Page 2 If further information is required, Thermo King Corporation should be consulted. Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request.
Page 3 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 5: Table Of Contents
Thermo King X430L Reciprocating Compressor ........
Page 6 Table of Contents Operating Instructions (continued) Changing the Setpoint ..............43 Selecting CYCLE-SENTRY or Continuous Mode .
Page 7 Table of Contents Engine Maintenance (continued) Engine Fuel System ..............80 Operation .
Page 8 Table of Contents Refrigeration Service Operations (continued) Pilot Solenoid ................118 Suction Vibrasorber .
Page 9: List Of Figures
Figure 1: SB-210/SB-310 Front View ........
Page 10 Figure 74: Correct Injection Timing Mark Alignment for SB-210 ....... .
Page 11 List of Figures Figure 100: Three-Way Valve ............. . 114 Figure 101: Gasket Tool P/N 204-424 .
Page 12 List of Figures...
Page 13: Safety Precautions
Safety Precautions Thermo King recommends that all service be DANGER: Avoid engine operation in performed by a Thermo King dealer. However, confined spaces and areas or you should be aware of several general safety circumstances where fumes from the practices: engine could become trapped and cause serious injury or death.
Page 14: Battery Removal
Safety Precautions Battery Removal CAUTION: When transferring refrigerant, use a process that prevents or DANGER: Disconnect the negative greatly restricts refrigerant from escaping battery terminal (-) first when removing a into the atmosphere. Refrigerant damages battery. Connect the positive terminal (+) the earth’s upper ozone layer.
Page 15: Electrical Hazards
Safety Precautions Electrical Hazards WARNING: Do not wear jewelry, watches or rings because they increase the risk of High Voltage shorting out electrical circuits and damaging equipment or causing severe DANGER: Lethal amounts of voltage are burns. present in some electrical circuits. Use extreme care when working on an Microprocessor Service operating refrigeration unit.
Page 16: Welding Precautions
Safety Precautions Move victim to fresh air and use Welding Precautions INHALATION: CPR (cardio pulmonary resuscitation) or Take precautions before electrically welding any mouth-to-mouth resuscitation to restore breathing, portion of the unit or the vehicle to which it is if necessary. Stay with victim until emergency attached.
Page 17: Specifications
-13 to 104 F (-25 to 40 C): SAE 10W-40 -13 to 86 F (-25 to 30 C): SAE 10W-30 -22 to 32 F (-30 to 0 C): SAE 5W-30 Engine rpm: SB-210 Low Speed Operation 1450 ± 25 rpm SB-210 High Speed Operation 2200 ± 25 rpm SB-310 Low Speed Operation 1450 ±...
Page 18: Belt Tension
Specifications Engine (Continued) 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® Caterpillar ELC Detroit Diesel POWERCOOL®...
Page 19: Refrigeration System
Specifications Refrigeration System Compressor Thermo King X430L Refrigerant Charge—Type: SB-210 13 lb (5.9 kg)—R404A SB-310 16 lb (7.3 kg)—R404A Compressor Oil Charge 4.3 qt (4.1 liters)* Compressor Oil Type Polyol Ester type P/N 203-513 Mechanical Throttling Valve Setting 27 to 29 psi (186 to 200 kPa)
Page 20: Electrical Components
Specifications Electrical Components NOTE: Disconnect components from unit circuit to check resistance. Component Current Draw (Amps) Resistance—Cold at 12.5 Vdc (Ohms) Fuel Solenoid: Pull-in Coil 35 to 45 0.2 to 0.3 Hold-in Coil 24 to 29 Damper Solenoid High Speed (Throttle) Solenoid Air Heater 0.14 Pilot Solenoid...
Page 21: Maintenance Inspection Schedule
Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours Microprocessor • Run Pretrip Test (see “Pretrip Tests” in the Operating Manual). Engine • Check fuel supply. • Check engine oil level. • • •...
Page 22 Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours Refrigeration • • • • Check refrigerant level. • • • Check for proper suction pressure. • Check compressor oil level and condition. • Check compressor efficiency and pump down refrigeration system.
Page 23: Unit Description
Unit Description Unit Overview The Thermo King SB-210/SB-310 is a one piece, self-contained, diesel powered, air cooling/heating unit operating under the control of a programmable microprocessor controller. The unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall.
Page 24: Design Features
Directional Air Delivery Thermo King X430L Reciprocating Vibration Isolation Compressor System Aluminum Undermount The unit is equipped with a Thermo King X430L Fuel Tank 50 Gal. (186 reciprocating compressor with 30.0 cu. in. Liter) (492 cm ) displacement. Fuel Heater...
Page 25: Electronic Throttling Valve
SMART REEFER 2 (SR-2) Control System The Electronic Throttling Valve (ETV) is optional on the Model SB-210 30 and standard on the WARNING: Do not operate the unit until Models SB-210 50 and SB-310 30. you are completely familiar with the location and function of each control.
Page 26: Data Logging
Unit Description CargoWatch™ is an optional CargoWatch™: Your Thermo King unit provides a wide datalogger systems that logs data of up to six range of control and programming temperature sensor/probes, four door switches, flexibility. However, pre-programming of humidity sensor, data averaging and the unit controller may prohibit operation programmable, temperature out of range alarms.
Page 27: Operating Modes
Unit Description Operating Modes Defrost The microprocessor uses a complex program to Frost gradually builds-up on evaporator coils as a determine which operating mode the unit should result of normal operation. The unit uses hot be in. Therefore, it is difficult to predict which refrigerant to defrost the evaporator coils.
Page 28: Engine Compartment Components
Unit Description The air filter Normally, longer defrost timer intervals are used Air Filter Restriction Indicator: restriction indicator is attached to the engine for colder loads. The defrost interval may need to intake manifold. When the diaphragm indicates be changed if the unit will not hold the 25, service the air filter.
Page 29: Unit Protection Devices
Unit Description Unit Protection Devices Overload Relay—Manual Reset (Model 50): overload relay protects the standby electric motor. The coolant level switch Coolant Level Switch: The overload relay opens the circuit to the electric closes if the coolant level drops below an motor if the motor overloads for any reason (e.g., acceptable level.
Page 30: Serial Number Locations
Unit Description Serial Number Locations Nameplates on the bulkhead above the Unit: compressor inside the curbside door, and on the top, roadside corner of the evaporator. See the engine identification plate located Engine: on the engine valve cover. Stamped between the cylinders on Compressor: the front end above the oil pump.
Page 31: Unit Photos
Unit Description Unit Photos AJA1617 Figure 6: Front View...
Page 32: Figure 7: Back View
Unit Description AJA1930 Defrost Damper X430L Compressor TK 486 Engine Figure 7: Back View...
Page 33: Figure 8: Front View With Doors Open (Model 30)
Unit Description AJA1931 Condenser Fan X430L Compressor Condenser Coil Fuel Filter/Water Separator Expansion Tank Air Cleaner TK 486 Engine Figure 8: Front View with Doors Open (Model 30)
Page 34: Figure 9: Front View With Doors Open (Model 50)
Unit Description Condenser Fan Electric Motor Condenser Coil X430L Compressor Expansion Tank Fuel Filter/Water Separator TK 486 Engine Air Cleaner Figure 9: Front View with Doors Open (Model 50)
Page 35: Figure 10: High Voltage Tray (Model 50 Only)
Unit Description AJA1932 Overload Relay Heaters Contactor Phase Selector Drive Motor Contactors Figure 10: High Voltage Tray (Model 50 Only)
Page 36 Unit Description...
Page 37: Operating Instructions
Use the HMI control panel to operate the unit. Refer to the SB-210/310 Operator’s Manual TK 51585 and the SR-2 Microprocessor Control System Diagnostic Manual TK 51587 for more information.
Page 38: Figure 13: Dedicated And Soft Keys
13. Their functions are listed below. Press this key to turn the unit On Key: on. The Thermo King Logo screen will appear briefly. The display will then show the Standard Display of box temperature and setpoint when the unit is ready to run.
Page 39: Unit Operation
Figure 14: Press On Key The engine oil level should be at the Engine Oil: 2. The display briefly shows a Thermo King FULL mark with the dipstick turned (threaded) Logo. into oil pan. Never overfill. The engine coolant must have antifreeze Coolant: protection to -30 F (-34 C).
Page 40: Turning Unit Off
Operating Instructions Turning Unit Off 3. The “Configuring System” Screen briefly appears while communications are established Complete the following steps to turn unit off: between the microprocessor and the HMI control panel. 1. Press the key. 4. The “Programming Language” Screen briefly appears.
Page 41: Standard Display
Operating Instructions Standard Display Standard Display Variations The Standard Display is the default display. It The Standard Display has variations. A display appears if no other display function is selected. showing any of the following variations is still The Standard Display shows the box temperature considered a Standard Display.
Page 42: Starting The Diesel Engine
Operating Instructions Starting the Diesel Engine After Start Inspection Diesel engine preheats and starts automatically in After the unit is running, check the following both Continuous Mode and CYCLE-SENTRY items to confirm that the unit is running properly. mode. The engine will preheat and start if Check the engine oil pressure by Oil Pressure: necessary when the unit is turned on.
Page 43: Changing The Setpoint
Operating Instructions Changing the Setpoint 3. Press the soft keys to change the setpoint reading. See Figure 22. To change the setpoint complete the following steps. 4. Press the soft key accordingly as ES OR described below. See Figure 22. 1.
Page 44: Selecting Cycle-Sentry Or Continuous Mode
Operating Instructions Selecting CYCLE-SENTRY or Continuous Mode When CYCLE-SENTRY mode is selected the unit will start and stop automatically to maintain the setpoint, keep the engine warm, and the battery charged. When Continuous mode is selected, the unit will start automatically and run continuously to maintain setpoint and provide constant airflow.
Page 45: Selection Of Operating Modes
Operating Instructions Selection of Operating Modes The Thermo King CYCLE-SENTRY system is designed to save refrigeration fuel costs. The savings vary with the commodity, ambient temperatures and trailer insulation. However, not all temperature controlled products can be properly transported using CYCLE-SENTRY operation.
Page 46: Initiating A Manual Defrost Cycle
Operating Instructions Initiating a Manual Defrost Cycle Defrost cycles are usually initiated automatically based on time or demand. Manual Defrost is also available if the unit is running and the coil temperature is less than 45 F (7 C). Other features such as door switch settings may not allow Manual Defrost to be initiated.
Page 47: Viewing Gauge Readings
Operating Instructions Viewing Gauge Readings 3. Press soft keys to scroll through following gauges: Coolant Temperature, Use the following steps to view miscellaneous Coolant Level, Engine Oil Pressure, Amps, gauge readings: Battery Voltage, Engine RPM, Discharge 1. Start at the Standard Display. If the Pressure, Suction Pressure, ETV Position, and Temperature Watch Display is showing, press I/O.
Page 48: Viewing Sensor Readings
Operating Instructions Viewing Sensor Readings 3. Press the soft keys to scroll through the following sensor screens: Control Use the following steps to view miscellaneous Return Air Temperature, Display Return Air sensor readings. Temperature, Control Discharge Air 1. Start at the Standard Display. If the Temperature, Display Discharge Air Temperature Watch Display is showing, press Temperature, Temperature Differential,...
Page 49: Figure 32: Viewing Sensors Screen Sequence
Operating Instructions Figure 32: Viewing Sensors Screen Sequence...
Page 50: Navigating The Operator Menu
Operating Instructions Navigating the Operator Menu LANGUAGE The Operator Menu contains nine individual menu areas that allow the operator to view ALARMS information and modify unit operation. Use the following steps to access these menu areas: DATALOGGER 1. Start at the Standard Display. If the Temperature Watch Display is showing, press HOURMETERS soft key once to return to the...
Page 51: Language Menu
Operating Instructions Language Menu 3. The Language Menu Screen appears. Press the soft key to choose the Language Menu ELECT If the Language feature is enabled, an alternate Screen. See Figure 36. language can be selected from the Language Menu. After a new language is chosen all displays 4.
Page 52: Alarms Menu
Operating Instructions Alarms Menu 5. If no alarms are present, the “No Alarm” Screen is shown. Press the soft key to Alarms are viewed and cleared using the Alarm return to the Standard Display. Menu as follows: 6. If alarms are present, the quantity of alarms 1.
Page 53: Datalogger Menu
Operating Instructions Datalogger Menu 3. Press the soft key until the Datalogger Menu appears. See Figure 40. The SR-2 controller is equipped with datalogging capability. Datalogging can store trip information 4. Press the soft key on the Datalogger ELECT for later use. A “Start of Trip” is initiated to Menu.
Page 54: Figure 40: Datalogger Screen Sequence
Operating Instructions Figure 40: Datalogger Screen Sequence...
Page 55: Hourmeters Menu
Operating Instructions Hourmeters Menu Hourmeters that are enabled are displayed. Hourmeters that are not enabled are not displayed, but they do count hours. The default settings display the Total Run Time Hours, the Engine Hours, and the Electric Run Hours (Model 50 only).
Page 56: Mode Menu
Operating Instructions Mode Menu 2. Press the soft key on the Standard Display. Selecting CYCLE-SENTRY or Continuous 3. Press the soft key until the Mode Menu Mode appears. The easiest way to switch between 4. Press soft key to enter the Mode Menu. ELECT CYCLE-SENTRY and Continuous Run is to press See Figure 44.
Page 57: Figure 45: Standard Display
Operating Instructions Selecting Economy Mode Economy mode is used on selected loads that do not require critical temperature control. The temperature control points are relaxed and other features are optimized for maximum fuel economy. Economy mode will be enabled or disabled per your company policy.
Page 58: Figure 48: Standard Display
Operating Instructions Selecting Sleep Mode 6. Press the soft key to start the Sleep ELECT mode. Normal CYCLE-SENTRY mode starts and stops the unit as required to maintain the desired 7. You now choose to program a Sleep mode compartment temperature, maintain the unit Wake-up Time or simply enter Sleep mode battery in a charged condition and keep the unit immediately.
Page 59: Figure 49: Selecting Sleep Mode Screen Sequence
Operating Instructions 15. To exit Sleep mode before the selected Wake-up time press the soft key or turn the unit off and back on. The unit will resume normal operation and control to setpoint. Figure 49: Selecting Sleep Mode Screen Sequence...
Page 60: Pretrip Tests
Operating Instructions Pretrip Tests • Report Test Results – The test results are reported as “PASS”, “CHECK” or “FAILED” A Pretrip test verifies unit operation. The Pretrip when the Pretrip is completed. If test results Menu allows the operator to select and initiate a are Check or Failed, alarm codes will exist to Pretrip Test.
Page 61: Figure 51: Pretrip Test Screen Sequence
Operating Instructions out of a total of 26. The soft keys may be used If the results are Check or Failed, the during the Pretrip Test to select the accompanying alarm codes will direct the Hourmeter, Gauge or Sensor menus. technician to the cause of the problem.
Page 62: Electric Standby/Diesel Mode
Operating Instructions Electric Standby/Diesel Mode The Electric Standby/Diesel Mode display allows the operator to manually select Electric Standby or Diesel Mode operation. The unit can also be programmed to automatically select Electric Standby operation when standby power is available and Diesel Mode operation if standby power fails or is removed.
Page 63: Adjust Brightness Menu
Operating Instructions Adjust Brightness Menu Adjust the display brightness as follows: 1. Start at the Standard Display. If the Temperature Watch Display is showing, press soft key once to return to the Standard Display. 2. Press the soft key on the Standard Display.
Page 64: Time Display
Temperature Watch Display is showing, press 4. Products should be pre-cooled before loading. soft key once to return to the Thermo King transport refrigeration units are Standard Display. designed to maintain loads at the temperature 2. Press the soft key on the Standard at which they were loaded.
Page 65: Electrical Maintenance
P/N 204-615 (FLUKE 23) digital multimeter terminal F2 to ground. Attempting to and a Thermo King P/N 204-613 amp clamp full-field the alternator by applying or an equivalent. battery voltage to terminal F2 will cause voltage regulator failure.
Page 66 Electrical Maintenance • Make sure the drive belts and pulleys of the b. The B pin is the excitation circuit and charging system are in good condition and are should be at 10 volts or higher. If not, adjusted properly before testing the alternator. check the excitation circuit (7K or Worn belts and pulleys or loose belts will equivalent) in the alternator harness and in...
Page 67 Electrical Maintenance NOTE: An alternator can easily exceed its 2. Connect a jumper wire between the F2 rated output. An alternator MUST at least terminal on the alternator and a chassis reach its rated output when full fielded. An ground, and note the ammeter reading. alternator that has a defective rectifier diode 3.
Page 68: Figure 59: Full Field Test
Electrical Maintenance Check Point for 2A Amperage Position for Full Fielding Jumper Figure 59: Full Field Test...
Page 69: Alternator (Prestolite) Model 50
Thermo King CAUTION: Full-fielding alternators P/N 204-615 (FLUKE 23) digital multimeter with the integral regulator is and a Thermo King P/N 204-613 amp clamp accomplished by installing a jumper from or an equivalent. terminal F2 to ground. Attempting to...
Page 70: Battery
Electrical Maintenance • Make sure the drive belts and pulleys of the 11. Connect a jumper wire between the F2 charging system are in good condition and are terminal and a chassis ground. This will full adjusted properly before testing the alternator. field the alternator.
Page 71: Fuses
Electrical Maintenance Fuses A number of fuses, located on the interface board, protect various circuits and components. The interface board is located inside the control box. See the SR-2 Microprocessor Controller Diagnostic Manual for a complete list of the size and function of the fuses.
Page 72: Fuse Link
Electrical Maintenance Fuse Link Smart Reefer 2 ™ Microprocessor Controller The fuse link is located in the positive battery cable. The fuse link protects the electrical system See the SR-2 Microprocessor Control System from a short in the 2 circuit. If the fuse link burns Diagnostic Manual TK51587 for complete service out, check for a grounded 2 wire before replacing information about the Microprocessor Controller...
Page 73 Electrical Maintenance a. The three wires from the PSM should be If the electric motor does not run at all: connected to the heater contactor terminals 1. Make sure that the unit is turned On, that as follows: Brown wire to terminal L1, Electric Standby has been selected in the Blue wire to terminal L2, and Black wire Operator Menu, and that the power supply is...
Page 74: Figure 63: High Voltage Tray
Electrical Maintenance ARD077 Overload Relay HC—Heaters Contactor PSM—Phase Selection Module MC2—Motor Contactor MC1—Motor Contactor Figure 63: High Voltage Tray...
Page 75: Engine Maintenance
The EMI package allows standard maintenance The oil filter should be changed along with the intervals to be extended to 3,000 hours, or 2 years, engine oil. Use a genuine Thermo King extended whichever occurs first. maintenance oil filter. NOTE: Units equipped with the EMI 3000 1.
Page 76: Low Oil Pressure
Engine Maintenance Low Oil Pressure pressure regulating valve, or worn bearings. Low oil pressure is not normally caused by a faulty oil Oil pressure is affected by oil temperature, oil pump. Use the following “Low Oil Pressure Flow viscosity, and engine speed. Low oil pressure can Chart”...
Page 77: Engine Cooling System
The following are the Extended Life Coolants 1. Prevents freezing down to -30 F (-34 C). currently approved by Thermo King for use in ELC units for five years or 12,000 hours: 2. Retards rust and mineral scale that can cause engine overheating.
Page 78: Antifreeze Maintenance Procedure
Engine Maintenance NOTE: The use of 50/50 percent pre-mixed CAUTION: Avoid direct contact with hot Extended Life Coolant (ELC) is recommended to coolant. assure that de-ionized water is being used. If 100 percent full strength concentrate is used, a. Run clear water into the radiator and allow de-ionized or distilled water is recommended it to drain out of the block until it is clear.
Page 79: Bleeding Air From The Cooling System
Engine Maintenance Expansion Tank Water Pump Radiator Cap Thermostat Coolant Level Sensor Thermostat Housing Radiator Figure 65: Engine Cooling System Bleeding Air from the Cooling CAUTION: IF YOU SUSPECT THAT System AIR IS TRAPPED IN THE BLOCK, DO NOT START THE ENGINE WITHOUT Jiggle pin thermostats are original equipment on BLEEDING THE AIR OUT OF THE units that have TK 482/486 engines.
Page 80: Engine Thermostat
Engine Maintenance 3. Pour coolant into the system until it appears to off-center on the filter head. It bleeds off air. be full. Filtered fuel passes through a line from the outlet fitting on the filter base to the injection pump. 4.
Page 81: Figure 66: Engine Fuel System
Engine Maintenance Check Valve (Keeps air from entering fuel Fuel Transfer Pump system when engine is not running.) Filter Head Inlet Strainer (Prefilter) Injection Pump Priming Pump Bleed Screw Fuel Filter/Water Separator Figure 66: Engine Fuel System...
Page 82: Maintenance
Engine Maintenance Maintenance 8. Nozzle spray pattern testing and adjustment. The injection pump and fuel transfer pump are 9. Minor rebuilding of nozzles. relatively trouble-free and if properly maintained Bleeding the Fuel System will usually not require major service repairs between engine overhauls.
Page 83: Draining Water From Fuel Tank
Engine Maintenance NOTE: Some fuel tanks have a check valve in the drain plug fitting. Push the check valve open with a small screw driver to drain the tank. 3. Let the water and fuel drain into the container until no water is visible in the fuel draining from the tank.
Page 84: Engine Speed Adjustments
1. Use the Service Test Mode to run the unit in Boot high speed and check the high speed rpm. It Ball Joint should be 2200 ± 25 rpm for the SB-210 and Speed Control Rod 2600 ± 25 rpm for the SB-310. Low Speed Adjustment Screw 2.
Page 85: Figure 71: Component Location
Engine Maintenance AEA701 Index Mark Top Dead Center Mark for 1 and 4 ARA113 Figure 72: Top Dead Center One and Four Number One Cylinder Injection Line b. Check the rocker arms on the number one Timing Mark Access Hole cylinder to see if they are loose.
Page 86: Figure 73: Timing Mark Alignment
Stop as soon as you see the fuel rise. 14. Check position of the timing marks. a. On the SB-210 the 10 degree BTDC Index Mark timing mark on the flywheel should be 12 Degree BTDC Timing Mark...
Page 87: Injection Pump Removal
Engine Maintenance a. Pull the top of the injection pump away 6. Remove the screw and adapter leaving the tool from the engine to advance the timing. plate in place. This holds the gear in proper tooth alignment until the injection pump is b.
Page 88: Fuel Solenoid
Engine Maintenance AGA1056 Injection Pump Adapter Gear Case Tool Long Screw Cover Plate Tool Short Screw Cover Plate Bolt Tool Plate Figure 76: Injection Pump Gear Tool Fuel Solenoid The fuel solenoid is located on the end of the injection pump. It contains two coils: the pull-in coil, and the hold-in coil.
Page 89: Figure 78: Fuel Solenoid Connector Pin Identification
Engine Maintenance Testing the Fuel Solenoid NOTE: The fuel solenoid pull-in coil will require 35 to 45 amps to turn on the fuel. The unit’s battery must be in good condition. If the battery has enough power to crank the engine over, it has enough power to energize the fuel solenoid pull-in coil.
Page 90: Engine Valve Clearance Adjustment
Engine Maintenance b. Momentarily energize the pull-in coil by placing a jumper between the white wire (8DP—pin B) in the fuel solenoid connector and the positive battery terminal. The fuel solenoid should make a definite click when the pull-in coil is energized, but should not click when the pull-in coil is de-energized.
Page 91: Figure 80: Top Dead Center One And Four
Engine Maintenance b. Check the rocker arms on the number one cylinder to see if they are loose. c. If the rocker arms are loose, the engine is at top dead center of the compression stroke for the number one cylinder. d.
Page 92: Crankcase Breather
Engine Maintenance Crankcase Breather 4. Use a feeler gauge to check the valve clearance on both valves for the number one The crankcase breather is located on top of the cylinder, the intake valve for the number two rocker arm cover. The crankcase breather system cylinder, and the exhaust valve for the number ducts crankcase gases formed in the crankcase three cylinder.
Page 93: Emi 3000 Air Cleaner
“EMI 3000.” It cannot be interchanged with air indicator periodically to assure the air filter is not filters used on previous Thermo King trailer units, restricted. Service the air filter when the yellow however it can be retrofit on previous units by diaphragm indicates 25 in.
Page 94: Belts
Engine Maintenance Belts NOTE: Do not attempt to remove or install belts without loosening adjustments. Belts that are Belts should be regularly inspected during unit installed by prying over pulleys will fail pre-trip inspections for wear, scuffing or cracking. prematurely due to internal cord damage. Belt tension should also be checked during scheduled maintenance inspections.
Page 95: Model 30 Belt Adjustments
Engine Maintenance Model 30 Belt Adjustments Lower Fan Belt Removal Alternator Belt Adjustment 1. Loosen both idler adjusting arm bolts and both The alternator belt tension should read 35 on the idler assembly pivot bolts. belt gauge. 2. Push the idler adjusting arm IN. The lower fan 1.
Page 96: Model 50 Belt Adjustments
Engine Maintenance NOTE: If the condenser fan does not slide on the fan shaft with light tapping, remove the small access panel located on the condenser coil header above the expansion tank. Thread a 1/4-20 x 1 in. diameter bolt into the end of the fan shaft.
Page 97: Figure 88: Model 50 Belt Arrangement
Engine Maintenance 2. Move the hex nuts on the compression spring 3. Reinstall the belt on the pulley and replace the adjustment screw to adjust the belt tension to sliding pulley section on the pulley. 79 on the belt tension gauge. 4.
Page 98: Model 50 Compressor Belt Replacement
Engine Maintenance Model 50 Compressor Belt NOTE: If the condenser fan does not slide Replacement on the fan shaft with light tapping, remove the small access panel located on the Removal condenser coil header above the expansion tank. Thread a 1/4-20 x 1 in. diameter bolt 1.
Page 99: Clutch (Model 50)
Engine Maintenance Clutch (Model 50) NOTE: The refrigeration lines may be removed from the compressor to allow more Periodically inspect the clutch for worn bearings, movement of the compressor for better access worn friction shoes and for broken springs. To to the clutch.
Page 100 Engine Maintenance 9. Inspect the friction shoes and springs. 12. To assemble the clutch, press the pulley into the bearing. a. Replace the friction shoes if the linings are worn to a thickness of less than 1/16 to 13. Place the key in the compressor crankshaft. 3/32 in.
Page 101 Engine Maintenance...
Page 102 Engine Maintenance...
Page 103: Refrigeration Maintenance
Refrigeration Maintenance NOTE: The following procedures involve 8. Under these conditions, refrigerant should be servicing the refrigeration system. Some of these visible in the receiver tank sight glass. If service procedures are regulated by Federal, and refrigerant is not visible in the receiver tank in some cases, by State and Local laws.
Page 104: Moisture Indicating Sight Glass
Refrigeration Maintenance NOTE: If the liquid level in the receiver sight h. Close the hand valve on the refrigerant glass drops during step 4, the unit is not tank when the liquid level approaches the overcharged and it is not necessary to top of the receiver sight glass.
Page 105: Checking Compressor Oil
Refrigeration Maintenance Checking Compressor Oil To add compressor oil pump down the compressor and equalize the pressure to slightly positive. The compressor oil should be checked when there Disconnect the compressor oil filter return line is evidence of oil loss (oil leaks) or when from the top of the compressor and add the oil.
Page 106: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance 2. Use the Service Test Mode to run the unit in 1. Remove the condenser pressure bypass check high speed cool. valve cap from the three-way valve. 3. Raise the discharge pressure of the 2. Using a screwdriver, gently turn the check compressor first by blocking the condenser valve stem in until the valve is front seated.
Page 107: Electronic Throttling Valve (Etv)
Electronic Throttling Valve (ETV) The Electronic Throttling Valve (ETV) is optional on the SB-210 30. It is standard on the SB-210 50 and SB-310 30. The Electronic Throttling Valve (ETV) is a variable position valve operated by a stepper ARD078 motor.
Page 108: Hot Gas Solenoid
Refrigeration Maintenance Hot Gas Solenoid The hot gas solenoid (or hot gas bypass valve) is used in conjunction with the electronic throttling valve to reduce the capacity of the unit during modulation. This normally closed solenoid valve is located in the refrigeration line that connects the discharge line to the hot gas line.
Page 109: Refrigeration Service Operations
Refrigeration Service Operations NOTE: It is generally good practice to replace 2. Place the compressor in position, install the the filter drier whenever the high side is opened compressor belts on Model 50 units, and or when the low side is opened for an extended install the mounting bolts.
Page 110: Compressor Coupling Installation (Model 30)
Refrigeration Service Operations 4. Use the appropriate Allen tool to loosen the not fit easily into the keyway, it will push the coupling mounting screw. tapered components apart and the reduced friction could lead to slippage and premature failure. 5. Once the center screw has been loosened, back the head against the tool and it should The following procedure requires the key to be push the coupling off the crankshaft as you...
Page 111: Condenser Coil
Refrigeration Service Operations 3. Using no lubricants, set the coupling on the key into the keyway beyond the front face crankshaft and align the keyways using the of the coupling. If tapped in farther it may Keyway Tool (P/N 204-972). Insert the cause the coupling to move off center on the tapered end of the tool into the keyway and shaft.
Page 112: Discharge Vibrasorber
Refrigeration Service Operations In-Line Condenser Check Valve 5. Unsolder the inlet line and liquid line connections. Lift the coil from the unit. This unit uses an in-line condenser check valve. The in-line check valve is not repairable and must Installation be replaced if it fails.
Page 113: Bypass Check Valve
Refrigeration Service Operations 5. Pressurize the refrigeration system and test for 5. Unbolt the mounting brackets and remove the leaks. receiver tank from the unit. 6. If no leaks are found, evacuate the system. Installation 7. Recharge the unit with proper refrigerant and 1.
Page 114: Expansion Valve Assembly
Refrigeration Service Operations 5. Pressurize the system and inspect for leaks. If no leaks are found, open the refrigeration valves and place the unit in operation. Expansion Valve Assembly Removal 1. Pump down the low side and equalize the pressure to slightly positive. 2.
Page 115: Evaporator Coil
Refrigeration Service Operations Evaporator Coil 8. Unsolder the remaining outlet suction line and inlet liquid line connections from the condenser side of the bulkhead. Remove any Removal putty from around the lines before unsoldering 1. Pump down the low side and equalize the the connections.
Page 116: Accumulator
Refrigeration Service Operations Accumulator Three-Way Valve Repair NOTE: The three-way valve can be repaired in Removal the unit if leakage or damage to the Teflon seals 1. Pump down the low side and equalize the should occur. There is usually enough give in pressure to slightly positive.
Page 117: End Cap Checks
Refrigeration Service Operations 2. Clean the exterior surface of the valve. NOTE: The valve body cannot be reconditioned. Seat positions change and 3. Remove the line from the three-way valve to improper sealing will result. the pilot solenoid. 4. Loosen the four 1/4 in. Allen head screws (DO NOT REMOVE OR CAP MAY POP OFF);...
Page 118: Figure 103: Check Bleed Hole Diameter
Refrigeration Service Operations 4. Deburr the hole in the check valve piston bore. 2. Leave the stem back seated against the snap A used drill bit can be modified to use as a ring. Use a paper clip bent into a 90 degree deburring tool.
Page 119: Assembly/Installation
Refrigeration Service Operations Assembly/Installation 6. Install the spring and end cap. After cleaning and inspecting all parts, reassemble 7. Line up the passageways in the cap and body. the valve. Failure to line up the holes will result in improper operation of the valve. 1.
Page 120 Refrigeration Service Operations Pilot Solenoid 6. Inspect the check valve seat in the three-way valve. Removal 7. If replacement parts are needed, a kit P/N 60-163 must be used which includes the 1. Recover the refrigerant charge. piston, spring, O-ring, valve stem, and snap 2.
Page 121 Refrigeration Service Operations 3. Pressurize the refrigeration system and test for CAUTION: Use a heat sink or wrap leaks. If no leaks are found, evacuate the vibrasorber with wet rags to prevent system. damaging the vibrasorber. 4. Recharge the unit with the proper refrigerant 3.
Page 122: Figure 108: Electronic Throttling Valve
Refrigeration Service Operations Electronic Throttling Valve (ETV) Removal 1. Pump down the low side and equalize the pressure to slightly positive. 2. Remove the evaporator access panels. 3. Remove the clip and disconnect the ETV harness connector from the stepper motor. 4.
Page 123: Figure 109: Stepper Motor And Piston Assembly With Piston In Fully Open Position
Refrigeration Service Operations c. Place the new valve body (and any tubes CAUTION: The ETV may stick in the that were removed) in the same position closed position if the stepper motor and from which the old one was removed. The piston assembly is installed with the piston new ETV could interfere with the in the closed position.
Page 124: Figure 110: Mechanical Throttling Valve Assembly
Refrigeration Service Operations Mechanical Throttling Valve 2. Front seat the discharge and suction service valves. Recover the refrigerant remaining in See Figure 110 for an illustration of the the compressor. mechanical throttling valve assembly. 3. Remove the suction service valve. Removal 4.
Page 125: Figure 111: Inspect Parts
Refrigeration Service Operations Disassembly 1. Remove the piston end cap (round end). 2. Remove the cotter pin from the castle nut and remove the nut. 3. Remove the spring and piston. 4. Loosen all the bolts on the bellows end cap. CAUTION: This end cap is under slight spring pressure.
Page 126: Figure 114: Throttling Valve Reassembly
Refrigeration Service Operations 5. Back off the castle nut, one full turn only. 6. Insert the cotter pin. AEA716 Tighten castle nut to bottom, then back off 1 turn only. Insert cotter pin Figure 114: Throttling Valve Reassembly 7. Oil the gasket and install the end cap. 8.
Page 127: Figure 115: Compressor Oil Filter
Refrigeration Service Operations Hot Gas Solenoid Valve 7. Attach and tighten the oil lines to the compressor oil filter. Hold the oil filter with a back-up wrench on the hex behind the ORS Removal fitting. 1. Recover the refrigerant charge. 8.
Page 128 Installations the compressor oil pump and relief valve. Thermo King remanufactured compressors have 6. As soon as the compressor develops 10 psi had a special break in process to assure that the oil (96 kPa) of net oil pressure, re-connected the pump is primed, functioning, and broken in.
Page 129: Figure 116: Unit And Engine Mounting Bolts
Structural Maintenance Unit and Engine Mounting Bolts Unit Inspection Check and tighten all unit and engine mounting Inspect the unit during pretrip inspection and bolts during scheduled maintenance inspections. scheduled maintenance inspections for loose or Torque the unit mounting bolts to 60 ft-lb broken wires or hardware, compressor oil leaks, (81 N•m).
Page 130: Figure 117: Defrost Damper Adjustment
Structural Maintenance Defrost Damper 4. If necessary, adjust Distance A to the proper dimension by loosening the locknut on the end Check the damper during scheduled maintenance of the solenoid plunger and turning the eye inspections for shaft wear, end play, and the bolt.
Page 131: Figure 118: Condenser Blower Alignment
Structural Maintenance 8. De-energize and energize the damper several 5. Pass a gauge wire completely around the times to make sure that the damper operates blower orifice to check for uniform clearance. correctly and seals properly. 6. Spin the blower by hand to check for blower 9.
Page 132: Figure 120: Fan Shaft Assembly
NOTE: The fan shaft assembly requires a 6. After all the parts are cleaned, inspect the special lubricant, Thermo King P/N 203-278. bearings and bearing races for wear or damage. Fan Shaft Assembly Overhaul 7.
Page 133 Department After the shaft has been removed, clean all the 0.020 in. (0.500 mm) Thermo King P/N 99-4231 parts in clean solvent. 0.007 in. (0.177 mm) Thermo King P/N 99-2902 4. Using a punch, remove the oil seal from the 0.005 in.
Page 134 Shims available from the Service Parts Department 0.020 in. (0.500 mm) Thermo King P/N 99-4231 0.007 in. (0.177 mm) Thermo King P/N 99-2902 0.005 in. (0.127 mm) Thermo King P/N 99-2901 AEA722...
Page 135 Mechanical Diagnosis Condition Possible Cause Remedy Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine Starter clutch defective Replace does not crank...
Page 136 Mechanical Diagnosis Condition Possible Cause Remedy Engine does not develop full Air intake system clogged Clean air intake system power Fuel tank vent clogged Unclog vent Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Speed adjustment wrong Adjust speed Insufficient fuel volume leaving filter Check for dirty filter or air in system...
Page 137 Mechanical Diagnosis Condition Possible Cause Remedy Engine runs hot Dirty radiator Wash radiator Coolant level is low Add coolant Cooling system heavily scaled Cleaning cooling system Cylinder head gasket leaks Replace cylinder head gasket. Use correct gasket Faulty thermostat Check or replace thermostat Loose or worn water pump belt Replace belt Oil pressure low...
Page 138 Mechanical Diagnosis Engine Emits Excessive Smoke White Smoke Black Smoke Blue Smoke Fuel is not burning Excessive Fuel to Air Ratio Oil Consumption • Air or water in fuel • Type of fuel used • Poor compression • Incorrect timing •...
Page 139 Electric Standby Diagnosis Condition Possible Cause Remedy Unit turned ON—LCD Blank Battery discharged Charge or replace battery Faulty battery cable connections Clean battery cables Fuse link blown Check for short circuit and replace fuse link Fuse F2 blown Check for short circuits and replace fuse Open circuit Check HMI Harness...
Page 140 Electric Standby Diagnosis...
Page 141 Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
Page 142 Refrigeration Diagnosis Possible Causes • • Loose or broken electrical connections • • • • • Sensor out of calibration • • • • Compound pressure gauge out of calibration • Leaky receiver tank outlet valve • Leaky bypass check valve •...
Page 143 Refrigeration Diagrams Cool Cycle With Mechanical Throttling Valve Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-Way Valve Three-Way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank Sight Glass 12. Receiver Outlet Valve 13.
Page 144 Refrigeration Diagrams Heat/Defrost Cycle With Mechanical Throttling Valve Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-Way Valve Three-Way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank Sight Glass 12. Receiver Outlet Valve 13.
Page 145 Refrigeration Diagrams Cool Cycle With Electronic Throttling Valve Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank Sight Glass 12. Receiver Outlet Valve 13.
Page 146 Refrigeration Diagrams Heat/Defrost Cycle With Electronic Throttling Valve Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank Sight Glass 12. Receiver Outlet Valve 13.
Page 147 Index coolant level switch 29 cooling system 77 AC components 72 cooling system, engine 77 accumulator, replacement 114 bleeding air from 79 adjust brightness menu 63 crankcase breather 92 air cleaner restriction indicator 28 CYCLE-SENTRY air cleaner, EMI 3000 93 selecting 44 air heater 72 CYCLE-SENTRY Operation 25...
Page 148 Index refrigerant 16 Mode key 38 refrigerant oil 16 mode menu 56 fuel filter/water separator, replacement 83 moisture indicating sight glass 102 fuel solenoid 88 mounting bolts, unit and engine 127 replacement 90 testing 89 fuel system 80 Off key 38 bleeding 82 oil change, engine 75 maintenance 82...
Page 149 Index temperature watch display 41 thermostat, engine 80 three-way valve condenser pressure bypass check valve 104 three-way valve condenser pressure bypass check valve, repair 117 three-way valve, repair 114 throttling valve, mechanical See mechanical throttling valve time display 64 transducers, pressure 105 trip report, printing 53 unit description 23 valve clearance adjustment, engine 90...
Page 150 Index...
Page 151 Wiring Diagram Index Drawing No. Drawing Title Page 1E07692 Model 30 and 50 Schematic Diagram 153-155 1E07693 Model 30 and 50 Wiring Diagram 156-159...
Page 152 Wiring Diagram Index...
Page 153 Model 30 and 50 Schematic Diagram - Page 1 of 3...
Page 154 Model 30 and 50 Schematic Diagram - Page 2 of 3...
Page 155 Model 30 and 50 Schematic Diagram - Page 3of 3...
Page 156 Model 30 and 50 Wiring Diagram - Page 1 of 4...
Page 157 Model 30 and 50 Wiring Diagram - Page 2 of 4...
Page 158 Model 30 and 50 Wiring Diagram - Page 3 of 4...
Page 159 Model 30 and 50 Wiring Diagram - Page 4 of 4...

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