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Jump Starting

91

6.

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.

7.

Connect the other end of the red positive (+) jumper cable
to the positive (+) battery terminal on the good battery.

8.

Connect the black negative (–) jumper cable to the
negative (–) battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.

9.

Connect the black negative (–) jumper cable to the lower
starter mounting bolt on the unit’s engine.

CAUTION: Allowing the positive (+) jumper cable
to short can produce dangerous sparks.

1.

Lower Starter Mounting Bolt

Figure 33: Unit Engine

1

Jump Starting

91

6.

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.

7.

Connect the other end of the red positive (+) jumper cable
to the positive (+) battery terminal on the good battery.

8.

Connect the black negative (–) jumper cable to the
negative (–) battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.

9.

Connect the black negative (–) jumper cable to the lower
starter mounting bolt on the unit’s engine.

CAUTION: Allowing the positive (+) jumper cable
to short can produce dangerous sparks.

1.

Lower Starter Mounting Bolt

Figure 33: Unit Engine

1

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Summary of Contents for SB-200TG

Page 1: ...Operator s Manual SB 200TG Operator s Manual SB 200TG TK 53598 2 OP Rev 0 02 07...

Page 2: ...Copyright 2007 Thermo King Corp Minneapolis MN USA Printed in USA Copyright 2007 Thermo King Corp Minneapolis MN USA Printed in USA SB 200TG TK 53598 2 OP Rev 0 02 07...

Page 3: ...recommendations and descriptions contained in this manual and such information recommendations and descriptions should not be regarded as all inclusive or covering all contingencies If you have questi...

Page 4: ...utions 11 General Safety Practices 11 Automatic Start Stop Operation 12 Electrical Hazard 12 Refrigerant 12 Refrigerant Oil 13 First Aid 13 First Aid Refrigerant 13 First Aid Refrigerant Oil 13 Safety...

Page 5: ...evices 32 TG VI Controller Description 35 TG VI Overview 35 Display Screen 36 Upper and Lower Display 37 Display Icons 38 Standard Display 39 Keypad 40 Remote Status Light Optional 43 Manual Pretrip I...

Page 6: ...83 Post Loading Inspection 85 Enroute Inspections 86 Jump Starting 89 Specifications 93 Engine 93 Belt Tension 95 Electrical Control System 95 Refrigeration System 96 Maintenance Inspection Schedule...

Page 7: ...6 Table of Contents 6...

Page 8: ...n 15 Figure 5 Door Latch Warning Located on curbside door 16 Figure 6 Front View 21 Figure 7 TK486V Tier 2 23 Figure 8 Control and Switch Panels 25 Figure 9 Door Latch Location 29 Figure 10 Opening Se...

Page 9: ...90 Figure 32 Sequence for Connecting Jumper Cables 90 Figure 33 Unit Engine 91 Figure 34 Sequence for Disconnecting Jumper Cables 92 Figure 35 Compressor Serial Number Location 113 Figure 36 Engine S...

Page 10: ...maintenance program will also help to keep your unit in top operating condition If factory recommended procedures are followed you will find that you have purchased the most efficient and dependable t...

Page 11: ...10 Introduction 10...

Page 12: ...ermo King units and describes the safety stickers on your unit that you should be familiar with General Safety Practices DANGER NEVER operate the unit with the compressor discharge valve closed Doing...

Page 13: ...working with refrigerants or in areas where they are being used CAUTION Use extreme caution when drilling holes in the unit Drilling into electrical wiring or refrigerant lines could cause a fire Do n...

Page 14: ...warm water Do not apply heat Wrap burns with dry sterile bulky dressing to protect from infection or injury Get prompt medical attention Inhalation Move victim to fresh air and restore breathing if ne...

Page 15: ...r housing AKB66 Safety Precautions 14 Ingestion Do not induce vomiting Immediately contact local poison control center or physician Safety Decals And Locations Figure 1 Belt Warning Located on condens...

Page 16: ...at contain fans which can cause severe injuries when unit automatically starts AKB67 AKB68 Safety Precautions 15 Figure 3 Automatic Start Caution Locations vary depending on model Decals are located n...

Page 17: ...igure 5 Door Latch Warning Located on curbside door WARNING ATENCI N NEW DOOR LATCH DESIGN REQUIRES DOOR TO BE SLAMMED SHUT BEFORE MOVING TRAILER FAILURE TO CLOSE DOOR FIRMLY CAN ALLOW WIND TO TEAR DO...

Page 18: ...e with all applicable regulations adopted by the United States Environmental Protection Agency EPA 2 Free from defects in materials and workmanship in specific emission related parts for a period of f...

Page 19: ...not being completed within 30 days constitutes an emergency As a condition of reimbursement replaced parts and received invoices must be presented at a place of business of a Thermo King authorized se...

Page 20: ...be denied Premium of overtime cost Cost to investigate complaints that are not caused by defects in Thermo King material or workmanship Providing timely notice of a warrantable failure and promptly m...

Page 21: ...20 EPA Emission Control System Warranty Statement 20...

Page 22: ...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...

Page 23: ...Standard Features Option Factory installed Option Dealer Installed Key Features Options SB 200TG EMI 3000 High Capacity Condenser Coil Easy Access Door Design Composite Exterior Panels Long Life Coola...

Page 24: ...pump Figure 7 TK486V Tier 2 ELC Extended Life Coolant ELC Extended Life Coolant is standard equipment The maintenance interval for ELC is five years or 12 000 hours A nameplate on the coolant expansio...

Page 25: ...3000 Hour Cyclonic Air Cleaner Assembly and Air Cleaner Element New EMI 3000 Hour Fuel Filter black with gold lettering New EMI 3000 Hour Dual Element Oil Filter black with gold lettering API Rating...

Page 26: ...programmable microprocessor controller that controls unit functioning and displays operating information quickly and accurately Features include Thermometer Displays return air temperature with 0 1 d...

Page 27: ...Speed Heat High Speed Heat Defrost In CYCLE SENTRY Operation Mode High Speed Cool Low Speed Cool Null Engine Off Low Speed Heat High Speed Heat Defrost Generally the unit will operate in low speed sw...

Page 28: ...ick easy starts are possible Defrost Frost gradually builds up on evaporator coils as a result of normal operation The unit uses hot refrigerant to defrost the evaporator coils Hot refrigerant gas pas...

Page 29: ...onnected sensors The DAS is also connected through a serial port to the unit microprocessor Sensor readings can be viewed on the microprocessor keyboard panel using the SELECT key See Figure 8 Control...

Page 30: ...gine compartment Opening the Secondary Door Latch These units are also equipped with a secondary door latch A secondary door latch nameplate is located below the front doors After opening the door lat...

Page 31: ...30 Unit Description 30 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: ...estriction indicator is attached to the engine intake manifold When the diaphragm indicates 25 service the air filter Press the button on the top of the restriction indicator to reset after servicing...

Page 33: ...ntains a full charge or an overcharge of refrigerant Unit Protection Devices Fuse Link Current Limiter The fuse link is located in the positive battery cable The fuse link protects the electric system...

Page 34: ...d inside the control box Refer to TK 53687 the TG VIc Diagnostic Manual for more information about the fuses Fuse Size Function F1 2A High Speed Relay F2 2A Defrost Relay F3 15A Damper Solenoid Motor...

Page 35: ...nit Description 34 Figure 12 Relay Board F31 2A Modulation F32 2A Remote Lights F33 2A Oil Level Switch Door Switch F34 2A Emergency Run F35 2A Pilot Solenoid F36 30A Main Power Fuse F37 30A Main Powe...

Page 36: ...ssor 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 w...

Page 37: ...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 t...

Page 38: ...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 An example of operating data would be r...

Page 39: ...ll units are equipped with all functions Optional functions are noted However all icons light up when the unit is powered on regardless of whether the unit has that function Cool Icon Indicates that t...

Page 40: ...e 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...

Page 41: ...erating system 1 SELECT Key 4 ENTER Key 2 UP Key 5 TK LOGO Key 3 DOWN Key Figure 17 Keypad ANA03 1 2 3 4 5 SELECT Key Scrolls through the following screens in the Standard Display mode Pnt Print lates...

Page 42: ...oprocessor to confirm the presence of the DAS SELECT Key Continued Hr6 Hourmeter 6 hours Displays only if hourmeter 6 is enabled oIL Engine oil pressure EnT Engine coolant temp rPn Engine revolutions...

Page 43: ...42 TG VI Controller Description 42...

Page 44: ...f 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 Amber sta...

Page 45: ...44 Remote Status Light Optional 44...

Page 46: ...ery trip involving refrigerated cargo NOTE Pretrip inspections are not intended to take the place of regular maintenance inspections Fuel Make sure the diesel fuel supply is adequate to guarantee engi...

Page 47: ...osion Electrolyte should be at the Full mark Belts Make sure belts are in good condition and adjusted to the proper tension For more information about belt tension see the Specifications chapter Elect...

Page 48: ...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...

Page 49: ...r The Microprocessor control panel contains the Display Screen 2 and Keypad 3 used to control microprocessor operations Basic operation of the unit is controlled with the On Off switch 6 located on th...

Page 50: ...heat 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 If the...

Page 51: ...and unit control circuits It should be used when first starting the unit for a trip before the cargo is loaded 1 Perform a Pretrip Inspection See the manual Pretrip Inspection in the previous chapter...

Page 52: ...e settings will be sequentially displayed These settings may be verified by the operator if necessary 12 The diesel engine RPM is checked in both high and low speed 13 The operation of the defrost dam...

Page 53: ...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 temperatur...

Page 54: ...y and easily changed 1 With the standard display on the screen press the UP or DOWN key until the setpoint is at the desired temperature setting Press and release either key repeatedly to cause the te...

Page 55: ...e products normally require continuous air circulation Use the following guidelines to select the proper operating mode to protect the commodity you are transporting Examples of products normally acce...

Page 56: ...when the CYCLE SENTRY mode is selected and the ON OFF switch is in the ON position Continuous Mode When Continuous mode is selected the unit will run continuously to maintain the setpoint and provide...

Page 57: ...ode or be in CYCLE SENTRY Null mode and the coil temperature must be below 45 F 7 C 2 Press the SELECT key until the dEF defrost prompt appears in the display 3 Press the ENTER key to enter a Defrost...

Page 58: ...he event that service is required To determine the software revision installed in your unit perform the following steps 1 Place the On Off switch in the ON position 2 Press and hold the TK LOGO key fo...

Page 59: ...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 1 Connect the printer to the Pr...

Page 60: ...Lod load and the printing process will begin 6 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 con...

Page 61: ...ata that is downloaded or printed from the DAS datalogger A Start Of Trip can be initiated through the use of WinTrac datalogging software or manually in the field The following procedure covers manua...

Page 62: ...pter 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 Check alarms and stored alarms are indicated by...

Page 63: ...b Press the ENTER KEY to clear the alarm Enter must be pushed to clear each alarm if more than one alarm is present After all alarms are cleared the alarm symbol will disappear After about ten seconds...

Page 64: ...ated alarms will be stored in memory until cleared by the operator Document all alarm occurrences and report them to the service technician NOTE The chart on the following pages shows all possible ala...

Page 65: ...Notice to take corrective action before an abnormal condition becomes severe The alarm icon will appear and remain on Shutdown Alarm Indicates conditions that could damage the unit The unit will auto...

Page 66: ...ues to occur the alarm that caused the shutdown will appear on the display and the unit will shut down until the alarm is cleared Code 84 will automatically clear after the final attempt at restarting...

Page 67: ...m 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 Code Description Corre...

Page 68: ...09 High Evaporator Temperature Unit shut down to prevent damage repair immediately X 10 High Discharge Pressure or Temp Unit shut down to prevent damage clear and retry if reoccurs repair immediately...

Page 69: ...Completed Engine was not manually started clear alarm and manually start engine X 17 Engine Failed to Crank Attempt to start in Continuous mode repair as required X 18 High Engine Water Temperature Ch...

Page 70: ...amage repair immediately X 25 Alternator Check Check alternator charging rate repair immediately X X 26 Check Refrigeration Capacity Monitor box temp repair as required X 27 Unassigned 28 Pretrip or S...

Page 71: ...repair as required X 34 Modulation Circuit Check modulation circuit breaker or fuse monitor box temp repair as required X 35 Run Relay Circuit Check run relay circuit repair immediately X 36 Electric...

Page 72: ...ne Water Temp Check Check belts and coolant level repair as required X 42 Unit Forced to Low Speed Temporary overheat condition if condition persists repair as required X 43 Unit Forced to Low Speed M...

Page 73: ...d X 48 Check Belts or Clutch Drive clutch or belts slipping repair immediately X 49 RF Tag Communications Error Data Tag disconnected or inoperative affects data tag only repair as required X 50 Reset...

Page 74: ...Engine Speeds Engine speed out of spec check RPM monitor box temp repair as required X 56 Evap Fan Low Speed Unit operating with no low speed evaporator fan repair as required RC units only X 57 Evap...

Page 75: ...ow Battery Volts Check charge rate and battery voltage repair as required X 62 Ammeter Out of Cal Range Ammeter inaccurate repair as required X 63 Engine Stopped Engine should be running try restart r...

Page 76: ...ry if alarm reoccurs or is shutdown repair as required RC units only X 70 Hourmeter Failure Will not affect unit operation repair after delivery X 71 Hourmeter 4 Exceeds Set Limit Maintenance alarm de...

Page 77: ...ve repair immediately X 77 P Internal Fault Code Controller may be defective repair immediately X 78 P Internal Fault Code Controller may be defective repair immediately X 79 Data Log Overflow Data lo...

Page 78: ...chapter X 85 Forced Unit Operation Temporary forced operation resulting from other alarm codes Refer to detailed explanation at start of chapter X 86 Discharge Press Transducer Unit operating with red...

Page 79: ...pressure lower than expected for current conditions repair as required X 94 Loader Valve 1 Suction pressure drops less than specified when Loader Valve 1 is energized during unit start up repair as r...

Page 80: ...air as required X 100 104 Unassigned 105 Receiver Tank Press Solenoid Circuit Unit operating with reduced heat performance monitor box temp repair as required X 106 Purge Valve Circuit Unit operating...

Page 81: ...nted X 110 Suction Line Solenoid CIrcuit Unit operating with reduced performance monitor box temp repair as required X 111 Unit Not Configured Correctly Controller not set properly for unit type repai...

Page 82: ...with reduced performance monitor box temp repair as required X Table of Alarm Codes Alarms with an asterisk can exist with Alarm Code 84 The alarm can clear automatically if condition does not reoccu...

Page 83: ...82 Alarm Codes 82...

Page 84: ...enroute procedures to help minimize temperature related problems Pre Loading Inspection 1 Pre cool products before loading Note any variances on the manifest 2 Inspect door seals and vent doors for c...

Page 85: ...ions 84 Figure 30 Loading Considerations ADZ30 6 8 9 1 2 5 4 7 1 Correct load height trailers without chutes 2 Tight doors and gaskets 3 Good air circulation around load 4 Proper cargo temperature pri...

Page 86: ...n if the truck is backed into a refrigerated warehouse and the dock door seals fit tightly around the trailer 3 Perform a final check of the load temperature If the load is above or below temperature...

Page 87: ...ost cycle after each enroute inspection Inspection Troubleshooting 1 If a temperature reading is not within the desired temperature range refer to the troubleshooting table on the following pages Corr...

Page 88: ...ed cargo compartment length of time on road etc Correct as required Continue monitoring return air temperature until the reading is within the desired temperature range of the setpoint The unit may ha...

Page 89: ...culation may be due to improper loading of the cargo shifting of the load or fan belt slippage Correct as required Continue monitoring return air temperature until problem is corrected The unit did no...

Page 90: ...make sure it has a 12 volt battery with a negative ground system Do not use a hot shot booster device or a 24 volt source Read and understand the following procedure completely before connecting any j...

Page 91: ...ve battery terminal on the unit s battery 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 it to explod...

Page 92: ...t let the other end of the jumper cable touch anything that conducts electricity 7 Connect the other end of the red positive jumper cable to the positive battery terminal on the good battery 8 Connect...

Page 93: ...battery 11 Turn the unit on and let it start automatically or start it manually If the unit will not crank or start contact a qualified technician NOTE Some units with microprocessors will show an al...

Page 94: ...ications 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...

Page 95: ...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 Sh...

Page 96: ...tor Belt 61 Lower Fan Belt Engine to Idler 67 Upper Fan Belt Fan to Idler 74 NOTE These are the field reset settings Because it is sometimes difficult to use the TK Gauge 204 427 in the field adjust e...

Page 97: ...L 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...

Page 98: ...in top operating condition The following general schedule is provided to assist in monitoring that maintenance For more details refer to the appropriate maintenance manual and to the Manual Pretrip I...

Page 99: ...r cleaner element at 3 000 hours or two years whichever occurs first if air cleaner restriction indicator has not reached 25 in The EMI 3000 air cleaner element has a nameplate that reads EMI 3000 Che...

Page 100: ...st fuel injection nozzles at least every 10 000 hours Replace fuel return lines between fuel injection nozzles every 10 000 hours Electrical Check damper door operation closes on defrost initiation op...

Page 101: ...level Check compressor oil level Check compressor efficiency and pump down refrigeration system Replace dehydrator and check discharge and suction pressure every 2 years Structural Visually inspect un...

Page 102: ...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...

Page 103: ...102 Warranty 102...

Page 104: ...A device located in the suction line to collect liquid refrigerant and meter it safety back to the compressor as gas ambient air temperature Temperature of the air surrounding an object amp Abbreviati...

Page 105: ...l circuit when the current in the circuit exceeds the predetermined amperage rating of the breaker See amp coil A cooling or heating element made of pipe or tube formed into a helical or serpentine sh...

Page 106: ...r drier See dehydrator ECT A ceiling mounted Thermo King remote evaporator See EW and TLE ERC Extended Remote Unit Control Door switches An option on Thermo King multi temperature units to improve tem...

Page 107: ...damages the earth s atmosphere in many countries it is illegal to release this type of refrigerant to the atmosphere HCFC refrigerants are not used in modern Thermo King units Hertz A unit of frequen...

Page 108: ...of diesel fuel formulated for moderate to warm ambient temperatures ohm An electrical unit measuring the amount of resistance opposition to the current flow in an electrical circuit pre cooling 1 To c...

Page 109: ...eration unit cycles between the heat and cool modes more often than normal sight glass A system component that permits visual inspection of oil or refrigerant level and condition thermostat A device t...

Page 110: ...m 25 alarm codes Code 84 restart null 65 Code 85 forced unit operation 65 corrective action 64 displaying and clearing 61 repair 63 types 64 alarm icon 38 amber status light 43 automatic start stop sa...

Page 111: ...displaying operating data during normal operation 52 door inspection 46 down key 41 E ELC extended life coolant 23 electric standby icon 38 electrical control system specifications 95 electrical haza...

Page 112: ...s 38 introduction 9 J jump starting 89 K keypad 40 down key 41 enter 41 select 40 TK logo 41 up key 41 L loading procedures enroute inspections 86 post loading inspection 85 pre loading inspection 83...

Page 113: ...ation 12 decal locations 14 electrical hazards 12 first aid for refrigerant 13 first aid for refrigerant oil 13 general safety practices 11 refrigerant 12 refrigerant oil 13 select key 40 selecting CY...

Page 114: ...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 c...

Page 115: ...ons on the bulkhead above compressor inside curbside door and on roadside of evaporator Serial Number Locations 114 Figure 36 Engine Serial Number Location Figure 37 Unit Serial Number Plate Locations...

Page 116: ...115 Figure 38 Unit Serial Number Plate Serial Number Locations 115 Figure 38 Unit Serial Number Plate...

Page 117: ...116 Serial Number Locations 116...

Page 118: ...ou 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 Emerge...

Page 119: ...g 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 poli...

Page 120: ...001 119 the State of California to cause cancer 001 119 CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer...

Page 121: ...class brands include Thermo King the leader in transport temperature control and Trane a provider of energy ef cient heating ventilating and air conditioning systems building and contracting services...

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