Thermo King Precedent C-600 Operator's Manual
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Thermo King Precedent C-600 Operator's Manual

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Operator's Manual
Precedent™
C-600
TK 55692-2-OP (Rev. 1, 10/14)

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Summary of Contents for Thermo King Precedent C-600

  • Page 1 Operator’s Manual Precedent™ C-600 TK 55692-2-OP (Rev. 1, 10/14)
  • Page 2 Precedent C-600 TK 55692-2-OP (Rev. 1, 10/14) Copyright© 2013 Thermo King Corp., Minneapolis, MN, USA Printed in USA...
  • Page 3 Thermo King dealer. The procedures described herein should only be undertaken by suitably qualified personnel. Failure to implement these procedures correctly may cause damage to the Thermo King unit or other property or personal injury.

  • Page 4: Table Of Contents

    Automatic Start/Stop Operation ....12 Thermo King X430L Reciprocating Compressor ..22 Electrical Hazard ......12 Electronic Throttling Valve .
  • Page 5 Remote Status Display (Optional) ....32 Both Numerical Setpoints and Named Products . 50 Changing the Setpoint - Numerical Setpoint ..51 Manual Pretrip Inspection Changing the Setpoint - Named Product .
  • Page 6 Languages (If Enabled) ......86 Optional Rear Remote Control Panel ...121 Available Languages .
  • Page 7 Alarm Codes ......142 Warranty ....... . . 186 Introduction .

  • Page 8: Introduction

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

  • Page 9: Epa Emission Control System Warranty Statement

    EPA Emission Control System Warranty Statement Thermo King warrants to the initial owner and each subsequent During the term of this warranty, Thermo King will provide, owner that the certified, non-road diesel engine in your unit is: through a Thermo King authorized service dealer or other...
  • Page 10 Thermo King parts. However, warranty. Thermo King is not liable for parts that are not genuine Thermo King parts. Responsibilities A part not being available within 30 days or repair not being This warranty is subject to the following: completed within 30 days constitutes an emergency.
  • Page 11 EPA Emission Control System Warranty Statement Owner Responsibilities Limitations During the emission warranty period, the owner is responsible Thermo King is not responsible for resultant damages to an for: emission-related part or component resulting from: • The performance of all required maintenance. A warranty •...

  • Page 12: Safety Precautions

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

  • Page 13: Automatic Start/Stop Operation

    This unit is capable of automatic operation and could start at any time without warning. WARNING: Improperly installed battery could result in a fire or explosion. A Thermo King approved WARNING: The unit can start at any time without battery must be installed and properly secured to the warning.

  • Page 14: Refrigerant

    Safety Precautions Refrigerant CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the Although fluorocarbon refrigerants are classified as safe, use battery to prevent unit from starting unexpectedly and caution when working with refrigerants or in areas where they causing personal injury.

  • Page 15: Refrigerant Oil

    Safety Precautions Refrigerant Oil Skin: Flush areas with large amounts of warm water. Do not apply heat. Wrap burns with dry, sterile, bulky dressing to Observe the following precautions when working with or protect from infection or injury. Get prompt medical attention. around refrigerant oil: Inhalation: Move victim to fresh air and restore breathing if necessary.

  • Page 16: Safety Decals And Locations

    Safety Precautions Safety Decals and Locations High Voltage Components Various components on the Precedent unit operate using Condenser and Evaporator Fans 220/3/60 or 460/3/60 high voltage and are identified by warning nameplates (examples in Figure 2). All high voltage Be aware of the warning nameplates near the condenser fans wiring is identified by ORANGE conduiting.
  • Page 17 Safety Precautions 1. Condenser Motors 4. High Voltage Control Box 2. Evaporator Motor 5. AC Generator Evaporator Motor High Voltage Junction 3. High Voltage 6. Electric Standby Motor & Distribution Box Power Receptacle High Voltage Heater All ORANGE conduiting (SmartPower Option) Strips contains High Voltage Figure 3: High Voltage Component Locations (Front)

  • Page 18: Do Not Use Ether Starting Aids

    Safety Precautions Do Not Use Ether Starting Aids Figure 5: Do Not Use Ether Starting Aids (Near Engine)

  • Page 19: Unit Description

    Unit Description Unit Overview The Thermo King Precedent C-600 is a one piece, self-contained, diesel powered, air cooling/heating unit operating under the control of a SMART REEFER 4 (SR-4) programmable microprocessor controller. The unit mounts on the front of the trailer with the evaporator extending through an opening in the front wall.

  • Page 20: Features And Options

    Unit Description Features and Options Precedent C-600 Key Features & Options Easy-access door design The following chart lists key design features and options. Composite Exterior Panels l Standard Features Long-Life Coolant/Silicone Hoses m Option/Factory installed Remote Status Display m / o...

  • Page 21: Diesel Engine

    Unit Description Diesel Engine Precedent C-600 Key Features & Options Fresh Air Exchange The 4-cylinder TK486V25 is a water cooled, direct injection Anti-Siphon Device diesel engine. The engine is coupled directly to the compressor on Standard Units. A centrifugal clutch transfers power from REB Wireless Communication Platform the engine to the compressor on Smart Power Units.

  • Page 22: Elc (Extended Life Coolant)

    Unit Description 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 expansion tank identifies units with ELC (see “Safety Decals and Locations”). The new engine coolant, Chevron Extended Life Coolant, is RED in color instead of the previous GREEN or BLUE-GREEN colored conventional coolants.

  • Page 23: Emi 3000

    3,000 hours, or 2 years, whichever occurs first. discharge pressures NOTE: Units equipped with the EMI 3000 package do • Protects the engine from high coolant temperature require regular inspection in accordance with Thermo King's shutdowns maintenance recommendations. • Provides a means of precise temperature control.

  • Page 24: Smart Reefer 4 (Sr-4) Control System

    Unit Description Diesel Operation SMART REEFER 4 (SR-4) In diesel operation the microprocessor will select the operating Control System mode from the following: The SR-4 is a microprocessor control system designed for • High Speed Cool transport refrigeration. The SR-4 integrates the following functions: changing setpoint and operating mode, viewing •...

  • Page 25: Electric Operation

    Hot Gas Heat maintain setpoint and provide constant airflow. • Full Heat (Hot Gas and Electric Heat) Your Thermo King unit provides a wide range of • Defrost (Hot Gas and Electric Heat) control and programming flexibility. However, pre-programming of the unit SR-4 microprocessor...

  • Page 26: Data Logging

    PROCESSOR ServiceWatch™: ServiceWatch is standard equipment. It records operating events, alarm codes and compartment temperatures as they occur and at preset intervals. This THERMO KING information is typically used to analyze unit performance. CargoWatch™: CargoWatch data logging requires the °F...

  • Page 27: Optiset Plus

    Contact your Thermo King dealer for information Manual Defrost: In Manual Defrost Mode, the operator about programming FreshSet.

  • Page 28: Opening The Front Doors

    Unit Description Opening the Front Doors Pull the right door handle to unlatch the doors and access the engine compartment. Do not push the doors closed while holding the door latch handle open or the door will not close properly. ARA2207 Figure 11: Door Latch Nameplate Figure 10: Door Latch Locations...

  • Page 29: Engine Compartment

    Unit Description Engine Compartment Operate the unit in high speed cool for approximately 15 minutes to stabilize operating conditions and temperature The following maintenance items can be checked visually. before attempting to check the refrigerant. NOTE: If the ball floats, there is sufficient refrigerant in the WARNING: The unit can start at any time without unit for that load at that particular trailer temperature.
  • Page 30 Take the unit to a Fuses: A number of fuses, located on the microprocessor, Thermo King dealer if this occurs. protect various circuits and components. The microprocessor is Low Oil Level Switch: The low oil level switch closes if the located inside the control box.
  • Page 31 F4 fuse Fuel Solenoid/Starter Circuit NOTE: The F5 preheat fuse is a “slow blow” type fuse. It is None No Fuse - All Bosch and Thermo King designed for use with the Yanmar trailer engine air Alternators (Note 1) pre-heater.
  • Page 32 Unit Description Control Box PC Only USB Poet HMI Control Panel 5. Flash Drive Only USB Port Microprocessor On/Off Switch Figure 12: Control Box With Service Door Open Figure 13: SR-4 Controller...

  • Page 33: Remote Status Display (Optional)

    Remote Status Display (Optional) The remote status display mounts on the cargo box for easy The remote status display indicates operating status as follows: viewing of the unit’s mode. White Status LEDs: Illuminate the “T” portion of the TK logo when the unit is functioning properly with no alarm codes.
  • Page 34 Remote Status Display (Optional) Amber Status LEDs: Illuminate the “K” portion of the TK White and Amber Status LEDs: The two bottom LEDs in logo when the unit has a check alarm code, but is still the “T” (in white) and the four bottom LEDs in the “K” (in functioning properly.
  • Page 35 Remote Status Display (Optional) Remote status displays that also show the fuel level or the fuel The temperature display shows the box temperature, except level and the box temperature are also available. The number when the unit is in defrost in which case it displays “dF”. of white LEDs illuminated in the fuel level indicator show the fuel level.

  • Page 36: Manual Pretrip Inspection (Before Starting The Unit)

    Manual Pretrip Inspection (Before Starting the Unit) Engine Coolant: The engine coolant must have antifreeze Pretrip inspections are an important part of a preventative maintenance program designed to minimize operating protection to -30 F (-34 C). Add coolant if Alarm Code 37 is problems and breakdowns.
  • Page 37 Manual Pretrip Inspection (Before Starting the Unit) Coils: Make sure the condenser and evaporator coils are clean and free of debris. Cargo Box: Check the interior and exterior of the cargo box for damage. Any damage to the walls or insulation must be repaired.

  • Page 38: Operating Instructions

    Operating Instructions SMART REEFER 4 (SR-4) Controller Overview Thermo King has applied the latest advances in computer MICRO PROCESSOR technology to develop a device that controls temperature and unit function, and displays operating information quickly and accurately. There is nothing complicated about learning to operate the...

  • Page 39: Control Panel

    Operating Instructions Control Panel The microprocessor components are located inside the control box, which is located inside the lower roadside service door. The control panel has a display and eight touch sensitive keys. The microprocessor is connected to a Human Machine The display is capable of showing both text and graphics.

  • Page 40: Display Icons

    Operating Instructions Display Icons Display symbols or Icons are used to present additional unit THERMO KING information °F Down-Pointing Arrow: (At the left side of the display) Shows the unit is cooling. If the arrow GAUGES SENSORS MENU POINT were pointing upward the unit would be heating.

  • Page 41: Hard Keys

    “Selecting Cycle Sentry or Continuous Mode” later in this section. On Key: Used to turn the unit on. First the display will briefly show the Thermo King Logo and then the statement “Configuring System - Soft Keys Please Wait”. When the power-up sequence is The four “soft”...

  • Page 42: Turning Unit On

    PLEASE WAIT IMPORTANT: The ON Key must be held down until the Thermo King Logo appears. If the ON Key is not held down long enough (approximately ½ second), the display may flicker but the unit will not start up. If this occurs, hold the ON Key down until the Thermo King logo appears.
  • Page 43 Operating Instructions IMPORTANT: The engine start is not delayed by the Flash Drive Menu shown above. The engine start prompt will appear and the engine will start. After the engine is started FLASH DRIVE the display will return to the Flash Drive Menu or the Standard Display.

  • Page 44: Configurable Soft Keys

    Operating Instructions The Flash Drive Menu will time out about 30 seconds after the The functions of these two keys can be changed as required for engine starts. When the Flash Drive Menu times out, the customer convenience. The functions of these two soft keys on Standard Display will appear.

  • Page 45: Display Heater

    Operating Instructions Display Heater If a Language is Enabled The HMI Control Panel is equipped with a display heater. This If more than one language has been enabled from the Guarded heater is needed to make the display visible in very cold Access Language Menu, a prompt will appear to allow the ambient temperatures.

  • Page 46: If Log Alarms Are Present

    Operating Instructions The Language menu will appear as shown in Figure 29. Press The new language is confirmed, and then the Standard Display the + or - Keys to select the desired language. When the will appear in the new language as shown in Figure 31. The desired language is shown press the YES Key to confirm the unit is ready to run.
  • Page 47 Operating Instructions and the remote indicator alarm light will go off. Pressing the EXIT soft key (Figure 32) will return to the Standard Display immediately. °F GAUGES SENSORS MENU LOG ALARMS ACTIVE POINT GO TO MENU TO VIEW EXIT Figure 33: Standard Display Figure 32: Log Alarms Active NOTE: The Alarm Icon does not appear on startup with log alarms present.

  • Page 48: Turning The Unit Off

    Operating Instructions Turning The Unit Off The Standard Display Pressing the OFF Key stops unit operation. The unit shuts The Standard Display is the default display that appears if no down immediately and the display briefly shows the power other display function is selected. The Standard Display shows down message (Figure 34).

  • Page 49: The Temperaturewatch Display

    Operating Instructions The TemperatureWatch Display The unit is running in Cycle Sentry Mode as shown by the Cycle Sentry Icon in the upper right The TemperatureWatch Display appears 2 ½ minutes after the corner of the display. If the Cycle Sentry icon is Standard Display appears so long as there is no key activity not present, the unit would be running in and no check, prevent or shutdown alarms are present.

  • Page 50: Changing The Setpoint

    Operating Instructions Changing The Setpoint TEMPERATURE SETPOINT The Setpoint is changed from the Standard Display. If the °F TemperatureWatch display is present, press any key to return to the Standard Display. MENU IMPORTANT: If OptiSet Plus is in use there are several possible options when changing the setpoint.

  • Page 51: Named Products - Optiset Plus

    Operating Instructions Named Products - OptiSet Plus Both Numerical Setpoints and Named Products OptiSet Plus allows the use of Named Products such as APPLES or BANANAS in place of a numerical setpoint. If OptiSet Plus can allow the use of both Numerical Setpoints and only named products are enabled the left soft key will be Named Products.

  • Page 52: Changing The Setpoint - Numerical Setpoint

    Operating Instructions Changing the Setpoint - Numerical Setpoint NEW SETPOINT WILL BE 40 F If the Temperature Watch display is shown, press any soft key +/- TO CHANGE to return to the Standard Display. From the Standard Display, press the SETPOINT Key. The setpoint display appears (Figure 41).
  • Page 53 Operating Instructions If the NO Key is pressed the display will briefly show SETPOINT NOT CHANGED and return to the Standard NEW SETPOINT WILL BE Display. The Standard Display will show the old setpoint. 40 F The display then returns to the Standard Display showing the +/- TO CHANGE new setpoint.
  • Page 54 Operating Instructions • If the YES Key is pressed, the setpoint change made with the “+” or “-” Key is accepted, the setpoint changes, and the display returns to the Standard Display. • If the NO Key is pressed the setpoint change made with the “+”...
  • Page 55 Operating Instructions NEW SETPOINT WILL BE NEW SETPOINT IS °F 40 F 40 F +/- TO CHANGE GAUGES SENSORS MENU POINT Setpoint Key + or - Keys New Setpoint CURRENT SETPOINT NEW SETPOINT WILL BE 35 F 40 F °F +/- TO CHANGE +/- TO CHANGE EXIT...

  • Page 56: Changing The Setpoint - Named Product

    Operating Instructions Changing the Setpoint - Named Product CURRENT PRODUCT IS GRAPEFRUIT, ARIZONA If the Temperature Watch display is shown, press any soft key to return to the Standard Display. From the Standard Display, +/- TO CHANGE EXIT press the PRODUCT Key. Note that PRODUCT is displayed in place of SETPOINT (Figure 47).
  • Page 57 Operating Instructions The YES and NO Keys confirm the product change (Figure After the YES Key has been pressed, the display briefly shows 50). When the desired product has been selected using the “+” PROGRAMMING NAMED PRODUCT - PLEASE WAIT. and/or “-”...
  • Page 58 Operating Instructions • If the YES or NO Key is not pressed within 10 seconds of making a change with the “+” or “-” Key, the product is POTATO, LATE CROP not changed and the display returns to the Standard °F Display.
  • Page 59 Operating Instructions GRAPEFRUIT, ARIZONA NEW PRODUCT WILL BE NEW NAMED PRODUCT IS °F POTATO, LATE CROP POTATO, LATE CROP +/- TO CHANGE PRODUCT GAUGES SENSORS MENU New Named Product If Yes Key Chosen, Product Key + or - Keys CURRENT PRODUCT IS NEW PRODUCT WILL BE POTATO, LATE CROP °F...

  • Page 60: Changing The Setpoint - Both Numerical Setpoint And Named Product Available

    Operating Instructions Changing the Setpoint - Both Numerical Setpoint and Named NAMED PRODUCT / NUMERIC Product Available SETPOINT? If the Temperature Watch display is shown, press any soft key EXIT NAMED NUMERIC to return to the Standard Display. From the Standard Display, press the SETPOINT Key.

  • Page 61: Starting The Diesel Engine

    Operating Instructions Starting the Diesel Engine Diesel engine preheats and starts are automatic in both DIESEL ENGINE STARTING Continuous Mode and Cycle Sentry Mode. The engine will preheat and start as required when the unit is turned on. The engine preheat and start will be delayed in Cycle Sentry Mode if there is no current need for the engine to run.

  • Page 62: Starting The Electric Motor

    Operating Instructions Starting the Electric Motor Units equipped with the SmartPower option only. Electric Power Receptacle: The electric power receptacle is used to connect the unit to an appropriate electric power source for electric standby operation (Figure 57). The electric power receptacle is usually mounted on the trailer below the HMI Control Panel.

  • Page 63: Switching From Diesel To Electric

    Operating Instructions Switching from Diesel to Electric PROGRAMMING ELECTRIC Units equipped with the SmartPower option only. STANDBY If the Diesel to Electric Auto-Switch Enabled feature in PLEASE WAIT Guarded Access is set YES then the unit will automatically switch to Electric Mode operation when standby power is connected and available.

  • Page 64: Switching From Electric To Diesel

    Operating Instructions Switching from Electric to Diesel ELECTRIC STANDBY NOT DETECTED Units equipped with the SMARTPOWER option only. DO YOU WISH TO SWITCH TO DIESEL? If the Electric to Diesel Auto-Switch Enabled feature in Guarded Access is set YES then the unit will automatically switch to Diesel Mode operation when standby power is turned off or is no longer available.

  • Page 65: Initiating A Manual Defrost Cycle

    Operating Instructions Diesel Mode operation will briefly be confirmed. If unit operation is required the diesel engine will start as shown previously under STARTING THE DIESEL ENGINE. °F If the Electric to Diesel Auto-Switch Enabled feature in GAUGES SENSORS MENU Guarded Access is set NO then the unit can also be switched POINT from Diesel Mode to Electric Mode operation using the Diesel...
  • Page 66 Operating Instructions The display then shows the Defrost display. The bar indicator shows approximately how much time remains to complete the DEFROST NOT AVAILABLE defrost cycle. The bar indicator shows that the defrost cycle is about 25% complete (Figure 65). Figure 66: Defrost Not Available GAUGES SENSORS...
  • Page 67 Operating Instructions °F GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT DEFROST STARTED DEFROST NOT AVAILABLE Figure 67: Initiating a Manual Defrost Cycle...

  • Page 68: Terminating A Defrost Cycle

    Operating Instructions Terminating a Defrost Cycle If the unit is operating in Cycle Sentry Mode, the Cycle Sentry Icon will be present in the upper right corner of the display as The defrost cycle terminates automatically when the coil shown below. If the Cycle Sentry Icon (Figure 68) is not temperature is greater than or equal to 58 F (14 C) or the present the unit is operating in Continuous Mode.
  • Page 69 Operating Instructions PROGRAMMING CONT MODE °F PLEASE WAIT GAUGES SENSORS MENU POINT Figure 69: Cycle Sentry/Continuous Key Figure 70: Continuous Mode NOTE: Cycle Sentry Mode or Continuous Mode can also be The new mode is confirmed for 3 seconds (Figure 71). selected using the Main Menu >...
  • Page 70 Operating Instructions The display then returns to the Standard Display. In the example shown in Figure 72 the absence of the Cycle Sentry Icon indicates that the unit is running in Continuous Mode. °F GAUGES SENSORS MENU POINT Figure 72: Cycle Sentry Icon Not Shown = Continuous Mode Pressing the Cycle Sentry/Continuous Key again allows the operator to change back to Cycle Sentry Mode operation.
  • Page 71 Operating Instructions PROGRAMMING CONT MODE °F °F PLEASE WAIT GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT Continuous Mode Selected NEW SYSTEM MODE IS °F CONTINUOUS GAUGES SENSORS MENU POINT Figure 73: Selecting Cycle Sentry or Continuous Mode...

  • Page 72: Using The Gauges Key

    Operating Instructions Using the Gauges Key BATTERY VOLTAGE The GAUGES Key allows the operator to view the unit gauges. If the function of this key has been reassigned, the GAUGES Menu is also available in the Maintenance Menu. EXIT LOCK BACK NEXT To access the GAUGES Menu, press the GAUGES Key...
  • Page 73 Operating Instructions Engine Oil Level Switch: Displays the engine oil level as I/O (Input/Output State): Displays the current state of the OK or LOW. input/output devices listed here: Amps: Displays the current flow in amps flowing to or from • High Speed •...

  • Page 74: Using The Sensors Key

    Operating Instructions • Spare Digital Input 3 • Electric overload (SmartPower units only) °F • Spare Digital Input 4 • Hot Gas Bypass (ETV units only) GAUGES SENSORS MENU POINT • Spare Analog Input 1 • Spare Analog Input 2 Figure 76: Sensors Key Using The Sensors Key The first sensor display will appear.

  • Page 75: Sensors Available

    Operating Instructions The sensors available are shown below. * Spare 1 Temperature: Displays the temperature of the spare 1 temperature sensor. To return to the Standard Display press the EXIT Key. * Log Sensor 1: Displays the temperature of the CargoWatch Data Logger temperature sensor 1.

  • Page 76: Using The Main Menu

    Operating Instructions Using the Main Menu MAIN MENU The Main Menu contains several additional submenus that PRETRIP LANGUAGE allow the operator to view information and modify unit ALARMS operation. To access the Main Menu press the MENU Key GAUGES EXIT SELECT DOWN (Figure 78).

  • Page 77: Pretrip

    Operating Instructions Alarms: The Alarm Menu allows the operator to view any SmartPower™ Electric Standby Option: The active alarms, and allows most alarms to be cleared. Diesel/Electric Standby selection from the Main Menu allows the operator to manually select Diesel or Electric Mode Gauges: The Gauges Menu allows the operator to view the operation on units equipped with the electric standby unit gauges and I/O conditions.
  • Page 78 Operating Instructions Mode a Running Pretrip Test is performed. Test results are Pretrip Test Sequence reported as PASS, CHECK or FAIL when the Pretrip Test is Pretrip tests proceed in the order shown below. A Full Pretrip completed. Test includes all tests. A Running Pretrip Test is started with the engine or motor running and does not include the Amp Pretrip Test Conditions Checks or Engine Start Check.

  • Page 79: Performing A Pretrip Test

    Operating Instructions Performing a Pretrip Test Pretrip Test Considerations When performing a Pretrip Test, the following issues should be If a Pretrip Test is initiated with the engine shut down a Full considered. Pretrip Test will be performed. If a Pretrip Test is initiated with the engine or motor running a Running Pretrip Test is •...
  • Page 80 Operating Instructions The Main Menu will appear. Press the UP or DOWN Key as required to choose the Pretrip Menu. When the Pretrip Menu is PROGRAMMING PRETRIP MODE shown press the SELECT Key to start a Pretrip Test (Figure 81). MAIN MENU PRETRIP LANGUAGE...
  • Page 81 Operating Instructions If all alarms were cleared, the Pretrip Test display appears • To stop a Pretrip Test at any time turn the unit off. This (Figure 84). will generate Alarm Code 28 Pretrip Abort. Other alarm codes may also be generated. This is normal when the Pretrip Test is halted before completion.
  • Page 82 Figure 86: Pretrip Pass If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected by a Thermo King service technician before the unit is released for service. To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
  • Page 83 Operating Instructions NON-RUNNING PRETRIP RUNNING PRETRIP PROGRAMMING PRETRIP MODE TEST 1 OF 26 TEST 21 OF 26 °F SENSOR CHECK COOL TEST GAUGES SENSORS MENU HOUR SENSORS GAUGES HOUR SENSORS GAUGES METERS POINT METERS Alarms Cleared? MAIN MENU PRETRIP PRETRIP NO PRETRIP -- ALARM ACTIVE PASS LANGUAGE...

  • Page 84: Flash Drive

    Operating Instructions Flash Drive Flash Drive Icon •“ The USB Icon (Figure 88) will appear in the If a properly configured USB Flash Drive is currently upper left corner of the display as shown below connected to the USB Port on the unit Control Panel, the Flash when a USB Flash Drive is inserted in the USB Drive Menu will appear as a Main Menu selection.

  • Page 85: Selecting The Flash Drive Menu From The Main Menu (If Already Connected)

    Operating Instructions Selecting the Flash Drive Menu MAIN MENU from the Main Menu (If Already FLASH DRIVE PRETRIP Connected) LANGUAGES ALARMS EXIT SELECT DOWN To select the Flash Drive Menu, press the MENU Key (Figure 89). The Main Menu will appear. Figure 90: Flash Drive Menu °F Flash Drive (If Connected While the Unit is Turned...

  • Page 86: Removing The Flash Drive

    Operating Instructions FLASH DRIVE DETECTED FLASH DRIVE REMOVED EXIT DOWN FLASH OPTISET EXIT HELP LOAD LOAD PLUS Figure 91: Flash Drive Figure 92: Flash Drive Removed If the HELP Soft Key is pressed the display shown in Figure 93 Removing the Flash Drive will appear.

  • Page 87: Languages (If Enabled)

    Operating Instructions Languages (If Enabled) Available Languages The following languages are available: If more than one language is enabled from the Guarded Access • English • French • Spanish > Language Menu, this menu item will appear. If only one language is enabled, this menu will not appear.
  • Page 88 Operating Instructions The display will briefly show PROGRAMMING LANGUAGE - PLEASE WAIT in the new language. The MAIN MENU display will then return to the Language Menu, but will show PRETRIP LANGUAGE the new language. Español (Spanish) is shown in Figure 97. ALARMS GAUGES EXIT...
  • Page 89 Operating Instructions Figure 98: New Language (Example: Español) To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again. See Figure 99 for an overview of the Languages selection procedure.
  • Page 90 Operating Instructions NEW LANGUAGE WILL BE °F °F DEUTSCH USE +/- TO CHANGE GAUGES SENSORS MENU MESSGE SENSORE MENU POINT POINT MAIN MENU HAUPTMENU PRETRIP SPRACHE LANGUAGE ALARMS GAUGES EXIT SELECT DOWN BEENDEN AUSWHAL WEITER Figure 99: Languages (If Enabled)

  • Page 91: Alarms

    Operating Instructions Language Menu Quick Access Should it be necessary at any time to change to English or any other installed language, return to the Standard Display and then press and hold the first and last soft keys for 5 seconds as shown below.

  • Page 92: Check Alarms

    Operating Instructions Shutdown Alarms If a Shutdown Alarm occurs while the unit is running it will be LOG ALARMS ACTIVE indicated by all of the following (Figure 104): GO TO MENU TO VIEW • The Alarm Icon will appear. EXIT •...

  • Page 93: Pretrip Alarms

    Operating Instructions Pretrip Alarms Clearing Alarm Codes If an alarm occurs during a Pretrip Test the alarm code will be Most alarm codes can be cleared conventionally from the displayed as Pretrip Alarm XX, where XX is the alarm code. Alarm Menu using the CLEAR Key.

  • Page 94: Displaying And Clearing Alarm Codes

    Operating Instructions • Alarm Code 91 Check Electric Ready Input - Clears automatically when the unit starts running. • Alarm Code 92 Sensor Grades Not Set - Clears when the sensor grade is changed from 5H. GAUGES SENSORS MENU POINT If the Limited Alarm Restarts feature is enabled the following additional alarm codes may only be cleared from the Guarded Access Menu.
  • Page 95 Operating Instructions The number of alarms (if more than one) and a list of the alarms with the most recent alarm first will be shown. In the 1 OF 2 ALARMS example below, there are two alarms. The most recent is Alarm CHECK AMBIENT TEMP SENSOR PRETRIP REMINDER Code 5 Check Ambient Temp Sensor (Figure 107).
  • Page 96 Operating Instructions The display will briefly show CLEARING ALARM 5 – PLEASE WAIT. Then the Alarm Menu will reappear (Figure 110). Note that Alarm Code 64 Pretrip Reminder cannot be cleared using the CLEAR Key. This alarm will clear automatically GAUGES SENSORS MENU...
  • Page 97 Operating Instructions A help message will appear. Press the EXIT Key to return to Important Alarm Notes the Alarms Menu (Figure 113). Check the oil level and add oil • If an alarm will not clear, it may still exist. If the alarm is as required, clear the alarm and restart the engine.
  • Page 98 Operating Instructions 1 OF 2 ALARMS LOG ALARMS ACTIVE CHECK AMBIENT TEMP SENSOR PRETRIP REMINDER GO TO MENU TO VIEW GAUGES SENSORS MENU EXIT CLEAR HELP DOWN GAUGES SENSORS MENU EXIT POINT POINT 1 OF 2 ALARMS MAIN MENU 1 OF 1 ALARMS CHECK AMBIENT TEMP SENSOR PRETRIP LOW ENGINE OIL LEVEL...

  • Page 99: Gauges

    Operating Instructions Gauges The Main Menu will appear. Press the UP or DOWN Key as required to choose the Gauges Menu. When the Gauges Menu The Gauges Menu allows the operator to view the unit gauges is selected, press the SELECT Key to choose the Gauges menu and I/O conditions.

  • Page 100: Sensors

    Operating Instructions Displaying Sensors BATTERY VOLTAGE Sensors are displayed using the Sensors Menu. From the Standard Display, press the MENU Key (Figure 118). EXIT LOCK BACK NEXT °F GAUGES SENSORS MENU Figure 117: Next, Back, Lock Keys POINT The gauges and I/O conditions available are described in this section of the manual.

  • Page 101: Data Logger (Cargowatch)

    Operating Instructions When shipped from the factory, CargoWatch sensors 1 and 2 are turned on to be logged and CargoWatch sensors 3 through 6 CONTROL DISCHARGE AIR TEMPERATURE are turned off. Also, digital input 1 is turned on to be logged °F and digital inputs 2 through 4 are turned off.

  • Page 102: Sending Start Of Trip Marker To Cargowatch And Servicewatch Data Loggers

    Operating Instructions Sending Start of Trip Marker to CargoWatch and ServiceWatch °F Data Loggers GAUGES SENSORS MENU To send a Start of Trip marker to the CargoWatch and POINT ServiceWatch Data Loggers press the SELECT Key. The display will briefly show START OF TRIP COMPLETE to confirm that a Start of Trip marker was set in the CargoWatch Figure 120: Standard Screen, Menu Key Data Logger (Figure 122).
  • Page 103 Operating Instructions Printing CargoWatch Data Logger Reports CONTROLLER VERSION NUMBER: B007 CONTROLLER TYPE: Press the DOWN Key to select the PRINT / VIEW feature and DATALOGGER VERSION NUMBER: 6512 TEMPERATURE UNITS: FAHRENHEIT press the SELECT Key to choose Print/View. START: 05/30/08 08:29:08 FINISH: 05/30/08 09:18:33...
  • Page 104 Operating Instructions UNIT SERIAL NUMBER: xxxxxxxxxx PRINT DATA CONTROLLER SERIAL NUMBER: A00021506190T3 DELIVERY TICKET TRAILER ID: xxxxxxxxxx TRIP TICKET CONTROLLER VERSION NUMBER: B007 CONTROLLER TYPE: DATALOGGER VERSION NUMBER: 6512 EXIT SELECT DOWN TEMPERATURE UNITS: FAHRENHEIT START: 05/30/08 09:50:08 FINISH: 05/30/08 13:07:33 SENSORS: SETPOINT: 32.0...

  • Page 105: Hourmeters

    Operating Instructions Hourmeters The Hourmeters Menu allows the operator to view the unit °F hourmeters that have the view feature enabled in the Guarded Access menu. If the view feature for a particular hourmeter is GAUGES SENSORS MENU POINT not enabled then that hourmeter will continue to accumulate time but cannot be viewed from the Main Menu.
  • Page 106 Operating Instructions Press the NEXT or PREVIOUS Key to scroll through the To return to the Main Menu press the EXIT Key. To return to hourmeters (Figure 129). the Standard display press the EXIT Key again. Hourmeter Names and Definitions HOURMETERS TOTAL UNIT RUN HOURS Only configured hourmeters that have been enabled in the...

  • Page 107: Mode Menu

    Operating Instructions IMPORTANT: If a programmable hourmeter is not enabled Total Run User Programmable - The number of hours or the view for that hourmeter is not turned on it will not Reminder 2 before a Total Unit Run Time Maintenance appear in the display sequence.
  • Page 108 Operating Instructions • Allows Keypad Lockout to be selected (if enabled from the Guarded Access > Main Menu Configuration Menu). °F • Start Sleep Mode (if enabled from the Guarded Access > Main Menu Configuration Menu). GAUGES SENSORS MENU POINT When shipped from the factory, only the Cycle Sentry/Continuous Mode is enabled.
  • Page 109 Operating Instructions Turn Cycle Sentry On or Off The first enabled Change Mode Menu selection will appear. To choose that function, press the SELECT Soft Key. To Scroll Cycle Sentry Mode can be turned On or Off if Cycle Sentry through the enabled features in the Change Mode Menu, press Mode is allowed by OptiSet Plus.
  • Page 110 Operating Instructions Select Temperature Units CHANGE MODE If this feature enabled in Guarded Access > Main Menu TURN OFF CYCLE SENTRY Configuration, the operator can select temperature units to be displayed as either degrees Fahrenheit or degrees Celsius. EXIT SELECT From the Main Menu >...
  • Page 111 Operating Instructions feature is only available with setpoints above 32 F (0 C). The feature is disabled with setpoints of 32 F (0 C) and below. This TEMPERATURE UNITS FAHRENHEIT feature may not be available if OptiSet Plus is in use. CELSIUS The Fresh Air Exchange feature should be used exactly as EXIT...
  • Page 112 Operating Instructions • The Fresh Air Exchange door will only be open when the unit engine is running. The door will close when the CHANGE MODE TURN ON CYCLE SENTRY MODE engine shuts down to preserve unit battery life. FAHRENHEIT KEYPAD LOCKOUT •...
  • Page 113 Operating Instructions If the YES Soft Key was pressed Keypad Lockout is active. Repeat the process to turn the Keypad Lockout feature off. CHANGE MODE TURN ON CYCLE SENTRY MODE • If the keypad is locked, only the On Key and Off Key FAHRENHEIT KEYPAD LOCKOUT function.

  • Page 114: Smartpower Electric Standby Option

    Operating Instructions Electric Mode Operation • Minute to Wake Up: This feature allows the minute the unit is to wake up to be specified. If a unit equipped with the electric standby SmartPower option • Run Pretrip on Wakeup: This feature allows a Pretrip is running in Diesel Mode, the Diesel to Electric Auto-Switch Test to be automatically run when the unit wakes up.
  • Page 115 Operating Instructions Switching from Diesel to Electric From the Main Menu choose Electric Standby and press the SELECT Soft Key (Figure 142). If the unit is running in Diesel Mode and the Diesel to Electric Auto-Switch Enabled feature in Guarded Access is set YES MAIN MENU then the unit will automatically switch to Electric Mode HOURMETERS...
  • Page 116 Operating Instructions Electric Standby Power Fails or is Switching from Electric to Diesel Disconnected If the unit is running in Electric Mode and the Electric to Diesel Auto-Switch Enabled feature in Guarded Access is set If the electric standby power source fails or is disconnected and YES then the unit will automatically switch to Diesel Mode manual switching to Diesel Mode is selected, the unit will operation when standby power is no longer available.
  • Page 117 Operating Instructions The new mode is confirmed for 10 seconds. The unit will start and run in Diesel Mode. °F Any electric standby related Shutdown Alarms become Log Alarms when the unit is switched to Diesel Mode operation. If GAUGES SENSORS MENU the unit is switched back to Electric Mode these alarms again...

  • Page 118: Time

    Operating Instructions The Display Brightness menu will appear as shown below. Press the UP or DOWN Soft Keys to select the desired display brightness. When the desired brightness is shown press the °F SELECT Soft Key to confirm the choice (Figure 148). GAUGES SENSORS MENU...

  • Page 119: Clear All Ecu Faults

    Operating Instructions The date and time held in the HMI Control Panel will be shown on the display (Figure 151). Time and Date cannot be changed from the Main Menu. °F GAUGES SENSORS MENU POINT TIME MENU 01:18 MONDAY 10 DEC 2012 EXIT Figure 149: Menu Key The Main Menu will appear.
  • Page 120 Clear All ECU Faults Menu is selected, press the SELECT Key to choose the Clear All ECU Faults Menu (Figure 153). • The Thermo King Alarm Codes and Engine Control Unit (ECU) Fault Codes that were cleared can be viewed in the ServiceWatch and ECU Data Loggers.
  • Page 121 Operating Instructions CLEAR ALL ECU FAULTS CLEAR ALL ECU FAULTS EXIT CLEAR Figure 154: Clear Key All Engine Control Unit (ECU) Faults and associated Thermo King Faults will be cleared. To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.

  • Page 122: Optional Rear Remote Control Panel

    Optional Rear Remote Control Panel Rear Remote Control Panel The optional Rear Remote Control Panel is connected to the control system and is used to operate the unit from a remote Functionality location, typically at the rear of the trailer. In the illustration below all display segments are turned on.

  • Page 123: Rear Remote Control Action Set To Stand By

    Optional Rear Remote Control Panel Rear Remote Control Action Set to If the control system is powered up from the Rear Remote Control Panel the Standard Display will appear in both the STAND BY Rear Remote Control Panel display and the unit Control Panel If the Rear Remote Control Action is set to STAND BY, display.
  • Page 124 Optional Rear Remote Control Panel When in STAND BY, the unit will not start and run and a When the StAnd bY display is shown, press the Select Key to defrost cycle or Pretrip Test cannot be started. show the Remote Standard Display. When the remote standard Display is shown, the setpoint and operating mode can be If the control system is powered up from the remote control changed, the discharge air temperature can be displayed and...

  • Page 125: Keypad

    Optional Rear Remote Control Panel Keypad Turns the unit on as determined ON Key by the setting of Rear Remote The nine touch sensitive keys are used to turn the unit on and Control Action. off. They also allow the setpoint to be changed, Cycle Sentry or Continuous Mode to be selected, Alarm Codes and other OFF Key Turns the unit off.

  • Page 126: Display

    Optional Rear Remote Control Panel TK Logo Sends a Start of Trip marker to This icon appears when the unit is Cool Icon the data logger. cooling. This icon appears when the unit is Heat Icon Initiates a defrost cycle if heating.

  • Page 127: Reading A Typical Remote Standard Display

    Optional Rear Remote Control Panel Reading a Typical Remote • The unit is cooling as shown by the icon at the upper left side of the display. Standard Display • The unit is operating in Cycle Sentry mode as shown by The Remote Standard Display shows the temperature and the icon at the upper right side of the display.

  • Page 128: Turning The Unit On Or Off (Configured For Stand By Operation)

    Optional Rear Remote Control Panel Turning the Unit ON or OFF (Configured for STAND BY Operation) The control system is turned on by pressing the ON Key and off by pressing the OFF Key. When the On Key is pressed the remote display briefly shows all segments and then StAnd by as shown in Figure 163.

  • Page 129: Changing The Setpoint

    Optional Rear Remote Control Panel Changing the Setpoint The setpoint can be changed when the Remote Standard Display is shown. When the Remote Standard Display is shown, press the Up or Down Arrow Keys to select the desired setpoint (Figure 165). Figure 164: Standard Display Figure 165: Press Up or Down Arrow Keys...

  • Page 130: Selecting Cycle-Sentry Or Continuous Mode

    Optional Rear Remote Control Panel Selecting Cycle-Sentry or When the desired setpoint is shown on the display, immediately press the Enter Key to load the new setpoint. Continuous Mode The display will briefly show [Lod] and then the new setpoint will reappear in the display. Cycle Sentry or Continuous Mode operation can be changed using the Select Key.

  • Page 131: Displaying The Discharge Air Temperature

    Optional Rear Remote Control Panel Displaying the Discharge Air Temperature The discharge air temperature can be shown using the Select Key. When the Remote Standard Display is shown, press the Select Key twice. The discharge air temperature will be Figure 168: Press Up or Down Arrow Keys shown in the display for about 10 seconds.

  • Page 132: Viewing And Clearing Alarm Codes

    Optional Rear Remote Control Panel Viewing and Clearing Alarm Codes Alarm Codes can be displayed and cleared using the Select Key. When the Remote Standard Display is shown, press the Select Key three times. Any alarm codes present will be shown in the display, with the most recent alarm code Figure 172: Press Enter Key shown first.

  • Page 133: Starting A Manual Defrost Cycle

    Optional Rear Remote Control Panel Starting a Manual Defrost Cycle If conditions allow, a manual defrost cycle can be initiated using the Defrost Key. Press the Defrost Key. The defrost prompt [EnTEr dEF] will appear in the display. Figure 175: Press Enter Key The display will return to the Remote Standard Display.

  • Page 134: Sending A Start Of Trip Marker

    Optional Rear Remote Control Panel Sending a Start of Trip Marker When the Start of Trip prompt is shown, press the Enter Key to send a Start of Trip marker to the CargoWatch and A Start of Trip marker can be sent to the data loggers using the ServiceWatch data loggers.

  • Page 135: Running A Pretrip Test

    Optional Rear Remote Control Panel Running a Pretrip Test When the Pretrip prompt is shown, press the Enter Key to start a Pretrip Test. The display will briefly show LOAd A Pretrip Test can be started using the Pretrip Key as long as PrE.
  • Page 136 Optional Rear Remote Control Panel When the Pretrip Test is running the display will show PrE When the Pretrip Test is complete the display will show trP. The Control Panel will show the Pretrip Test progress. PASS, CHEC or FAIL. Pressing the Select Key will return to the Remote Standard Display.

  • Page 137: Loading And Enroute Inspections

    Loading and Enroute Inspections This chapter describes pre-loading, post loading, and enroute Verify that the setpoint temperature is correct for your inspection procedures. Thermo King refrigeration units are cargo. Pre-cool the trailer as required. designed to maintain the required product load temperature Supervise product loading to ensure sufficient air space during transit.
  • Page 138 Loading and Enroute Inspections Correct load height (trailers without chutes) Tight doors and gaskets Good air circulation around load Proper cargo temperature (prior to loading) Interior/exterior walls and insulation in good condition Clear defrost drains Good outside air circulation Unit inspection Tight seals ADZ30 Figure 183: Loading Considerations...

  • Page 139: Post-Loading Inspection

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

  • Page 140: Enroute Inspections

    Verify setpoint is correct. Immediately contact the nearest Thermo King Service Check the return air temperature reading. It should be Center or your company office. within the desired temperature range.
  • Page 141 A competent refrigeration technician is required to add refrigerant or repair the system. Contact the nearest Thermo King dealer, authorized Service Center, or call the Thermo King Cold Line for referral. Consult the Table of Contents for Cold Line information.
  • Page 142 Loading and Enroute Inspections Problem Cause Remedy Improper air Inspect the unit and cargo compartment to determine if the evaporator fan(s) circulation in the are working and properly circulating the air. Poor air circulation may be due cargo compartment. to improper loading of the cargo, shifting of the load, or fan belt slippage. Correct as required.

  • Page 143: Alarm Codes

    Log Alarms: Log Alarms are indicated by the Log Alarms Maintenance Menu or the Guarded Access Menu. Contact screen, which appears for approximately 30 seconds (just your supervisor or a Thermo King dealer about clearing before the Standard Display appears) each time the unit is those alarms.
  • Page 144 Alarm Codes corrective action before a problem becomes severe. Maintenance items such as a maintenance reminder hour meter reaching its time limit are log alarms. GAUGES SENSORS MENU POINT LOG ALARMS ACTIVE GO TO MENU TO VIEW EXIT Figure 185: Alarm Display Prevent Alarms: Prevent Alarms are also indicated by the Alarm Display as shown in Figure 185.
  • Page 145 Alarm Codes Shutdown Alarms: Shutdown Alarms are indicated by the In the same manner, if a shutdown alarm occurs that affects Alarm Display. Shutdown alarms also cause the display and only Electric Mode operation and the unit is switched to diesel backlight to flash on and off, and the display will switch from (either manually or automatically), the Electric Mode normal video to reverse video and back to normal video (light...

  • Page 146: Clearing Alarm Codes

    Instructions chapter for procedures. NOTE: The chart on the following pages shows all possible The operator should contact a supervisor or a Thermo King alarm codes for all possible applications. Not all codes will be dealer about clearing alarms using the Guarded Access Menu.
  • Page 147 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action No Alarms Exist None required Manually monitor load temperature with independent Evaporator Coil Sensor thermometer.
  • Page 148 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shut down repair immediately. Otherwise, report High Discharge Pressure alarm at end of day.
  • Page 149 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shutdown repair immediately. Otherwise, report Engine Failed to Start alarm at end of day.
  • Page 150 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Pretrip Abort Report alarm at end of day. If unit is shutdown, repair immediately. Otherwise, report Defrost Damper Circuit alarm at end of day.
  • Page 151 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shutdown, repair immediately. Otherwise, report Electric Motor Failed to Run alarm at end of day.
  • Page 152 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Unit Forced to Low Speed Report alarm at end of day. Modulation Check Fuel System Refill fuel tank.
  • Page 153 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Service Test or Interface Board Test time out after 15 Test Mode Time-out minutes.
  • Page 154 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Abnormal Temperature If unit is shutdown, repair immediately. Otherwise, report Differential alarm at end of day Check engine oil level.
  • Page 155 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shutdown repair immediately. Otherwise, report Low Engine Coolant Temperature alarm at end of day.
  • Page 156 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Low Compressor Suction If unit is shutdown, repair immediately. Otherwise, report Pressure alarm at end of day.
  • Page 157 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action 108 Door Open Time-out Close Doors. Report alarm at end of day. If unit is shutdown, repair immediately.
  • Page 158 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Auto switch from Electric to Report alarm at end of day. Diesel If unit is shutdown, repair immediately.
  • Page 159 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Electric Run Time Maintenance Report alarm at end of day. Reminder #1 Electric Run Time Maintenance Report alarm at end of day.
  • Page 160 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Lost Expansion Module CAN If unit is shut down repair immediately. Otherwise, report Communication alarm at end of the day.
  • Page 161 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Manually monitor load temperature. Report alarm at the end 157 OptiSet Plus Mismatch of the day 158 Primary Software Failed to Load Report alarm at end of the day.
  • Page 162 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action 232 Future REB Alarm REB Transitioning From Report alarm at end of the day. Conservative to Full Null 234 Relative Humidity Sensor Report alarm at end of the day.
  • Page 163 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Host Condenser Fan 1 RPM If unit is shutdown, repair immediately. Otherwise, report Sensor alarm at end of day.
  • Page 164 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Engine Control Unit (ECU) Run If unit is shutdown, repair immediately. Otherwise, report Signal Failed alarm at end of day.
  • Page 165 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action I/O Controller to Application If unit is shutdown, repair immediately. Otherwise, report Controller Communication alarm at end of day.
  • Page 166 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Battery Temperature Sensor If unit is shutdown, repair immediately. Otherwise, report Alarm alarm at end of day.
  • Page 167 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shutdown, repair immediately. Otherwise, report 529 Check Fuel Pump Circuit alarm at end of day.
  • Page 168 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action 601 Check Camshaft Speed Sensor Report alarm at end of the day. Check Intake Throttle Position If unit is shut down repair immediately.
  • Page 169 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shut down repair immediately. Otherwise, report 609 Check Intake Pressure Sensor alarm at end of the day.
  • Page 170 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shut down repair immediately. Otherwise, report 616 Engine Overspeed alarm at end of the day.
  • Page 171 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Check Intake Air Temperature If unit is shut down repair immediately. Otherwise, report Sensor alarm at end of the day.

  • Page 172: Jump Starting

    Jump Starting If the battery in a unit is discharged or run down, the unit may IMPORTANT: Make sure to use a 12-volt battery to jump be jump started using jumper cables and another battery or start the unit. If you are using a vehicle, make sure it has a vehicle.
  • Page 173 Jump Starting CAUTION: Do not use a match or lighter as a light near the battery. Use a flashlight. A flame or a spark can ignite the gas in the battery and cause Unit it to explode. (Discharged) 12-Volt Remove the red cover from the positive (+) battery Battery terminal on the unit’s battery.
  • Page 174 Jump Starting Connect the red positive (+) jumper cable to the positive CAUTION: Be careful around fans and belts. (+) battery terminal on the unit’s battery. Do not let the Keep your hands away from moving parts when an other end of the jumper cable touch anything that conducts engine is running.
  • Page 175 Jump Starting Unit (Discharged) 12-Volt Battery Good 12-Volt Battery Unit Engine Starter Mounting Bolt on Unit Engine Negative (–) Terminal on Good Battery Positive (+) Terminal on Good Battery Positive (+) Terminal on Unit Battery Figure 188: Sequence for Disconnecting Jumper Cables...

  • Page 176: Specifications

    Specifications Engine Model TK486V25 (Tier 4) Number of Cylinders Cylinder Arrangement In-line vertical, number 1 on flywheel end Firing Order 1-3-4-2 Direction of Rotation Counterclockwise viewed from flywheel end Fuel Type No. 2 diesel fuel under normal conditions No. 1 diesel fuel is acceptable cold weather fuel Oil Capacity 12 quarts (11.4 liters) crankcase and oil filter Fill to full mark on dipstick...
  • Page 177 Specifications Engine (Continued) 14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic) Oil Viscosity 5 to 104 F (-15 to 40 C): SAE 15W-40 5 to 104 F (-15 to 40 C): SAE 10W-30 (Synthetic or Synthetic Blend) -13 to 104 F (-25 to 40 C): SAE 10W-40 -13 to 86 F (-25 to 30 C): SAE 10W-30...
  • Page 178 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 179: Belt Tension

    Specifications Engine (Continued) Drive: Standard Units Direct to compressor; belts to AC generator, alternator, and water pump Smart Power Units Centrifugal clutch to compressor; belts to electric standby motor, AC generator, alternator, and water pump Belt Tension Belt New Belt Field Reset AC Generator and Alternator Belt - Standard Units: 37 or 65 Amp Alternator...

  • Page 180: Refrigeration System

    Alternator Belt - Smart Power Units Only: All Alternators 216 Hz (75 lbs) 187 Hz (56 lbs) Refrigeration System Compressor Thermo King X430LSC5 Refrigerant Charge—Type 14.5 lb (6.6 kg)—R404A Compressor Oil Charge 4.3 qt (4.1 liters)* Compressor Oil Type Polyol Ester type P/N 203-513...
  • Page 181 Specifications Refrigeration System * When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the replacement compressor in the unit.

  • Page 182: Electrical Control System

    One, group C31, 12 volt, (950 CCA recommended for Battery operation below -15 F [-26 C]) Fuses See “Fuses” on page 29. Battery Charging 12 volt, 37 amp, brush type, Thermo King Alternator Voltage Regulator Setting 13.95 to 14.35 volts @ 77 F (25 C)

  • Page 183: 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 High Speed (Throttle) Solenoid Air Heater 0.14 Pilot Solenoid...
  • Page 184 Specifications Electrical Components AC Generator 230 Vac at 54.9 Hz Nominal Vac - Measured Vac, Load Low Engine Speed (1450 rpm) Output Dependent High Engine Speed (2200 rpm) Output 345 Vac at 90 Hz Nominal Vac - Measured Vac, Load Dependent Fan Motors Evaporator Fan Motor: Low Speed Power Rating...

  • Page 185: Electric Heater Strips

    Specifications Electrical Standby (Smart Power Units Only) NOTE: A transformer is used to convert 460 Vac to 230 Vac in units configured to use electric standby input voltage of 460 Vac. Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts Full Load Overload Relay (amps) Setting (amps)

  • Page 186: Standby Power Cord Requirements

    Specifications Standby Power Cord Requirements Supply Circuit Breaker: 12 HP Motor 230/3/60 70 amps 12 HP Motor 460/3/60 40 amps 19 HP Motor 460/3/60 60 amps Extension Cord Size: 12 HP Motor 230/3/60 8 AWG Power Cable, 25 to 50-foot length (All 4 conductor, 2000 Vac, Type W Power Cable) 12 HP Motor 230/3/60...

  • Page 187: Warranty

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

  • Page 188: Glossary

    Thermo King unit. (Loading too close to the unit restricts air flow and system efficiency.) 2) bulkhead ambient air temperature: Temperature of the air divider.
  • Page 189 Glossary CFC: Chlorofluorocarbon. A chlorine-based refrigerant condenser: An arrangement of tubing in which the consisting of chlorine, fluorine and carbon. Example: R12. In vaporized and compressed refrigerant is liquefied as heat is many countries it is illegal to release this type of refrigerant to removed.
  • Page 190 ERC: Extended Remote Unit Control. (Door switches) An fuse: An electrical safety device (typically a cartridge) option on Thermo King multi-temperature units to improve inserted into an electrical circuit. It contains material that will temperature control when doors are opened during delivery.
  • Page 191 (horsepower): A unit of power equivalent to 746 watts truck or trailer. See bulkhead. or 550 foot-pounds per second. Multi-Temp: A Thermo King truck or trailer unit capable of HPCO (High Pressure Cut Out Switch): A maintaining different set-points in multiple compartments.
  • Page 192 Some engines use an intake manifold heater rather in the front of a trailer and designed to prevent restriction of than glow plugs. return air flow to the Thermo King unit due to improper loading. See bulkhead. pre-trip inspection: Checking the operation of a refrigeration system before loading.
  • Page 193 Glossary Vac (volts alternating current): An electric current that reverses direction at regularly recurring intervals. Vdc (volts direct current): An electric current that flows in one direction only and is constant in value. volts: The basic measuring unit of electrical potential. watt: The basic measuring unit of electrical power.

  • Page 194: 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 Engine • Check fuel supply. • Check engine oil level. • • • • Inspect belts for condition and proper tension. •...
  • Page 195 Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours • • • • Check engine coolant level and antifreeze protection (-30 F [-40 C]). • • • Drain water from fuel tank and check vent. •...
  • Page 196 Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours • Adjust engine valve clearance. Test fuel injection nozzles at least every 3,000 hours. ** Replace fuel return lines between fuel injection nozzles every 10,000 hours.
  • Page 197 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. •...
  • Page 198 Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours Structural • • • • Visually inspect unit for fluid leaks. • • • • Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads).

  • Page 199: Serial Number Locations

    Serial Number Locations Unit: Nameplates on the evaporator fan housing and on the roadside of the evaporator. Engine: See the engine identification plate located on the engine valve cover. Compressor: Stamped between the cylinders on the front end above the oil pump. Figure 189: Compressor Serial Number Location...
  • Page 200 Serial Number Locations Figure 190: Engine Serial Number Location Figure 191: Unit Serial Number Plate Locations...
  • Page 201 Serial Number Locations ARA793 Unit Serial Number Bill of Material Number Unit Model Unit ID Figure 192: Unit Serial Number Plate...

  • Page 202: Emergency Cold Line

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

  • Page 203: Recover Refrigerant

    Recover Refrigerant At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.

  • Page 204: California Proposition 65 Warning

    CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.

  • Page 205: Index

    defrost 26 alarm codes 142 defrost drain inspection 36 corrective action 145 Defrost key 39, 40, 48, 83 types 142 door inspection 36 amber status light 33 automatic start/stop safety precautions 12 ELC (extended life coolant) 21 electrical components, specifications 182 battery inspection 35 electrical control system, specifications 181 belt tension, specifications 178...
  • Page 206 ETV (electronic throttling valve) 22 enroute inspections 139 extended life coolant (ELC) 21 post-loading inspection 138 pre-loading inspection 136 first aid for refrigerant 14 low oil level switch 29 first aid for refrigerant oil 14 low oil pressure switch 29 FreshSet 26 front doors maintenance inspection schedule 193...
  • Page 207 protection devices 28 soft keys 40 specifications rear remote control panel 121 electric fuel heater 185 receiver tank sight glass 28 SR-2 Controller 23, 37 refrigerant oil safety 14 status light, remote 32 refrigerant safety 12 structural inspection 35 refrigeration system, specifications 179 remote status light 32 unit description 18 safety precautions 11...

Table of Contents