Installation Manual—A

Trailer Edition
SB-III Single Temperature Systems
SB-III TCI Multi-Temperature Systems
SB-III DE Multi-Temperature Systems
TK 50555-2-IM (Rev. 8, 02/06)

Copyright© 1999 Thermo King Corp., Minneapolis, MN, U.S.A.

Release History
Released (09/00)
Rev. 1 (01/01) Added new controller.
Rev. 2 (02/01) Minor art corrections.
Rev. 3 (03/01) Minor art corrections.
Rev. 4 (03/01) Changed “Right Side” to “Roadside” in Installing Battery.
Rev. 5 (03/01) Page 28, Changed bottom warning “support maximum weight” to “support minimum weight”.
Rev. 6 (03/03) Minor text changes.
Rev. 7 (05/03) Minor text changes.
Rev. 8 (02/06) Page 36 - Added DOT/Federal Highway Regulations information regarding installing fuel tank under trailer.

2
 Trailer Edition
Installation Manual for SB-III Systems

AGA778

3
 Introduction
Installation Manual-A was written to assist with the installation of the
Thermo King SB-III, SB-III DE and SB-III TCI 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 TLE 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 Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Uncrating the SB-III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installing the SB-III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Status Light (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SB-III Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Installing the Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Bulkhead Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DE Split-Evaporator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Rear Remote Controller Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . 24 System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Status Light Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 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 7. Work Platform (Recommended)
2. Drill 8. Torque Wrench
3. Drill Bits 9. Forged Eyebolts
4. Tape Measure NOTE: Equipment such as scales, gauges, refrigerant leak detectors, and
torque wrenches should be in good working condition and routinely
5. Mechanics Tools
calibrated to assure accurate readings.
6. Lifting Bar

8
Required Tools

ABN21

9
 Installation Components
1. Locking Nuts 9. Drain Hose Check Valve
1/2 in. x 13 10. Vinyl Taper Strips
2. Washers 11. Fuel Tank
3. Self Tapping Screws 12. Fuel Tank Hanger
4. Clamps 13. Fuel Tank Support Channel
5. Cable Ties 14. Fuel Tank Mounting Strap
6. Fuel Lines Hose 15. Fuel Tank Mounting Brackets
1/4 in. 16. Fuel Tank Nameplate
3/8 in. 17. Fuel Tank Backing Plate
7. Fuel Line Fittings 18. LdB Foam Insulation (option)
1/4 in. 19. Bulkhead (option)
3/8 in. 20. Muffler Rain Cap
8. Fuel Line Connector

10
Installation Components

AGA793

11
 Trailer Requirements

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

Approximate Weight
SB-III 758 kg (1670 lbs.) to 885 kg (1950 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 1553.2 mm (61.15 in.) or severe damage to the equipment will result.
VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

12
Trailer Requirements

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
of the trailer to prevent damage.
1. The evaporator opening must be square. The diagonal measurements
must be ± 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 effect 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

AGA779

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 be
torqued to 82 N•m (60 ft. lbs.) from outside the trailer.
1. Mounting bolts are to extend 57.2 mm (2.25 in.) beyond the front wall
(Detail I).
2. Surface of all mounting bolts are to be flat within 2.5 mm (0.10 in.).

16
Mounting Bolt Dimensions

AGA784

17
 SB-III Dimensions
I. Front View
II. Side View
III. Top View

18
SB-III Dimensions

AGA782

19
 Bulkhead Dimensions

THERMO KING RECOMMENDS USING A BULKHEAD

Bulkheads are available from authorized Thermo King dealers.
Return Airflow Typical Bulkhead Shown
Restrictions of the return airflow adversely affects the performance of the (Dimensions are approximate)
unit. The area directly behind the evaporator return air inlet must not be I. Front View
restricted.
II. Side View
Bulkhead Function NOTE: DE Applications Require a Special Design Bulkhead - see
pages 48-49.
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

AGA791

21
 Battery Dimensions
NOTE: The specified battery, electrical wiring and electronic controls The SB-III is designed for a group 31 battery (see dimensions below).
were designed to operate and maintain only the Thermo King
The battery must be suitable for deep cycling and heavy duty rated with a
refrigeration system and factory authorized Thermo King options.
minimum of 95 amp/hr.
CAUTION: Do not connect other manufacturer’s equipment or
accessories to the Thermo King unit! This could result in severe
damage to equipment and void the warranty!

22
Battery Dimensions

AGA781

23
 Rear Remote Controller Dimensions
(Option)
Remote 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. Recommended material: 76.2 mm (3.00 in.) x 12.7 mm (0.50 in.)
WARNING: Do not use a fork lift to install unit!
mild steel.
II. Use forged chain links and hooks, clevis and pins with strength equal
to total lift capacity of hoist mechanism and meet all safety
WARNING: Thermo King requires a 3 point lifting bar to safely
standards.
lift and install units. A lifting bar can be made from the drawings
provided. III. Bolt together for maximum strength and safety.
1. Forged Clevis Pin.
WARNING: All hardware used to assemble the lifting bar must be
DIN 931 class 10.9 (SAE grade 8). The use of hardware other 2. Forged Chain Links.
than specified may cause personal injury, severe damage to the 3. Locking Master Chain Link.
evaporator 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

AGA783

29
 Uncrating the SB-III

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

Unpacking the SB-III
result in severe damage to the equipment, void the warranty or • Carefully remove plastic stretch wrap from unit.
cause personal injury or death!
• Carefully remove the top cardboard cover.

WARNING: Thermo King requires a 3 point lifting bar to safely • Carefully remove the outer cardboard wrap.
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.
SB-III units are shipped attached to disposable wooden pallet and wrapped • Securely attach 3 point lifting bar to unit.
with protective cardboard and plastic stretch wrap.
• Remove hardware holding unit to the wooden base.
NOTE: To avoid unnecessary damage to your unit, place the unit near
the trailer prior to its removal from the wooden pallet. • Unit is now ready for installation.
IMPORTANT: DO NOT use a sharp knife to remove the stretch wrap or
cardboard wrap as damage to the exterior of the unit will result!

30
Uncrating the SB-III

AGA794

31
 Installing the SB-III
Unit Installation
WARNING: Do not use a forklift to install the unit! This could
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 (Detail IV).
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 (Detail IV).
equipment, void the warranty or cause personal injury or death!
(Detail I). Vinyl Taper Strip Installation Instructions

WARNING: Thermo King requires a 3 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
NOTE: For Whisper Edition units, King of the Road units or units of seam.
equipped with LdB Noise Abatement option, you must install the sound
11. Install two 5/8-11 forged lifting eyebolts into threaded holes located on
reducing foam insulation panel before installing the host unit (Detail II).
the top of the unit (Detail I).
Access to Mounting Holes (Detail III). 12. Use the lifting bar to lift unit up to the trailer opening.
1. Access the top mounting hole through hinged condenser grille. NOTE: All nuts that hold the unit to the trailer should be elastic stop
nuts (Nylock Type) provided in the installation kit.
2. Access the center mounting hole through hinged condenser grille.
13. Attach washer and elastic stop nuts provided in the installation kit.
3. Access the lower mounting hole by opening the control box.
Torque to 82 N•m (60 ft. lbs.).
4. Access the center mounting hole by reaching through the center of the
engine compartment above the bell housing.
5. Access the lower mounting hole through the front hinged access doors.
6. Access the center mounting hole through the hinged condenser grille.
7. Access the top mounting hole through the hinged condenser grille.
8. Access the top center mounting hole from the top of the unit.

32
Installing the SB-III

AGA785

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

AGA792

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 •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 III).
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 pump 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
DANGER: Do not route fuel lines with battery cables or electrical
fuel pickup tube until it is 25.4 mm (1.00 in.) from bottom of tank and
wires, as this could cause a fire!
tighten securely (Detail IV).
1. Install the fuel line bracket to the pre-drilled hole in the frame. This 6. Route fuel return line from the bracket to the fuel tank return fitting.
hole is located in the frame under the compressor (Detail I). Attach fuel line connectors and tighten securely.
2. Fuel lines should be routed in a protective housing with no kinks or 7. Remove plastic cap from the fuel vent and point the outlet to the rear of
sharp bends (Detail II). the trailer.
3. Rubber grommets must be used when routing fuel lines through holes NOTE: Add a sufficient amount of fuel (1/4 tank) to allow the unit to run
in metal (Detail II). for 8 to 12 hours during engine break-in and pre-delivery procedures.

38
Installing the Fuel Lines

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.) inside
remote controller. 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 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.

44
Installing the Status Light
(Option)

AGA787

45
 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
Bulkhead Function
mechanical components or severe damage to the equipment will A bulkhead is used to keep the return airflow from being restricted if the
result! load shifts. The bulkhead also prevents the load from shifting into the
return airflow passageway on the front wall of the trailer.
Return Airflow
Typical Bulkhead Shown
Restrictions of the return airflow adversely affects the performance of the
unit. The area directly behind the evaporator return air inlet must not be Follow bulkhead manufacturer specific details for proper installation and
restricted. recommendations.

NOTE: DE Applications Require a Special Design Bulkhead - page 48-page 49.

46
Installing the Bulkhead

47
 DE Split-Evaporator Installation
SB-III DE Split-Evaporator Installations Center Wall Partition (Detail II)
All center-partition (longitudinally split trailer) installations are unique due 7. A small section of the center partition must be modified to route the air
to the splitting of the air supply outlets and air supply returns. supply from the roadside evaporator to the roadside compartment.
The following details are critical to this installation:
• A special bulkhead must be installed and sealed properly to “split” the
air supply returns for each compartment.
• The center wall partition must be modified and sealed properly to
“split” the air supply outlets for each compartment.
• Air gaps must be properly sealed with foam insulation or caulking.

Bulkhead (Detail I)
1. A special bulkhead must be installed that allows the return air to be
routed back to each roadside and curbside evaporator.
2. From the center line (C/L) of the unit measure 11.5 in. (292 mm) to
locate the unit’s internal center divider.
3. The bulkhead must have a divider channel that runs from the unit’s
internal center divider down to the trailer floor. This diagonal partition
divider must be insulated with the 2.00 in. (50.8 mm) thick foam
insulation supplied in the installation kit.
4. Insulate the entire triangular area, inside the bulkhead, where the air
return crosses over into the opposite compartment with the 1.00 in.
(25.5 mm) thick foam insulation supplied in the installation kit.
5. All air gaps between the top edge of the bulkhead and the evaporator
panel must be sealed completely with foam insulation or caulking.
6. The bulkhead must be equipped with a lower air inlet screen to prevent
debris from entering into the air inlet openings.

48
 DE Split-Evaporator Installation
I II

49
 DE Split-Evaporator Installation
Sealing Air Gaps 5. Front Wall and Center Divider Interface - Special care must be taken
NOTE: The following areas must be properly sealed to prevent air because the insides of the trailer walls are not necessarily flat. If the
leakage and allow the unit to operate correctly. slanted center divider in the bulkhead is not flexible, foam tape and/or
caulking must be added to conform to the front wall.
1. Area Above the DE Evaporator Section - If the remote tubing is routed
across the trailer to the curbside compartment, this area requires foam 6. Trailer Trough Area - The center divider in the bulkhead must extend
block be cut to fit around the insulated tubing and harness. Foam blocks to the bottom of the floor/trough, even though the bulkhead itself must
are supplied in the DE installation kit. These self-adhering blocks can end 6 to 10 in. (152.5 to 254 mm) above the trailer floor. This lower
be placed back-to-back in pairs and squeezed into place. extension of the divider should be flush with the bulkhead surface to
make it easy to seal the front edge of the center partition.
2. Gap Between Top of Evaporator and Trailer Header - This gap (below
trailer header and above the evaporator) should be filled with foam I = Standard Bulkhead
insulation or caulking. II = Foam Blocks
3. Front Edge of Center Partition - Although the front edge of the center III = Full Height Bulkhead
wall partition may have a conforming gasket it cannot conform to
severe steps anywhere along the bulkhead or above the evaporator. The
long foam adhesive backed strip (1.00 in. x 4.00 in.) supplied in the DE
installation kit may be used here, if necessary.
4. Top of Slanted Center Divider in Bulkhead - This area needs gaskets
to conform and seal against the bottom of the internal center divider
between the two DE evaporator. This prevents air leakage between the
two return air areas. Because the evaporators are offset towards the
trailer curbside, this center divider is located 11.5 in. (292 mm) to the
curbside of the trailer center line.

50
 DE Split-Evaporator Installation

I II III

51
 DE Split-Evaporator Installation
Typical DE Split-evaporator Installation 6. The entire triangular are, inside the bulkhead, where the air crosses
over to the opposite compartment must be insulated with at least
Only one of many possible configurations is shown for the SB-III DE-3
1.00 in. (25.4 mm) thick foam insulation.
application
NOTE: The SB-III DE-2 does not have the capability for a remote 7. The transition section of the center portion must be provided to
evaporator. accommodate the roadside and curbside air flow outlets. This must be
insulated similar to the center wall section.
1. Center Divider Partition must seal tight against the floor and ceiling of
the trailer. 8. If refrigeration tubes are routed for an optional remote evaporator, the
liquid and suction lines must be clamped together for heat exchange.
2. At least one rear bulkhead must always be installed with a frozen
compartment. 9. Remote evaporator (OPTIONAL).

3. Adjustable Bulkhead (OPTIONAL). 10. Minimum distance.

4. The trailer must be split into two separate compartments for proper 11. Maximum distance.
return air flow.
5. A special diagonal divider channel must be added within the return air
bulkhead to separate the roadside and curbside return air flow. This
diagonal partition must be insulated with foam at least 2.00 in.
(50.8 mm) thick and cover the bulkhead’s entire partition.

52
 DE Split-Evaporator Installation

11
6 (73 288
5
15 .0
4 mmin.
)

9 (6024.0
9 m0 i 10
m) n.

3
AFD59

53
 Installing the Battery
The battery is located on the roadside of the SB-III.
CAUTION: Set all electrical controls to the OFF position before
connecting the battery to prevent the unit from starting! 1. Install battery and secure with hold down bracket and rods. DO NOT
over tighten as this may crack or distort the battery!
CAUTION: Always wear protective clothing, gloves and eye wear 2. Install positive + battery cable on the positive battery post first to
when handling and installing batteries! minimize accidental electrical shorting.
3. Install negative - battery cable on negative battery post second to
CAUTION: Cover battery terminals to prevent accidental shorting minimize accidental electrical shorting.
during battery installation!

CAUTION: Do not route battery cables together with fuel lines as

this could cause a fire!

CAUTION: All battery connections must be clean and tightly

secured.

54
Installing the Battery

55
 STOP!

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

57
 STOP!

SB-III
MULTI-TEMPERATURE
SYSTEMS ONLY!
TO INSTALL THE TLE REMOTE EVAPORATORS AND COMPLETE THIS INSTALLATION REFER TO:
INSTALLATION MANUAL-B
TRAILER EDITION
MULTI-TEMPERATURE
TLE SYSTEMS
TK-50279-2-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 but will not start No fuel Add fuel to tank
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