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Trailer Edition
SB-130, SB-230 and SB-330
Single Temperature Systems
TK 54748-2-IM (Rev. 0, 12/10)
2
Installation Manual for
SB-130, SB-230 and SB-330 Systems
3
Introduction
This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
Thermo Kings warranty shall not apply to any equipment which has been so installed, maintained, repaired or altered as, in the
manufacturers judgment, to affect its integrity.
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or
descriptions contained herein.
4
Table of Contents
5
Safety Precautions
The symbol appears next to a point that is particularly important:
DANGER: Never operate the unit with the discharge valve WARNING: Keep your hands away from fans and belts
closed because it could cause the compressor to explode, when the unit is running. This should also be considered
causing death or serious injury. when opening and closing the compressor service valves.
7
Trailer Requirements
Unit Dimensions
IMPORTANT: Adequate clearance must be provided to allow for
routine service and maintenance of the Thermo King unit.
See Unit Dimensions on page 14.
8
Swing Radius and King Pin Requirements
9
Evaporator Opening Requirements
Evaporator Opening
DANGER: The front trailer wall must be structurally strong
enough to support the weight of the refrigeration unit!
The location of the unit mounting bolts and evaporator opening in the front
wall is critical.
VERIFY ALL DIMENSIONS BEFORE INSTALLING UNIT!
NOTE: It may be necessary to relocate the front corner clearance
lights to the corner radius of the trailer to prevent damage.
1. The evaporator opening must be square. The diagonal measurements
must be 3.0 mm (0.12 in.)
2. The gasket surface around the opening must be at least 76.2 mm
(3.00 in.) wide, be flat 3.2 mm (0.05 in.) and free of rivets, seams or
bolt heads.
10
Evaporator Opening Requirements
11
Mounting Hardware Requirements
Mounting Bolts Mounting Bolt Specifications
DANGER: Eight mounting bolts must be installed to properly DANGER: The use of mounting bolts other than those
secure the unit to the trailer front wall! Failure to do so could specified could result in severe damage to equipment, void
result in severe damage to equipment, void the warranty or the warranty or cause personal injury or death!
cause personal injury or death!
Use Metric M12 x 1.75 pitch class 8.8 (1/2 in.-13 UNC - 28 Rolled thread
NOTE: The location of the unit mounting bolts in the trailer front wall grade 5), medium carbon steel bolts and locking nuts. All hardware must
is critical to proper unit installation. be zinc plated with dichromate finish.
All mounting bolts must be square with the front wall and securely
fastened to the trailer wall in such a manner to allow the mounting nuts be
torqued to 82 Nm (60 ft. lbs.) from outside the trailer.
Mounting bolts are to extend 57.2 mm (2.25 in.) beyond the front
wall.
Surface of all mounting bolts are to be flat within 2.5 mm (0.10 in.).
12
Mounting Hardware Requirements
13
Unit Dimensions
14
BLANK PAGE
15
Bulkhead Dimensions (Option)
THERMO KING RECOMMENDS USING A BULKHEAD
16
Bulkhead Dimensions (Option)
17
Battery Selection Guide
Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance.
Trailer units are designed for one 12 volt, Group 31 battery supplied by the
CAUTION: Do not connect other manufacturers equipment or
installer.
accessories to the Thermo King unit! This could result in
severe damage to equipment and void the warranty! The battery must be suitable for deep cycling, heavy duty and rated with a
minimum of 95 amp/hr.
IMPORTANT: The specified battery, electrical wiring and electronic NOTE: See following table for Thermo King approved batteries.
controls were designed to operate and maintain only the Thermo Refer to Service Bulletin T&T 446 for more information regarding
King refrigeration system and factory authorized Thermo King Battery Selection and Maintenance.
options.
750 CCA Wet Cell 925 CCA Wet Cell 1150 CCA Dry Cell (AGM)
Thermo King ReliaMax 750S Thermo King ReliaMax 925N Thermo King EON
P/N 203-731 Threaded Stud P/N 203-733 Threaded Stud P/N 203-550 Threaded Stud
P/N 203-730 SAE Post P/N 203-732 SAE Post P/N 203-551 SAE Post
Wet Cell Technology Wet Cell Technology Dry Cell (AGM) Technology
Better suited for warmer climates Better suited for colder climates Better suited for all applications
Less cranking power at low High cranking power at low High cranking power at lower
ambient temperatures ambient temperatures ambient temperatures
18-24 month expected life *see 18-24 month expected life *see Suited for extreme temperatures
note below note below Best for high cycling applications
Choose for southern climates Choose for northern climates (Cycle-Sentry use)
5-7 year expected life
* NOTE: Wet cell battery life and maintenance requirements are determined by the operating environment and the
charge/discharge rate (cycles) while the battery is in service. Higher ambient temperatures and frequent discharges
will shorten a wet cell batterys overall life expectancy and increase maintenance requirements.
18
Group 31 Battery Dimensions
19
Lifting Bar Dimensions
I. Recommended material: 76.2 mm (3.00 in.) x 12.7 mm (0.50 in.) mild
WARNING: Do not use a fork lift to install unit!
steel.
II. Use forged chain links and hooks, clevis and pins with strength equal to
WARNING: Thermo King requires a 3 point lifting bar to safely total lift capacity of hoist mechanism and meet all safety standards.
lift and install units. A lifting bar can be made from the
drawings provided.
III. Bolt together for maximum strength and safety.
20
Lifting Bar Dimensions
21
Status Light Dimensions (Option)
22
Rear Remote Controller Dimensions (Option)
23
Door Switch Dimensions (Option)
24
BLANK PAGE
25
Required Tools
1. Safety Glasses
2. Drill
3. Drill Bits
4. Tape Measure
5. Mechanics Tools
6. Lifting Bar
7. Work Platform (Recommended)
8. Torque Wrench
9. Forged Eyebolts
NOTE: Equipment such as scales, gauges, refrigerant leak detectors,
and torque wrenches should be in good working condition and
routinely calibrated to assure accurate readings.
26
Required Tools
27
Installation Components
1. Locking Nuts
2. Washers
3. Self Tapping Screws
4. Clamps
5. Cable Ties
6. Fuel Line Hose
1/4 in.
3/8 in.
7. Fuel Line Fittings
1/4 in.
3/8 in.
8. Fuel Line Connector
9. Drain Hose Check Valve
10. Bulkhead (Option)
28
Installation Components
29
Unpacking the Unit
DANGER: Do not use a forklift to install the unit! This could Unpacking the Unit
result in severe damage to the equipment, void the warranty Carefully remove plastic stretch wrap from unit.
or cause personal injury or death!
Carefully remove the top cardboard cover.
WARNING: Thermo King requires a 3 point lifting bar to safely Carefully remove the outer cardboard wrap.
lift and install units. A lifting bar can be made from the
drawings provided. See Lifting Bar Dimensions on page 20. Remove installation kit boxes, bottom panel, and any other loose
components from rear of unit.
Units are shipped attached to disposable wooden pallet and wrapped with
protective cardboard and plastic stretch wrap. Attach forged eyebolts and 3 point lifting bar to unit.
NOTE: To avoid unnecessary damage to your unit, place the crated Remove hardware holding unit to wooden pallet.
unit near the trailer prior to its removal. Unit is now ready for installation.
IMPORTANT: DO NOT use a sharp knife to remove the stretch wrap or
cardboard wrap as damage to the exterior of the unit will result!
30
Unpacking the Unit
31
Installing the Unit
WARNING: Do not use a forklift to install the unit! This could Unit Installation
result in severe damage to equipment, void the warranty or 9. Install two 5/8-11 forged lifting eyebolts into threaded holes located on
cause personal injury or death! the top of the unit (Detail I).
WARNING: Use only locking hooks to safely lift the unit! 10. Use the lifting bar to lift unit up to the trailer opening.
Failure to use locking hooks could result in severe damage to NOTE: All nuts that hold the unit to the trailer should be elastic stop
the equipment, void the warranty or cause personal injury or nuts (Nylock Type) provided in the installation kit.
death! (Detail I).
11. Attach washer and elastic stop nuts provided in the installation kit.
WARNING: Thermo King requires a 3 point lifting bar to safely Torque to 82 Nm (60 ft. lbs.).
lift and install units. A lifting bar can be made from the
drawings provided. See Lifting Bar Dimensions on page 20.
32
Installing the Unit
33
Installing the Drain Hoses
Installation
1. Drain hoses should run straight down the trailer wall from the unit with
no kinks or bends.
2. Secure with screws and clamps provided in installation kit.
3. Cut off excess hose and attach drain hose check valves provided in
installation kit.
34
Installing the Drain Hoses
35
Installing the Fuel Tank
CAUTION: The trailers crossmembers must be strong enough B. Tank Strap Position
to safely support the combined weight of the mounting 30 Gallon Tanks - Fuel tank straps are positioned typically 381 mm
hardware, fuel tank and fuel. (15.00 in.) apart.
Fuel Tank Capacity Combined Total Weight
50 Gallon Tanks - Fuel tank straps are positioned typically 495 to
30 Gallon Diesel 142 KG (313 lbs.) 673 mm (19.5 in. to 26.5 in.) apart.
50 Gallon Diesel 214 KG (471 lbs.)
NOTE: Edge of tank to center of tank straps will typically be 102 to
191 mm (4.00 to 7.50 in.).
Open Style Tank Mounting Bracket - New fuel tank mounting kits were
released November 1, 2008. Factory Kit 701635 and Aftermarket Kit C. Rubber Strips and Pads
90-398 contain a new open style fuel tank mounting bracket. This new
Rubber strips must be properly installed on both the mounting
mounting bracket can be used to install either a 30 or 50 gallon, 22''
bands and the rubber pads must be installed onto the underside of
diameter fuel tanks onto a typical trailer with standard crossmember
the hanger assemblies to prevent metal to aluminum contact.
spacing of 6'', 8'', 10'' or 12''.
Trailers with non-standard crossmember spacing of 9'', 15'' and 16'' will D. Mounting Hardware
require the additional components found in Kit 701658 (90-399) to Grade 5 mounting hardware is supplied. Substitutions are not
complete the installation. acceptable!
These new kits can not be used to install a 75, 90, 110 or 120 gallon,
All mounting hardware must be properly installed and torqued to
22'' diameter fuel tanks. Those tanks require Kit 710278 (90-121).
the specifications listed.
DO NOT substitute any components from Kits 701635 (90-398) and
701658 (90-399) with any previously supplied fuel tank mounting kits Hardware Size Torque Specifications
as they are not interchangeable.
3/8-16 Grade 5 42 Nm (31 ft-lb)
Kits 701635 (90-398) and 701658 (90-399) are specifically designed to
1/2 -13 Grade 5 81 to 88 Nm (60-65 ft-lb)
install a 30 or 50 gallon fuel tank in a hanging position under a trailer
attached to the floor crossmembers. Substitutions are not acceptable! 1/2'' T-bolts 48 Nm (35 ft-lb.)
36
Installing the Fuel Tank
OPEN STYLE TANK MOUNTING BRACKET
See note
NOTE: Edge of tank to center of tank straps will typically be 102 to 191 mm (4.00 to 7.50 in.).
37
Installing the Fuel Tank
38
Installing the Fuel Tank
OPEN STYLE TANK MOUNTING BRACKET ONLY
39
Installing the Fuel Lines
Fuel Line Installation 4. Secure all fuel lines with provided clamps (Detail III).
DANGER: Leaking fuel lines could cause a fire resulting in 5. Route fuel supply line from the unit to the fuel pump to the fuel pickup
death or serious injury! All fuel line fittings must be tight and on the fuel tank. Install fuel line connector (provided in installation kit),
leak free! cut end of fuel line at a 45 degree angle and insert into fuel pickup tube
until it is 25.4 mm (1.00 in.) from bottom of tank and tighten securely
DANGER: Do not route fuel lines with battery cables or (Detail IV).
electrical wires, as this could cause a fire!
6. Route fuel return line from the unit to the fuel tank return fitting.
1. Install the fuel line bracket to the pre-drilled hole in the frame. This Attach fuel line connectors and tighten securely.
hole is located in the frame under the compressor (Detail I). 7. Remove plastic cap from the fuel vent and point the outlet to the rear of
IMPORTANT: Verify the factory installed fuel line fittings are tight the trailer.
prior to mounting the bracket onto the frame. NOTE: Add a sufficient amount of fuel (1/4 tank) to allow the unit to
run for 8 to 12 hours during engine break-in and pre-delivery
2. Fuel lines should be routed in a protective housing with no kinks or
procedures.
sharp bends (Detail II).
3. Rubber grommets must be used when routing fuel lines through holes
in metal (Detail II).
40
Installing the Fuel Lines
41
Installing the Fuel Level Sensor Harness (Option)
Ultrasonic Fuel Level Sensor (USFLS)
42
Installing the Fuel Level Sensor Harness (Option)
Ultrasonic Fuel Level Sensor (USFLS)
43
Installing the Status Light (Option)
Installation
1. Mount the Status Light in a location so that is visible in the tractor
mirror to the driver. Mount securely with the four provided screws.
2. Route harness as shown allowing a drip-loop to prevent water from
migrating into the Status Light.
3. Secure harness with clamps.
4. Connect the Status Light harness to the matching connector located
behind the battery tray and to the left of the control box.
44
Installing the Status Light (Option)
45
Installing the Rear Remote Controller (Option)
Foamed-In-Place Installation 5. Install cap in bottom of controller box before foaming trailer wall.
NOTE: Verify mounting location and all dimensions before installing 6. Apply chalking to controller box and install securely into trailer wall.
the remote controller.
Harness Connections
A = 69.8 mm (2.75 in.)
7. Apply Superlube (or equivalent) to Remote Controller Harness
B = 196.8 mm (7.75 in.) connector and attach securely to back of controller. Route harness
DANGER: Do not route electrical harness together with fuel through chase. Secure controller to controller box with screws.
lines as this could cause a fire resulting in death or serious 8. Route chase and Remote Controller Harness from controller to host
injury! unit. Secure with clamps.
CAUTION: Do not drill holes into refrigeration, electrical or 9. Cut off excess harness and strip wire ends.
mechanical components or severe damage to the equipment Attach the Remote Controller Harness wires to the splice
will result!
connectors on the Interface Harness.
Preferred Wire Routing (Steps 1,2, 6-10) .
1. Connect the harness chase to the bottom of controller while providing a PIN 1 BLU PIN 3 BLU
drip loop. PIN 2 GRN PIN 5 GRN
2. Install and route a 1/2 in. CPVC drain hose from the bottom of the PIN 3 No PIN 7 No
Connection Connection
controller box out of trailer floor.
PIN 4 ORN PIN 6 ORN
Alternative Wire Routing (Steps 3-10)
PIN 5 YEL PIN 4 YEL
NOTE: The alternative routing of the electrical harness chase and
interface harness is from the side of the controller box. PIN 6 BRN PIN 8 BRN
PIN 7 BLK PIN 1 BLK
3. Drill an appropriate size hole in the controller box for the harness chase
coupling. PIN 8 RED PIN 2 RED
4. Install harness chase coupling. 10. Apply Superlube (or equivalent) and securely connect the Interface
Harness 8-PIN connector to the mating 8-PIN Remote Controller
NOTE: Coupling should not protrude more than 6.4 mm (0.25 in.)
connector located on the side of the evaporator housing.
inside the controller box.
46
Installing the Rear Remote Controller (Option)
47
Installing the Rear Remote Controller (Option)
Retro-Fit Installation
NOTE: Verify mounting location and all dimensions before installing Harness Connections
the 4. Apply Superlube (or equivalent) to Remote Controller Harness
DANGER: Do not route electrical harness together with fuel connector and attach securely to back of controller. Route harness
lines as this could cause a fire resulting in death or serious through chase. Secure controller to controller box with screws.
injury!
5. Route harness under trailer through chase in floor or I-beam
crossmembers towards the unit.
CAUTION: Do not drill holes into refrigeration, electrical or
mechanical components or severe damage to the equipment 6. From inside the trailer, measure and drill an appropriate size hole and
will result! route the harness up into the trailer towards the unit.
7. Secure harness to the backside of the unit with clamps.
CAUTION: Rubber grommets must be used when routing
electrical harnesses through metal holes! 8. Measure the length of harness required for the harness to connect to the
8-Pin Remote Controller connector that is factory installed on the side
of the evaporator housing. Cut off excess harness and strip wire ends.
1. Cut opening in trailer wall per dimensions shown.
Crimp into existing splice and use heat shrink covering.
A = 203 mm (8.0 in.) .
49
Installing the Door Switch (Option)
NOTE: These instructions are intended as reference guide only to assist with a typical door switch installation. Your installation may be different
depending on the trailer, the amount and types of doors and the customers particular requirements.
50
Installing the Door Switch (Option)
51
Installing the Door Switch (Option)
The Door Switch Harness Connectors are located at the rear of the unit (See DETAIL C).
Single Door Switch Activation / Single Zone (Detail A) Multiple Door Switch Activation / Single Zone (Detail B)
1. Attach the interface harness to the door switch connector located at the 4. Attach the interface harness to the door switch connector at the rear of
rear of the unit. the unit.
2. Route a 3 wire harness (Installer Supplied) from the interface harness 5. Route a 3 wire harness (Installer Supplied) from the interface harness
to a single door switch. Connect matching wires per the table below to each door switch - Maximum Two Doors. Connect matching wires
(RED/RED, WHITE/WHITE, BLACK/BLACK) to each door per the table below (RED/RED, WHITE/WHITE, BLACK/
switch using splice connectors. Crimp splice connectors securely and BLACK) to each door switch using splice connectors. Crimp splice
apply heat with a heat gun. connectors securely and apply heat with a heat gun.
Interface Harness Wiring Door Switch Wiring Interface Harness Wiring Door Switch Wiring
RED = (12 Vdc) POWER RED = (12 Vdc) POWER RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT
3. All harnesses should be installed, routed and properly secured to 6. All harnesses should be installed, routed and properly secured to
protect from damage. protect from damage.
7. Operate unit and verify door switch operation.
52
Installing the Door Switch (Option)
Interface Harness Wiring Door Switch Wiring
RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT
Door Switch
Connectors
53
CargoWatch Sensor Locations (Option)
54
CargoWatch Sensor Locations (Option)
55
Connecting the CargoWatch Sensors (Option)
5. Insert WHITE pin connector and wire into correct connection until it 8. Secure sensor with appropriate clamps.
locks into position (Detail I). The wire side of the connector is shown.
SENSOR PLUGS
1 White into #1
2 White into #2
3 White into #3
4 White into #4
5 White into #5
6 White into #6
56
Connecting the CargoWatch Sensors (Option)
57
Installing the Bulkhead (Option)
THERMO KING RECOMMENDS USING A BULKHEAD
Bulkheads are available from authorized Thermo King dealers.
CAUTION: Do not drill holes into refrigeration, electrical or
mechanical components or severe damage to the equipment
will result!
Return Airflow
Restrictions of the return airflow adversely affects the performance of the
unit. The area directly behind the evaporator return air inlet must not be
restricted.
Bulkhead Function
A bulkhead is used to keep the return airflow from being restricted if the
load shifts. The bulkhead also prevents the load from shifting into the
return airflow passageway on the front wall of the trailer.
58
Installing the Bulkhead (Option)
59
Installing the Battery
CAUTION: Set all electrical controls to the OFF position before Optional Heavy Duty Battery Hold Down
connecting the battery to prevent the unit from starting! Bracket
1. Install the battery into the tray.
CAUTION: Always wear protective clothing, gloves and eye
wear when handling and installing batteries! 2. Install the battery hold down bracket and rods. Loosely install hardware
onto the rods.
CAUTION: Cover battery terminals to prevent accidental NOTE: One of the hold down rods must fit into the notch located on
shorting during battery installation! the channel under the battery. You may have to move the electrical
harness slightly to access this notch.
NOTE: Thermo King units are designed for one 12 volt, group 31
battery. The battery must be suitable for deep cycling, heavy duty 3. Align the tab of the battery hold down bracket over the two existing
and rated with a minimum of 95 amp/hr. holes in the frame support channel.
4. Install the two mounting bolts and flat washers through the hold down
Standard Battery Hold Down Bracket bracket and support channel. Torque hardware to 13.5 Nm
(120 in-lbs).
1. Install battery and secure with hold down bracket and rods.
Tighten the two battery hold down rods to 2.25 Nm (20 in -lbs.). 5. Tighten the two battery hold down rods to 2.25 Nm (20 in -lbs.)
DO NOT over tighten as this may crack or distort the battery! DO NOT over tighten as this may crack or distort the battery!
NOTE: One of the hold down rods must fit into the notch located on 6. Install positive + battery cable on the positive battery post first to
the channel under the battery. You may have to move the electrical minimize accidental electrical shorting. Tighten securely.
harness slightly to access this notch. 7. Install negative - battery cable on negative battery post second to
2. Install positive + battery cable on the positive battery post first to minimize accidental electrical shorting. Tighten securely.
minimize accidental electrical shorting.
3. Install negative - battery cable on negative battery post second to
minimize accidental electrical shorting.
60
Installing the Battery
Standard Optional
Battery Hold Down Bracket Heavy Duty Battery Hold Down Bracket
61
Installing the Bottom Pan
Installation 3. Front Mounting Bolts - Open the center curbside and roadside doors
to access the bottom pan front mounting tabs.
NOTE: Anti-seize lubricant applied to the threads of the stainless
steel mounting hardware is recommended. MODEL 30 Units - From inside the unit, secure the bottom pan
with the four 1/4-20 x .75'' screws, lock washers and flat washers
1. Remove the four 1/4-20 x .75 screws, lock washers and flat washers removed in Step #1.
attached to the front of the bottom pan. These will be re-installed in
Step #3. MODEL 50 Units - The receptacle box needs to be lifted up to
access one of the bottom pans front mounting bolts.
2. Rear Mounting Bolts - Position the bottom pan under the unit and
align the four holes in the rear of the bottom pan with the four holes in Remove the front bolt securing the receptacle box to the frame.
the rear of the frame. Loosen the rear bolt securing the receptacle box to the control
box. Lift the receptacle box up. From inside the unit, secure the
From under the unit, attach the rear of the bottom pan with the four
bottom pan with the four 1/4-20 x .75'' screws, lock washers and
1/4-20 x 1.00'' torx head screws, 1/4 lock washers and 1.00''
flat washers removed in Step #1.
diameter flat washers supplied in the installation kit.
4. Torque all eight bottom pan mounting bolts to 30 in-lb.
MODEL 50 Units - Reinstall the receptacle box securely.
5. Close and secure all doors.
62
Installing the Bottom Pan
63
Programming the SR-3 Controller for Fuel Level
Procedures
NOTE: The Guarded Access Menu is not available if the engine is
running.
1. Turn off the engine.
2. Go to the Guarded Access Menu.
3. Scroll down to and select the Unit Configuration.
4. Scroll down to and select Fuel Level Sensor.
The choices are: NONE, SOLID STATE or FLOAT.
USFLS STYLE - scroll to SOLID STATE by pressing + key
then YES key.
FLOAT STYLE - scroll to FLOAT by pressing + key then
YES key.
Fuel Level Percent will now be in the gauge menu.
5. The unit is now programed, press the exit key.
64
SYSTEM CHECK LIST
All unit mounting hardware torqued to specifications. Battery secured correctly and all connections clean and tight.
No air gaps between unit and trailer wall. Doors, covers, guards and bottom pan installed securely.
Drain hoses properly routed and secured. Run Pre-Trip test (refer to Host Unit Operating Manual).
Fuel tank properly installed. Run unit under load for eight hours to properly break-in engine.
Fuel lines properly routed and fuel fittings tightened securely. Release to customer.
Bulkhead properly designed and installed.
65