Thermo King SB-200TG Operation Manual
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Thermo King SB-200TG Operation Manual

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Operator's Manual
SB-200TG
TK 53598-2-OP (Rev. 0, 02/07)

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  • Page 1 Operator’s Manual SB-200TG TK 53598-2-OP (Rev. 0, 02/07)
  • Page 2 SB-200TG TK 53598-2-OP (Rev. 0, 02/07) Copyright© 2007 Thermo King Corp., Minneapolis, MN, USA Printed in USA...
  • Page 3 Thermo King dealer. The procedures described herein should be undertaken only by qualified personnel. Failure to implement these procedures correctly may cause damage to the Thermo King unit or other property or personal injury. Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence...

  • Page 4: Table Of Contents

    Safety Decals And Locations ....14 Thermo King X430L Compressor ....24...
  • Page 5 Table of Contents TG-VI Microprocessor Controller ....25 Unit Operation with TG-VI Controller ... 47 CYCLE-SENTRY Start-Stop Controls .
  • Page 6 Table of Contents Loading and Enroute Inspections ....83 Warranty ........101 Pre-Loading Inspection .
  • Page 7 Table of Contents...

  • Page 8: List Of Figures

    List of Figures Figure 1:Belt Warning Figure 14:Display Screen With all Possible Icons and (Located on condenser housing) ....14 Characters Displayed ......36 Figure 2:Belt Replacement Caution Figure 15:Upper and Lower Displays .
  • Page 9 List of Figures Figure 29:Alarm Symbol Location ....61 Figure 35:Compressor Serial Number Location ..113 Figure 30:Loading Considerations ....84 Figure 36:Engine Serial Number Location .

  • Page 10: Introduction

    Introduction There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational your Thermo King unit, but a few minutes studying this purposes only and the information furnished herein should manual will be time well spent.
  • Page 11 Introduction...

  • Page 12: Safety Precautions

    Safety Precautions Thermo King recommends that servicing be done only by a WARNING: Keep hands and loose clothing clear of Thermo King dealer. However, you should be aware of several fans and belts at all times when the unit is operating safety practices.

  • Page 13: Automatic Start/Stop Operation

    Safety Precautions Electrical Hazard CAUTION: Use extreme caution when drilling holes in the unit. Drilling into electrical wiring or CAUTION: Turn off the high voltage power supply refrigerant lines could cause a fire. Do not drill into and disconnect the electric cable before working on structural components.

  • Page 14: Refrigerant Oil

    Safety Precautions First Aid WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally First Aid–Refrigerant released into the atmosphere from the liquid state. Eyes: For contact with liquid, immediately flush eyes with Refrigerant Oil large amounts of water. Get prompt medical attention. Observe the following precautions when working with or Skin: Flush areas with large amounts of warm water.

  • Page 15: Safety Decals And Locations

    Safety Precautions Safety Decals And Locations Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician. AKB65 Figure 1: Belt Warning (Located on condenser housing) AKB66 Figure 2: Belt Replacement Caution (Located on condenser housing)

  • Page 16: Figure 3:Automatic Start Caution

    Safety Precautions AKB67 AKB68 Figure 3: Automatic Start Caution (Locations vary depending on model. Decals are Figure 4: Fan Caution located near areas that contain moving parts which (Locations vary depending on model. Decals are can cause severe injuries if hands or clothing become located near areas that contain fans which can cause tangled when unit automatically starts.) severe injuries when unit automatically starts.)

  • Page 17: Figure 5:Door Latch Warning (Located On Curbside Door)

    Safety Precautions WARNING NEW DOOR LATCH DESIGN REQUIRES DOOR TO BE SLAMMED SHUT BEFORE MOVING TRAILER. FAILURE TO CLOSE DOOR FIRMLY CAN ALLOW WIND TO TEAR DOOR FROM REFRIGERATION UNIT AND CAUSE INJURY TO OTHERS. ATENCIÓN NUEVO DESEÑO DE CERRADURA REQUIERE ASOTAR LA PUERTA ANTES DE CONDUCIR EL TRAILER.

  • Page 18: Epa Emission Control System Warranty Statement

    EPA Emission Control System Warranty Statement Thermo King warrants to the initial owner and each subsequent During the term of this warranty, Thermo King will provide, owner that the certified, non-road diesel engine in your unit is: through a Thermo King authorized service dealer or other...

  • Page 19: Responsibilities

    Thermo King parts. However, warranty. Thermo King is not liable for parts that are not genuine Thermo King parts. Responsibilities A part not being available within 30 days or repair not being This warranty is subject to the following: completed within 30 days constitutes an emergency.

  • Page 20: Owner Responsibilities

    • Premium of overtime cost. Remedies under this warranty are limited to the provision of material and services as specified herein. Thermo King is not • Cost to investigate complaints that are not caused by responsible for incidental or consequential damages such as defects in Thermo King material or workmanship.
  • Page 21 EPA Emission Control System Warranty Statement...

  • Page 22: Unit Description

    Unit Description Unit Overview The Thermo King SB-200TG is a one piece, self-contained, diesel powered, air cooling/heating unit operating under the control of a TG-VI programmable microprocessor controller. The unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall.

  • Page 23: Design Features

    Unit Description Design Features Key Features & Options SB-200TG The following chart lists key design features and options. EMI-3000 Standard Features High-Capacity Condenser Coil Easy-Access Door Design Option/Factory installed Composite Exterior Panels Option/Dealer Installed Long-Life Coolant/Silicone Hoses Standard Unit Color White...

  • Page 24: Diesel Engine

    Unit Description Diesel Engine ELC (Extended Life Coolant) The unit uses a quiet running TK486V (Tier 2), which is a ELC (Extended Life Coolant) is standard equipment. The 4-cylinder, water cooled, direct injection diesel engine. The maintenance interval for ELC is five years or 12,000 hours. A engine is coupled directly to the compressor.

  • Page 25: Emi 3000

    Thermo King X430L Compressor EMI 3000 is an extended maintenance interval package. It is The unit is equipped with a Thermo King X430L, four-cylinder standard equipment. The EMI 3000 package consists of the compressor with 30 cu. in. (492 cm ) displacement.

  • Page 26: Tg-Vi Microprocessor Controller

    Unit Description TG-VI Microprocessor Controller Thermo King has applied the newest technological advances to develop a programmable microprocessor controller that controls unit functioning and displays operating information quickly and accurately. ANA03 Features include: Thermometer: Displays return air temperature with 0.1 degree accuracy.
  • Page 27 Unit Description In CYCLE-SENTRY Operation Mode: CAUTION: Firmly close the controller access door • High Speed Cool after operating the microprocessor controller or before starting a trip. The control panel might be • Low Speed Cool damaged in transit if the door is not firmly closed. •...

  • Page 28: Cycle-Sentry Start-Stop Controls

    Unit Description CYCLE-SENTRY Start-Stop Controls Defrost The CYCLE-SENTRY Start-Stop fuel saving system provides Frost gradually builds-up on evaporator coils as a result of optimum operating economy. normal operation. The unit uses hot refrigerant to defrost the evaporator coils. Hot refrigerant gas passes through the CYCLE-SENTRY automatically starts the unit on evaporator coil and melts the frost.

  • Page 29: Das (Optional)

    The data can be retrieved using an IBM PC compatible laptop or desktop computer and Thermo King WinTrac 4.1 (or higher) software. The computer is connected to the computer port on the front of the control box. See “Figure 8: Control and Switch Panels,”...

  • Page 30: Opening The Front Doors

    Unit Description Opening the Front Doors Opening the Secondary Door Latch These units are also equipped with a secondary door latch. A Pull the door latch handle to open the door and access the secondary door latch nameplate is located below the front engine compartment.

  • Page 31: Closing The Front Doors

    Unit Description Closing the Front Doors Slam the door to close it. Do not push the door closed while holding the door latch handle open or the door will not close properly.

  • Page 32: Engine Compartment Components

    Unit Description Engine Compartment Components The following maintenance items can be checked visually. WARNING: The unit can start at any time without warning. Place the On/Off switch in the Off position before inspecting any part of the unit. Air Filter Restriction Indicator: The air filter restriction indicator is attached to the engine intake manifold.

  • Page 33: Unit Protection Devices

    Take the unit to a minutes to stabilize operating conditions and temperature Thermo King dealer if this occurs. before attempting to check the refrigerant. Low Oil Level Switch: The low oil level switch closes if the NOTE: If the ball floats, there is sufficient refrigerant in the oil drops below an acceptable level.
  • Page 34 Figure 12 on page 34) is located inside the control box. Refer to TK 53687 the TG-VIc Diagnostic Manual for more High Speed Light information about the fuses. None No Fuse - All Thermo King and Bosch Alternators Fuse Size Function 2A Fuse - All Prestolite Alternators...

  • Page 35: Figure 12:Relay Board

    Unit Description Fuse Size Function Modulation Remote Lights Oil Level Switch/ Door Switch Emergency Run Pilot Solenoid Main Power Fuse Main Power Fuse AJA1069 Figure 12: Relay Board...

  • Page 36: Tg-Vi Controller Description

    TG-VI Controller Description TG-VI Overview This unit is controlled by a ThermoGuard TG-VI microprocessor. The TG-VI control panel consists of a display screen and a keypad. The TG-VI control panel is shown in Figure 13. This display shows all possible icons and characters. Not all icons and characters will be displayed at the same time in normal operation.

  • Page 37: Display Screen

    TG-VI Controller Description IMPORTANT: To prevent damage to the controller, always push the controller access door firmly closed. Display Screen The display screen indicates operating status, including temperature, setpoint, mode, alarm codes, and other information depending on the unit status. The display consists of an upper and lower display in the center and icons around the edges.

  • Page 38: Upper And Lower Display

    TG-VI Controller Description Upper and Lower Display The center of the display screen has a five character row of large digits called the upper display and a four character row of small digits called the lower display. The upper and lower displays show operating data for the screen you are viewing.

  • Page 39: Display Icons

    TG-VI Controller Description Display Icons Defrost Icon: Indicates that the unit is defrosting. Lit icons indicate the operating modes of the unit and show if alarm codes are present. They appear around the left, right, and bottom edges of the display, and are listed here in that order. CYCLE-SENTRY Icon: Indicates that the NOTE: Not all units are equipped with all functions.

  • Page 40: Standard Display

    TG-VI Controller Description Standard Display The Standard Display is the default display screen showing setpoint temperature and return air temperature. See “Figure 16: Standard Display,” on page 39. On the Standard Display screen: • The upper display shows the return air temperature in Fahrenheit or Celsius depending on the unit’s programming.

  • Page 41: Keypad

    TG-VI Controller Description Keypad Key: Scrolls through the following ELECT screens in the Standard Display mode: This section describes the keypad keys that control the operating system. [Pnt]: Print latest trip report. Displays only if DAS is connected and Print Shortcut is enabled.
  • Page 42 TG-VI Controller Description Key: On the Standard Display screen, it Key (Continued) ELECT increases the setpoint. On other screens, it [Hr6]: : Hourmeter 6 hours. Displays only if changes the displayed prompt or other setting. hourmeter 6 is enabled. [oIL]: Engine oil pressure. [EnT]: Engine coolant temp.
  • Page 43 TG-VI Controller Description...

  • Page 44: Remote Status Light (Optional)

    Remote Status Light (Optional) The Remote Status Light mounts on the cargo box for easy viewing of the unit’s mode. The remote light indicates operating status as follows: Green status light: Illuminates the “T” portion of the TK logo when the unit is functioning properly with no alarm codes.
  • Page 45 Remote Status Light (Optional)

  • Page 46: Manual Pretrip Inspection (Before Starting The Unit)

    Manual Pretrip Inspection (Before Starting the Unit) Engine Coolant: Check the engine coolant level. The engine Pretrip inspections are an important part of a preventative maintenance program designed to minimize operating coolant must have antifreeze protection to –30 F (–34 C). problems and breakdowns.
  • Page 47 Manual Pretrip Inspection (Before Starting the Unit) Keep the radiator clean and clear of debris by gently spraying Damper: Make sure the damper in the evaporator air outlets with water. move freely, with no sticking or binding. NOTE: Used Ethylene Glycol based coolant is a regulated Coils: Make sure the condenser and evaporator coils are clean substance requiring proper disposal.

  • Page 48: Unit Operation With Tg-Vi Controller

    Unit Operation with TG-VI Controller Thermo King has applied the latest advances in computer technology to develop a device that controls temperature and unit functioning, and displays operating information quickly and accurately. There is nothing complicated about learning to operate the...

  • Page 49: Control Panel

    Unit Operation with TG-VI Controller Control Panel WARNING: Do not operate the unit until you are completely familiar with the location and function of each control. ANA03 Two sets of controls are used to operate a unit that has a TG-VI Microprocessor Controller.

  • Page 50: Starting The Diesel Engine

    Unit Operation with TG-VI Controller Starting the Diesel Engine Turn the On/Off switch to the On position. If no key is pressed, the engine will automatically preheat and start in about 10 seconds. If a key is pressed (to change setpoint or view display screens), the engine will automatically preheat and start about 10 seconds after the last key is pressed.

  • Page 51: Starting The Unit With A Unit Self Check Test

    Unit Operation with TG-VI Controller Starting the Unit with a Unit Self Check Test This procedure is used for a complete check of the trailer, unit, and unit control circuits. It should be used when first starting the unit for a trip before the cargo is loaded. Perform a Pretrip Inspection.
  • Page 52 Unit Operation with TG-VI Controller If any alarms were not cleared before starting the Unit Self 17. At the completion of the Unit Self Check, the check results Check, they will be displayed at this time. They can be will appear on the display. They will remain until any key cleared by pressing the E key.

  • Page 53: Displaying Operating Data During Normal Operation

    Unit Operation with TG-VI Controller Displaying Operating Data During Normal Operation During normal operation, the standard display appears on the screen. Return air temperature is displayed in the upper readout, and the setpoint is displayed in the lower readout. In this example, the return air temperature is 50.8 F and the setpoint temperature is 35 F.

  • Page 54: Changing The Setpoint

    Unit Operation with TG-VI Controller Changing the Setpoint The setpoint temperature of the Thermo King unit can be quickly and easily changed. With the standard display on the screen, press the U key until the setpoint is at the desired temperature setting.

  • Page 55: Selection Of Operating Modes

    • Film • All non-edible products. The Thermo King CYCLE-SENTRY system is designed to save refrigeration fuel costs. The savings vary with the Examples of products normally requiring Continuous Run commodity, ambient temperatures and trailer insulation. Operation for air flow: However, not all temperature controlled products can be •...

  • Page 56: Selecting Cycle-Sentry Or Continuous Mode

    Unit Operation with TG-VI Controller Selecting CYCLE-SENTRY or Continuous Mode NOTE: The CYCLE-SENTRY icon will appear when the CYCLE-SENTRY mode is selected and the O switch is in the O position. Continuous Mode: When Continuous mode is selected, the unit will run continuously to maintain the setpoint and provide constant airflow.

  • Page 57: Initiating A Manual Defrost Cycle

    Unit Operation with TG-VI Controller Initiating a Manual Defrost Cycle The unit must be running in Continuous or CYCLE-SENTRY mode or be in CYCLE-SENTRY Null mode and the coil temperature must be below 45 F (7 C). Press the S key until the dEF (defrost) prompt ELECT appears in the display.

  • Page 58: Checking Software Revision

    Unit Operation with TG-VI Controller Checking Software Revision There are currently several different software revisions in use. This information may be requested in the event that service is required. To determine the software revision installed in your unit, perform the following steps. Place the On/Off switch in the ON position.

  • Page 59: Printing A Trip Report

    Unit Operation with TG-VI Controller Printing a Trip Report This procedure is only available on units equipped with an optional DAS datalogger. It prints the current DAS record directly to an handheld printer. Only data from the directly connected DAS sensors can be printed. Graphs are not available with a handheld printer.
  • Page 60 Unit Operation with TG-VI Controller Press the E key. The display will briefly show Lod NTER (load) and the printing process will begin. Place the On/Off switch in the Off position to stop printing. NOTE: If printing is initiated without a printer connected, or if the printer cable is not connected properly, printing will be aborted after 30 seconds and the standard display will appear.

  • Page 61: Initiating A Start Of Trip

    Unit Operation with TG-VI Controller Initiating a Start of Trip 10. Press the E key. The display will briefly show Lod NTER (load). A Start Of Trip Marker has been inserted. This procedure is only available on units equipped with an If no keys are pressed for 30 seconds, the standard display will optional DAS datalogger.

  • Page 62: Displaying And Clearing Alarm Codes

    Unit Operation with TG-VI Controller Displaying and Clearing Alarm Codes For detailed alarm code information refer to the “Alarm Codes” chapter in this manual. NOTE: Alarms are indicated by the appearance of an alarm symbol (exclamation point within a triangle) in the upper-right on the screen.
  • Page 63 Unit Operation with TG-VI Controller To reset the alarm system. Press the S to display the alarm screen. ELECT KEY Press the E to clear the alarm. Enter must be NTER KEY pushed to clear each alarm if more than one alarm is present After all alarms are cleared, the alarm symbol will disappear.

  • Page 64: Alarm Codes

    The operator can repair certain faults, other faults can only be abnormal condition. Alarms direct an operator or service repaired by your Thermo King Dealer. Refer to the table on the technician to the source of a problem. following pages for the proper corrective action.

  • Page 65: Alarm Types

    Alarm Codes Alarm Types Corrective Action The three types of alarms are described below. They can occur There are three levels of corrective action that can be taken individually or with other alarms. More than one alarm can be when an alarm condition occurs. present at one time.

  • Page 66: Alarm Code 84 (Restart Null)

    Alarm Codes Alarm Code 84 (Restart Null) Alarm Code 85 (Forced Unit Operation) Alarm Code 84 is a temporary abnormal condition resulting from other alarms. The unit shuts down for approximately 15 Alarm Code 85 is also a temporary abnormal condition minutes.

  • Page 67: Table Of Alarm Codes

    Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 68 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 69 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 70 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 71 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 72 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 73 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 74 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 75 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 76 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 77 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 78 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 79 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 80 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 81 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 82 Alarm Codes Table of Alarm Codes *Alarms with an asterisk (*) can exist with Alarm Code 84. The alarm can clear automatically if condition does not reoccur. NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description...
  • Page 83 Alarm Codes...

  • Page 84: Loading And Enroute Inspections

    Loading and Enroute Inspections This chapter describes pre-loading, post loading, and enroute Verify that the setpoint temperature is correct for your inspection procedures. Thermo King refrigeration units are cargo. Pre-cool the trailer as required. designed to maintain the required product load temperature Push the microprocessor controller access door firmly during transit.

  • Page 85: Figure 30:Loading Considerations

    Loading and Enroute Inspections Correct load height (trailers without chutes) Tight doors and gaskets Good air circulation around load Proper cargo temperature (prior to loading) Interior/exterior walls and insulation in good condition Clear defrost drains Good outside air circulation Unit inspection Tight seals ADZ30 Figure 30: Loading Considerations...

  • Page 86: Post-Loading Inspection

    Loading and Enroute Inspections Post-Loading Inspection Close or supervise the closing of the cargo box doors. Make sure they are securely locked. Post-loading inspections ensure the cargo has been loaded Make sure the setpoint is at the temperature listed on the properly.

  • Page 87: Enroute Inspections

    Verify setpoint is correct. Immediately contact the nearest Thermo King Service Check the return air temperature reading. It should be Center or your company office. within the desired temperature range.
  • Page 88 A competent refrigeration technician is required to add refrigerant or repair the system. Contact the nearest Thermo King dealer, authorized Service Center, or call the Thermo King Cold Line for referral. Consult the Table of Contents for Cold Line information.
  • Page 89 Loading and Enroute Inspections Problem Cause Remedy Improper air Inspect the unit and cargo compartment to determine if the evaporator fan(s) circulation in the are working and properly circulating the air. Poor air circulation may be due cargo compartment. to improper loading of the cargo, shifting of the load, or fan belt slippage. Correct as required.

  • Page 90: Jump Starting

    Jump Starting If the battery in a unit is discharged or run down, the unit may IMPORTANT: Make sure to use a 12-volt battery to jump be jump started using jumper cables and another battery or start the unit. If you are using a vehicle, make sure it has a vehicle.

  • Page 91: Figure 31:Unit Battery

    Jump Starting CAUTION: Do not use a match or lighter as a light near the battery. Use a flashlight. A flame or a spark can ignite the gas in the battery and cause Unit it to explode. (Discharged) 12-Volt Remove the red cover from the positive (+) battery Battery terminal on the unit’s battery.

  • Page 92: Figure 33:Unit Engine

    Jump Starting Connect the red positive (+) jumper cable to the positive (+) battery terminal on the unit’s battery. Do not let the other end of the jumper cable touch anything that conducts electricity. CAUTION: Allowing the positive (+) jumper cable to short can produce dangerous sparks.

  • Page 93: Figure 34:Sequence For Disconnecting

    Jump Starting 10. If you are using a vehicle to jump start the unit, start the vehicle and let it run for a few minutes. This will help charge the discharged battery. Unit (Discharged) CAUTION: Be careful around fans and belts. 12-Volt Keep your hands away from moving parts when an Battery...

  • Page 94: Specifications

    Specifications Engine Engine TK486V (Tier 2) Fuel Type No. 2 diesel fuel under normal conditions No. 1 diesel fuel is acceptable cold weather fuel Oil Capacity: Crankcase 13 quarts (12.3 liters) Fill to full mark on dipstick Oil Type API Classification CI-4 or better Oil Viscosity 5 to 122 F (-15 to 50 C): SAE 15W-40 -13 to 104 F (-25 to 40 C): SAE 10W-40...
  • Page 95 Specifications Engine (Continued) Engine Thermostat 160 F (71 C) Engine Coolant Type ELC (Extended Life Coolant), which is red. Use a 50/50 concentration of any of the following equivalents: Chevron Dex-Cool Texaco ELC Havoline Dex-Cool® Havoline XLC for Europe Shell Dexcool® Shell Rotella Saturn/General Motors Dex-Cool®...

  • Page 96: Belt Tension

    Specifications Belt Tension Belt Tension No. on TK Gauge 204-427 Alternator Belt Lower Fan Belt (Engine to Idler) Upper Fan Belt (Fan to Idler) NOTE: These are the field reset settings. Because it is sometimes difficult to use the TK Gauge 204-427 in the field, adjust each belt to allow 1/2 inch (13mm) deflection at the center of the longest span.

  • Page 97: Refrigeration System

    Specifications Refrigeration System Compressor Thermo King X430L Compressor Oil Charge 4.3 quarts (4.1 liters) Compressor Oil Type Polyol Ester Type P/N 203-413 Refrigerant Charge - Type 13 lb (5.9 kg) - R404A Heat/Defrost Method Hot gas High Pressure Cutout Switch Opens 470 +7/-35 psi (3241 +48/-241 kPa) Automatic Reset @ 375 ±...

  • Page 98: Maintenance Inspection Schedule

    A closely followed maintenance program will help to keep For more details, refer to the appropriate maintenance manual your Thermo King unit in top operating condition. The and to the “Manual Pretrip Inspection” in this manual. following general schedule is provided to assist in monitoring that maintenance.
  • Page 99 Maintenance Inspection Schedule Every Every Annual Pretrip 1,500 3,000 4,500 Inspect/Service These Items Hours Hours* Hours Engine (Continued) • • • Check air cleaner restriction indicator (change when indicator reaches 25 in.). Replace EMI 3000 air cleaner element at 3,000 hours or two years (whichever occurs first) if air cleaner restriction indicator has not reached 25 in.
  • Page 100 Maintenance Inspection Schedule Every Every Annual Pretrip 1,500 3,000 4,500 Inspect/Service These Items Hours Hours* Hours Engine (Continued) — Change ELC (red) engine coolant every 5 years or 12,000 hours. — Test fuel injection nozzles at least every 10,000 hours. —...
  • Page 101 Maintenance Inspection Schedule Every Every Annual Pretrip 1,500 3,000 4,500 Inspect/Service These Items Hours Hours* Hours Refrigeration • • • • Check refrigerant level. • • • Check compressor oil level. • Check compressor efficiency and pump down refrigeration system. —...

  • Page 102: Warranty

    Warranty Terms of the Thermo King Warranty are available on request. Please reference document TK 50046 for the Thermo King Trailer Unit Warranty. See the “EPA Emission Control System Warranty Statement” chapter earlier in this manual for the EPA Emission Control...
  • Page 103 Warranty...

  • Page 104: Glossary

    Thermo King unit. (Loading too close to the unit restricts air flow and system efficiency.) 2) bulkhead ambient air temperature: Temperature of the air divider.
  • Page 105 Glossary CFC: Chlorofluorocarbon. A chlorine-based refrigerant condenser: An arrangement of tubing in which the consisting of chlorine, fluorine and carbon. Example: R12. In vaporized and compressed refrigerant is liquefied as heat is many countries it is illegal to release this type of refrigerant to removed.
  • Page 106 Also establishes a maximum defrost heat during the cooling cycle. duration if normal circuits malfunction. EW: A wall-mounted Thermo King remote evaporator. See dehydrator: A device used to remove moisture from ECT and TLE. refrigerant. Also called a drier.
  • Page 107 HCFC refrigerants are not kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar = used in modern Thermo King units. 0.145 psi. Hertz: A unit of frequency equal to one cycle per second.
  • Page 108 Some engines use an intake manifold heater rather in the front of a trailer and designed to prevent restriction of than glow plugs. return air flow to the Thermo King unit due to improper loading. See bulkhead. pre-trip inspection: Checking the operation of a...
  • Page 109 A device that controls unit modes of operation to maintain a selected box temperature. TLE: Thin-line evaporator. A Thermo King remote evaporator designed to be compact (thin) while supplying superior air flow. See ECT and EW.

  • Page 110: Index

    Index air cleaner restriction indicator 31 changing setpoint 53 alarm 25 coils inspection 46 alarm codes compressor 24 Code 84 (restart null) 65 compressor oil sight glass 31 Code 85 (forced unit operation) 65 continuous mode 55 corrective action 64 control panel 48 displaying and clearing 61 cool icon 38...
  • Page 111 Index display 36 engine oil level 45 alarm icon 38 engine specifications 93 cool icon 38 enroute inspections 86 CYCLE-SENTRY 38 enter key 41 defrost icon 38 extended life coolant (ELC) 23 electric standby 38 heat icon 38 icons 38 first aid for refrigerant 13 setpoint 38 first aid for refrigerant oil 13...
  • Page 112 Index high pressure relief valve 32 maintenance inspection schedule 97 manual defrost cycle, initiating 56 icons 38 manual pretrip inspection 45 introduction 9 microprocessor controller TG-VI 25 jump starting 89 oil type compressor 96 engine 93 keypad 40 On/Off switch 48 down key 41 enter 41 select 40...
  • Page 113 Index refrigeration system specifications 96 starting unit with unit self check test 50 remote status light 43 status light, remote 43 restart null alarm code 65 structural inspection 46 switch panel and controls 25 safety precautions 11 automatic start/stop operation 12 TG-VI decal locations 14 controller 25...

  • Page 114: Serial Number Locations

    Serial Number Locations Compressor: Stamped between the cylinders on the front end above the oil pump. Engine: See the engine identification plate located on the engine valve cover. Unit: Nameplates on the bulkhead above the compressor inside the curbside door and on the roadside of the evaporator. Figure 35: Compressor Serial Number Location...

  • Page 115: Figure 36:Engine Serial Number Location

    Serial Number Locations Figure 37: Unit Serial Number Plate Locations Figure 36: Engine Serial Number Location (on the bulkhead above compressor inside curbside door and on roadside of evaporator)

  • Page 116: Figure 38:Unit Serial Number Plate

    Serial Number Locations Figure 38: Unit Serial Number Plate...
  • Page 117 Serial Number Locations...

  • Page 118: Emergency Cold Line

    If you can’t get your rig rolling, and you have tried the Thermo King North American Service Directory (available from any Thermo King dealer) to reach a dealer without success, then call the Toll Free Emergency Cold Line Number (888) 887-2202.

  • Page 119: Recover Refrigerant

    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.

  • Page 120: California Proposition 65 Warning

    CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
  • Page 121 Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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