the door and secure with
out or roll-up doors and can be mounted in various positions to supplied hardware.
accommodate particular applications.
IMPORTANT INSTALLATION NOTES: 2. Close the door and mount the switch to the door sill parallel with the
magnet, being sure the “cross hairs” are aligned and that the maximum
• The door switch must be installed away from traffic (i.e. forklifts) or gap of 19 mm (0.75 in.) is maintained
protected from it.

44
 Installing the Door Switch
(OPTION)

Right Angle Mounting

Top x Top Mounting

Side x Side Mounting

45
 Installing the Door Switch
(OPTION)

NOTE: The Door Switch Harness Connectors are located at the rear of the host unit.

Single Door Switch Activation / Single Zone (Detail A) Multiple Door Switch Activation / Single Zone (Detail B)
1. Attach the interface harness (1E29281) to matching door switch 4. Attach the interface harness (1E30238) to matching door switch
connector (Zone 1, 2 or 3) located at the rear of the host unit. connector (Zone 1, 2 or 3) located at the rear of the host unit.
2. Route a 3 wire harness (INSTALLER SUPPLIED) from the interface 5. Route a 3 wire harness (Installer Supplied) from the interface harness
harness to a single door switch. Connect matching wires per the table to each door switch in that zone - Maximum Two Doors. Connect
below (RED/RED, WHITE/WHITE, BLACK/BLACK) to each matching wires per the table below (RED/RED, WHITE/WHITE,
door switch using splice connectors. Crimp splice connectors securely BLACK/BLACK) to each door switch using splice connectors. Crimp
and apply heat with a heat gun. splice connectors securely and apply heat with a heat gun.

Interface Harness Wiring Door Switch Wiring Interface Harness Wiring Door Switch Wiring
RED = (12 Vdc) POWER RED = (12 Vdc) POWER RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT

3. All harnesses should be installed, routed and properly secured to 6. All harnesses should be installed, routed and properly secured to
protect from damage. protect from damage.
7. Operate unit and verify door switch operation.

46
 Installing the Door Switch
(OPTION)
Interface Harness Wiring Door Switch Wiring
RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT

Interface Harness Wiring Door Switch Wiring

RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT

47
 Installing the Status Light
(OPTION)
1. Mount the Status Light in a location so that is visible in the tractor
mirror to the driver. Mount securely with the provided screws.
2. Route harness as shown allowing a “drip-loop” to prevent water from
migrating into the Status Light.
3. Secure harness with clamps.
4. Connect to matching connector located under control box.

48
Installing the Status Light
(OPTION)

AGA817

49
 Installing the Bulkhead

Thermo King Recommends Using A Bulkhead

Bulkheads are available from authorized Thermo King dealers.
CAUTION: Do not drill holes into refrigeration, electrical or
Typical Bulkhead Shown
mechanical components or severe damage to the equipment will NOTE: Follow bulkhead manufacturer specific details for proper
result! installation and recommendations.

Return Airflow
Restrictions of the return airflow adversely affects the performance of the
unit. The area directly behind the evaporator return air inlet must not be
restricted.

Bulkhead Function
A bulkhead is used to keep the return airflow from being restricted if the
load shifts. The bulkhead also prevents the load from shifting into the
return airflow passageway on the front wall of the trailer.

50
Installing the Bulkhead

51
 Installing the Battery
The battery location is on the curbside of the Super II 100, Super II 190 and
CAUTION: Set all electrical controls to the OFF position before Spectrum Super II.
connecting the battery to prevent the unit from starting!
1. Install battery onto tray.
CAUTION: Always wear protective clothing, gloves and eye wear 2. Place hold down bracket onto battery.
when handling and installing batteries!
3. Assemble J-bolts to hold down bracket and tighten nuts. DO NOT over
tighten as this may crack or distort the battery!
CAUTION: Cover battery terminals to prevent accidental shorting
4. Adjust item 4 to prevent movement of battery.
during battery installation!
5. Install positive + battery cable on the positive battery post first to
minimize accidental electrical shorting.
CAUTION: Do not route battery cables together with fuel lines as
this could cause a fire! 6. Install negative - battery cable on negative battery post second to
minimize accidental electrical shorting.
CAUTION: All battery connections must be clean and tightly
secured.

52
Installing the Battery

AGA816

53
 Installing the Bottom Panels
1. Install bottom panels and tighten hardware securely.

54
Installing the Bottom Panels

AGA818

55
 STOP!

SUPER II 100 and SUPER II 190

SINGLE TEMPERATURE
SYSTEMS ONLY!
REFER TO SYSTEM CHECK LIST BELOW TO COMPLETE THIS INSTALLATION

56
 System Check List
All unit mounting hardware torqued to specifications.
No air gaps between unit and trailer wall.
Drain hoses properly routed and secured.
Fuel tank properly installed.
Fuel lines properly routed and fuel fittings tightened securely.
Bulkhead properly designed and installed.
Battery secured correctly and all connections clean and tight.
Doors, covers and guards installed securely.
Run Pre-Trip test (refer to Host Unit Operating Manual).
Run unit under load for eight hours to properly break-in engine.
Release to customer.

57
 STOP!

SPECTRUM SUPER II
MULTI-TEMPERATURE
SYSTEMS ONLY!
TO INSTALL THE SPECTRUM REMOTE EVAPORATORS AND COMPLETE THIS INSTALLATION
REFER TO:

INSTALLATION MANUAL-B

TRAILER EDITION

MULTI-TEMPERATURE

SPECTRUM SYSTEMS

TK 51331-2-IM

58
 STOP

Caution
Thermo King Multi-Temp host units are shipped with a 35 kPa (5 psi) holding charge of
R-404A. This holding charge of approximately 1 kg (2 lbs.) of refrigerant must be recovered.

SEVERE COMPRESSOR DAMAGE will result from operating the engine before completing the
system installation which includes: installing the components, recovering the host unit
holding charge, releasing the remote unit holding nitrogen charge, soldering the refrigeration
lines, leak testing the system, evacuation and clean-up, and charging the system. (SEE
INSTALLATION MANUAL-B)

Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment and limit the potential
harm to the ozone layer that can result from allowing refrigerant to escape into the
atmosphere.
We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into
the atmosphere.

59
 Troubleshooting Guide
NOTE: All Thermo King refrigeration units are pre-tested at the factory prior to shipping. If your unit has problems after installation, check the items
listed below first. If further assistance is required, consult your Thermo King dealer.
SYMPTOM CAUSE CURE

No display on control panel No power to unit Turn unit switch “ON”

Bad battery connection Clean and tighten connections
Low voltage Recharge or replace battery

Diesel engine cranks over No fuel Add fuel to tank

but will not start Kinked/pinched fuel lines Check fuel line routing
Fuel lines connected wrong at tank or unit Check connections
Air in fuel lines Bleed air from fuel lines

Diesel engine starts but lacks power Air in fuel lines Bleed air from fuel lines
Low fuel pressure Check fuel lines for kinks

Rattling noise from unit when running Loose component Secure doors
Secure grilles
Secure guards and covers

Ice buildup on evaporator coil Evaporator coil restriction Check for bulkhead blocking air return inlet
Check for pinched or kinked drain hoses
Air leakage into trailer Check installation of sill gasket

60