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Unit Description

EMI 3000

EMI 3000 is an extended maintenance interval package. It is
standard equipment. The EMI 3000 package consists of the
following key components:

•

New EMI 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 CI-4 Mineral Oil

•

Five Year or 12,000 Hour ELC (Extended Life Coolant)

The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.

NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.

NOTE: The new EMI 3000 oil filters and new EMI 3000 air
cleaners are NOT interchangeable with the older style oil
filters and air cleaners.

Thermo King X430L Compressor

The unit is equipped with a Thermo King X430L, four-cylinder

compressor with 30 cu. in. (492 cm

) displacement. The unit is

also equipped with a compressor oil filter.

Unit Description

EMI 3000

EMI 3000 is an extended maintenance interval package. It is
standard equipment. The EMI 3000 package consists of the
following key components:

•

New EMI 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 CI-4 Mineral Oil

•

Five Year or 12,000 Hour ELC (Extended Life Coolant)

The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.

NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.

NOTE: The new EMI 3000 oil filters and new EMI 3000 air
cleaners are NOT interchangeable with the older style oil
filters and air cleaners.

Thermo King X430L Compressor

The unit is equipped with a Thermo King X430L, four-cylinder

compressor with 30 cu. in. (492 cm

) displacement. The unit is

also equipped with a compressor oil filter.

Содержание SB-200TG

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 7: ...6 Table of Contents 6...

Страница 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...

Страница 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...

Страница 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...

Страница 11: ...10 Introduction 10...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 83: ...82 Alarm Codes 82...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 103: ...102 Warranty 102...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 117: ...116 Serial Number Locations 116...

Страница 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...

Страница 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...

Страница 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...

Страница 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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