Page 1 Operator’s Manual Precedent™ S-600 and S-700 TK 55538-2-OP (Rev. 5, 12/14)
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
Electrical Hazard ......13 Thermo King X430 Reciprocating Compressor ..24 Battery Installation and Cable Routing .
Page 5 Remote Status Display (Optional) ....34 Both Numerical Setpoints and Named Products . 53 Changing the Setpoint - Numerical Setpoint ..53 Manual Pretrip Inspection Changing the Setpoint - Named Product .
Page 6 Select Temperature Units .....108 Removing the Flash Drive ..... . 85 Fresh Air Exchange Open or Closed .
Page 7 Turning the Unit On and Off (Configured for RUN Jump Starting ......170 Operation) .
Page 8 Recover Refrigerant ......203 CALIFORNIA Proposition 65 Warning ..... 204 Index .
Page 9: 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 10: 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 11 The owner should ensure that such parts are equivalent in design and durability to genuine Thermo King parts. However, This warranty is subject to the following: Thermo King is not liable for parts that are not genuine Thermo King Corporation Thermo King parts.
Page 12 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 13: 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 14: 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 15: 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 16: 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 17: 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 18 Safety Precautions 1. Condenser Motors 4. High Voltage Control Box Evaporator Motor High Voltage Junction 2. Evaporator Motor 5. AC Generator 3. High Voltage 6. Electric Standby Motor & Distribution Box Power Receptacle High Voltage Heater All ORANGE conduiting Strips contains High Voltage (SmartPower Option) Figure 4: High Voltage Component Locations (Rear)
Page 19: 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 20: Unit Description
Unit Description Unit Overview The Thermo King Precedent S-600 and S-700 are one piece, self-contained, diesel powered, air cooling/heating units operating under the control of the 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 21: Features And Options
Unit Description Features and Options Precedent S-600 & S-700 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 Hoses m Option/Factory installed Remote Status Display...
Page 22: Rail Options
Unit Description The following chart list key features of the rail option Precedent S-600 & S-700 Key Features & Options packages. Anti-Siphon Device Std = Standard REB Wireless Communication Platform Opt - Optional TracKing Telematics m / o PrimAir Bulkhead and Duct system...
Page 23: Diesel Engine
Unit Description Diesel Engine Rail Options - Features and TOFC Special Considerations The S-600 uses the TK488CR. The S-700 uses the 156 Gal. (591 Liter) TK488CRH. These are 4-cylinder, water cooled, direct Rectangular Fuel Tank injection diesel engines. The engine is coupled directly to the compressor on Standard Units.
Page 24: 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. The new engine coolant, Chevron Extended Life Coolant, is RED in color instead of the previous GREEN or BLUE-GREEN colored conventional coolants.
Page 25: 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 26: Smart Reefer 4 (Sr-4) Control System
Unit Description SMART REEFER 4 (SR-4) Control Diesel Operation System In diesel operation the microprocessor will select the operating 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 27: 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 28: Data Logging
ThermoServ™ software. ServiceWatch™: ServiceWatch is standard equipment. It records operating events, alarm codes and compartment THERMO KING temperatures as they occur and at preset intervals. This information is typically used to analyze unit performance.
Page 29: Optiset Plus
30 minutes if maximize protection of cargo, while keeping operating costs to required. a minimum. Contact your Thermo King dealer for information Manual Defrost: In Manual Defrost mode, the operator about programming FreshSet.
Page 30: Opening The Front Doors
Unit Description Opening the Front Doors Pull the right door latch handle out at a 45 degree angle and turn it down (clockwise) 90 degrees (see Figure 6) to open the doors and access the engine compartment. Push the door closed while holding the door latch handle open and then turn it up (counterclockwise) 90 degrees to close the door.
Page 31: 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 32 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 33 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 34 Unit Description Control Box 4. PC Only USB Port (option) HMI Control 5. Flash Drive Only USB Port Panel Microprocessor On/Off Switch Figure 7: Control Box With Service Door Open Figure 8: SR-4 Controller...
Page 35: 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 36 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 37 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 38: 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 39 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 40: 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 41: 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 42: 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 43: 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 44: Turning Unit On
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 Figure 3: ON Key ON Key down until the Thermo King logo appears.
Page 45: If A Flash Drive Is Connected
Operating Instructions If a Flash Drive is Connected: If a properly configured USB Flash Drive is inserted in the FLASH DRIVE DETECTED Flash Drive Only USB Port on the Control Panel when the unit is turned on, the display (Figure 24) will briefly show FLASH EXIT DOWN FLASH...
Page 46: Configurable Soft Keys
Operating Instructions Configurable Soft Keys • DOWNLOAD • “Download the ServiceWatch Data Logger When the Standard Display is shown, the default functions of the two center soft keys are GAUGES and SENSORS. • “Download the CargoWatch Data Logger (Figure 26) •...
Page 47: Display Heater
Operating Instructions Display Heater The GAUGES and SENSORS functions are always available from the Maintenance Menu. The HMI Control Panel is equipped with a display heater. This In the example shown in Figure 27, the soft key functions from heater is needed to make the display visible in very cold the Standard Display have been changed to PRETRIP and SOT ambient temperatures.
Page 48 Operating Instructions specifically enabled from the Guarded Access Menu are available. If a different language is desired, press the NO Key (Figure 28). IMPORTANT: The engine start is not delayed by the language prompt shown below. The prompt will appear for 10 seconds and then the engine will start.
Page 49: If Log Alarms Are Present
Operating Instructions The new language is confirmed, and then the Standard Display If log alarm(s) are present the Log Alarm notice shown in will appear in the new language as shown in Figure 31. The Figure 32 will appear on the display for 60 seconds. The unit is ready to run.
Page 50: Turning The Unit Off
Operating Instructions SYSTEM IS POWERING DOWN °F GAUGES SENSORS MENU POINT Figure 14: Standard Display Figure 15: Power Down Message Turning The Unit Off The display briefly shows OFF (Figure 35) and then goes blank. To start the unit again, press the ON Key. Pressing the OFF Key stops unit operation.
Page 51: The Standard Display
Operating Instructions The Standard Display The unit is running in Cycle Sentry Mode as shown by the Cycle Sentry Icon in the upper right The Standard Display is the default display that appears if no corner of the display. If the Cycle Sentry icon is other display function is selected.
Page 52: The Temperaturewatch Display
Operating Instructions The TemperatureWatch Display TEMPERATURE SETPOINT The TemperatureWatch Display appears 2 ½ minutes after the °F Standard Display appears so long as there is no key activity and no check, prevent or shutdown alarms are present. The MENU TemperatureWatch Display will remain on until any key is pressed or a check, prevent or shutdown alarm occurs.
Page 53: Changing The Setpoint
Operating Instructions Changing The Setpoint Named Products - OptiSet Plus OptiSet Plus allows the use of Named Products such as The Setpoint is changed from the Standard Display. If the APPLES or BANANAS in place of a numerical setpoint. If TemperatureWatch display is present, press any key to return to only named products are enabled the left soft key will be the Standard Display.
Page 54: Both Numerical Setpoints And Named Products
Operating Instructions Both Numerical Setpoints and Named Changing the Setpoint - Numerical Products Setpoint OptiSet Plus can allow the use of both Numerical Setpoints and If the Temperature Watch display is shown, press any soft key Named Products. If both numerical setpoints and named to return to the Standard Display.
Page 55 Operating Instructions NEW SETPOINT WILL BE NEW SETPOINT WILL BE 40 F 40 F +/- TO CHANGE +/- TO CHANGE Figure 24: Yes and No Keys Figure 23: Setpoint Changed Using “+” Key After the YES Key has been pressed, the display briefly shows The YES and NO Keys (Figure 43) confirm the setpoint PROGRAMMING NEW SETPOINT - PLEASE WAIT.
Page 56 Operating Instructions If the NO Key is pressed the display will briefly show • If the YES Key is pressed, the setpoint change made with SETPOINT NOT CHANGED and return to the Standard the “+” or “-” Key is accepted, the setpoint changes, and Display.
Page 57: Changing The Setpoint - Named Product
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 58 Operating Instructions The “-” and “+” Keys are used to change the Named Product until the desired product is shown. In Figure 49 the product has GRAPEFRUIT, ARIZONA been changed to Potato, Late Crop. °F PRODUCT GAUGES SENSORS MENU NEW PRODUCT WILL BE POTATO, LATE CROP +/- TO CHANGE Figure 28: Product Displayed...
Page 59 Operating Instructions Failure to confirm the new product by pressing Yes or No within 10 seconds of changing the product will result in no NEW NAMED PRODUCT IS product change. In addition, Alarm Code 127 Setpoint Not Entered is set, to indicate that the product change was initiated POTATO, LATE CROP but not completed.
Page 60 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 61: Changing The Setpoint - Both Numerical Setpoint And Named Product Available
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 If Yes Key Chosen, New Named Product Product Key + or - Keys CURRENT PRODUCT IS NEW PRODUCT WILL BE POTATO, LATE CROP °F...
Page 62 Operating Instructions • Press the NUMERIC Soft Key to proceed with Changing the Setpoint - Numeric Setpoint change as previously shown. °F • Press the NAMED Soft Key to proceed with Changing the PRODUCT/ GAUGES SENSORS MENU Setpoint - Named Product change as shown previously. SETPOINT •...
Page 63: 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 64: 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 65: Switching From Diesel To Electric
Operating Instructions Switching from Diesel to Electric If NO is selected, then the unit will continue to operate in Diesel Mode. If YES is selected then the display will briefly Units equipped with the SmartPower option only. show the screen in Figure 60. If the Diesel to Electric Auto-Switch Enabled feature in Guarded Access is set YES then the unit will automatically PROGRAMMING ELECTRIC...
Page 66: 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 67: Initiating A Manual Defrost Cycle
Operating Instructions Initiating a Manual Defrost Cycle Diesel Mode operation will briefly be confirmed. If unit operation is required the diesel engine will start as shown Defrost cycles are usually initiated automatically based on time previously under STARTING THE DIESEL ENGINE. or demand.
Page 68 Operating Instructions The display briefly shows [DEFROST], [PROGRAMMING DEFROST - PLEASE WAIT] and then [DEFROST STARTED] (Figure 64). GAUGES SENSORS MENU POINT DEFROST STARTED Figure 46: Bar Indicator If conditions do not allow a defrost cycle, the display shown in Figure 66 will briefly appear.
Page 69: Terminating A Defrost Cycle
Operating Instructions °F GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT DEFROST STARTED DEFROST NOT AVAILABLE Figure 48: Initiating a Manual Defrost Cycle Terminating a Defrost Cycle The defrost cycle terminates automatically when the coil temperature is greater than or equal to 58 F (14 C) or the defrost timer expires.
Page 70: Selecting Cycle Sentry Or Continuous Mode
Operating Instructions Selecting Cycle Sentry or Continuous Mode °F When Cycle Sentry Mode is selected the unit will start and stop automatically to maintain setpoint, keep the engine warm and GAUGES SENSORS MENU POINT the battery charged. When Continuous Mode is selected, the unit starts automatically and runs continuously to maintain setpoint and provide constant airflow.
Page 71 Operating Instructions NOTE: Cycle Sentry Mode or Continuous Mode can also be selected using the Main Menu > Mode Submenu. NEW SYSTEM MODE IS If the unit is in Cycle Sentry Mode, pressing the Cycle Sentry/Continuous Key changes the mode from Cycle Sentry CONTINUOUS Mode to Continuous Mode.
Page 72 Operating Instructions Pressing the Cycle Sentry/Continuous Key again allows the IMPORTANT: Cycle Sentry or Continuous Mode may not be operator to change back to Cycle Sentry Mode operation. selectable if OptiSet Plus is in use. IMPORTANT: If the unit is in Cycle Sentry Null and the mode is switched to Continuous Mode, the unit will start automatically.
Page 73: 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 74 Operating Instructions Engine Oil Pressure: Displays the engine oil pressure as Fresh Air Exchange: Displays the current position of the OK or LOW. optional Fresh Air Exchange Door Engine Oil Level Switch: Displays the engine oil level as I/O (Input/Output State): Displays the current state of the OK or LOW.
Page 75: Using The Sensors Key
Operating Instructions • Spare Digital Input 2 • Electric Ready Input (SmartPower units only) °F • Spare Digital Input 3 • Electric overload (SmartPower units only) GAUGES SENSORS MENU POINT • Spare Digital Input 4 • Hot Gas Bypass (ETV units only) •...
Page 76: 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 77: 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 78: 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 79 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 80: 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 81 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 82 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 83 Operating Instructions If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected by a Thermo King service PRETRIP technician before the unit is released for service. PASS To return to the Main Menu press the EXIT Key. To return to EXIT the Standard display press the EXIT Key again.
Page 84: Flash Drive
Operating Instructions Flash Drive Flash Drive Icon If a properly configured USB Flash Drive is currently •“ The USB Icon (Figure 88) will appear in the 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 into the Drive Menu will appear as a Main Menu selection.
Page 85 Operating Instructions MAIN MENU FLASH DRIVE °F PRETRIP LANGUAGES ALARMS EXIT SELECT DOWN GAUGES SENSORS MENU POINT Figure 70: Menu Key Figure 71: Flash Drive Menu Flash Drive (If Connected While the Unit is Turned If a properly configured USB Flash Drive is connected to the Flash Drive Only USB Port on the Control Panel, the Flash Drive Menu will appear as a main Menu selection.
Page 86: Removing The Flash Drive
Operating Instructions FLASH DRIVE DETECTED FLASH DRIVE REMOVED EXIT DOWN FLASH OPTISET EXIT HELP LOAD LOAD PLUS Figure 72: Flash Drive Figure 73: 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 If more than one language is enabled from the Guarded Access The following languages are available: > Language Menu, this menu item will appear. If only one • English • French • Spanish language is enabled, this menu will not appear.
Page 88 Operating Instructions MAIN MENU PRETRIP LANGUAGE ALARMS GAUGES EXIT SELECT DOWN Figure 76: Main Menu Figure 77: Language Menu The Language menu will appear as shown in Figure 96. Press The display will briefly show PROGRAMMING the + or - Keys to select the desired language. Only languages LANGUAGE - PLEASE WAIT in the new language.
Page 89 Operating Instructions Repeat the process to select a different language. To select a different Main Menu item press the NEXT (SIGUIENTE) Key. To return to the Standard Display press the EXIT (SALIDA) Key. All displays will now be in the new language. Español (Spanish) is shown in Figure 98.
Page 90: Language Menu Quick Access
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 80: Languages (If Enabled) 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...
Page 91: Alarms
Operating Instructions Log Alarms After 5 seconds the Language Menu will appear in the current language as shown below. Press the + or - Keys to select the If only Log Alarms exist the display shown in Figure 102 will desired language.
Page 92: Shutdown Alarms
Operating Instructions GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT Figure 84: Alarm Icon Figure 85: Reverse/Normal Video Shutdown Alarms Pretrip Alarms If a Shutdown Alarm occurs while the unit is running it will be If an alarm occurs during a Pretrip Test the alarm code will be indicated by all of the following (Figure 104): displayed as Pretrip Alarm XX, where XX is the alarm code.
Page 93: Clearing Alarm Codes
Operating Instructions shutdown alarm that is preventing diesel mode operation. If the The following alarm codes clear automatically: unit is switched back to diesel mode, the alarm again become a • Alarm Code 64 Pretrip Reminder - Clears when a Pretrip diesel mode shutdown alarm and prevents unit operation.
Page 94: Displaying And Clearing Alarm Codes
Operating Instructions Displaying and Clearing Alarm Codes MAIN MENU Alarms are displayed and cleared using the Alarm Menu. From PRETRIP the Standard Display, press the MENU Key (Figure 105). LANGUAGE ALARMS GAUGES EXIT SELECT DOWN GAUGES SENSORS MENU POINT Figure 87: UP/Down, Select Keys The number of alarms (if more than one) and a list of the alarms with the most recent alarm first will be shown.
Page 95 Operating Instructions If necessary to view all alarms, scroll down using the DOWN The display will briefly show CLEARING ALARM 5 – Key (Figure 108). PLEASE WAIT. Then the Alarm Menu will reappear (Figure 110). Note that Alarm Code 64 Pretrip Reminder cannot be cleared 1 OF 2 ALARMS CHECK AMBIENT TEMP SENSOR using the CLEAR Key.
Page 96 Operating Instructions A help message will appear. Press the EXIT Key to return to the Alarms Menu (Figure 113). Check the oil level and add oil as required, clear the alarm and restart the engine. LOW ENGINE OIL LEVEL GAUGES SENSORS MENU POINT...
Page 97 Operating Instructions See Figure 114 for an overview of the Displaying and Clearing Alarm Codes procedure. 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...
Page 98: 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 99: 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 98: Next, Back, Lock Keys POINT The gauges and I/O conditions available are described in this section of the manual.
Page 100: Data Logger (Cargowatch)
Operating Instructions and digital inputs 2 through 4 are turned off. Sensors and digital inputs can be turned on, off and configured using the CONTROL DISCHARGE AIR TEMPERATURE CargoWatch menu in Guarded Access or with Wintrac. The °F CargoWatch Data Logger can also be configured using the USB Flash Drive OptiSet Plus Feature.
Page 101: Sending Start Of Trip Marker To Cargowatch And Servicewatch Data Loggers
Operating Instructions Sending Start of Trip Marker to CargoWatch The Main Menu will appear. Press the UP or DOWN Key as required to choose the Data Logger Menu. When the Data and ServiceWatch Data Loggers Logger Menu is selected, press the SELECT Key to choose the To send a Start of Trip marker to the CargoWatch and Data Logger menu (Figure 121).
Page 102: Printing Cargowatch Data Logger Reports
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 103 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 104: 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 not enabled then that hourmeter will continue to accumulate POINT time but cannot be viewed from the Main Menu.
Page 105: Hourmeter Names And Definitions
Operating Instructions Hourmeter Names and Definitions Press the NEXT or PREVIOUS Key to scroll through the hourmeters (Figure 129). Only configured hourmeters that have been enabled in the Viewable Hourmeter Setup Menu will be shown: HOURMETERS TOTAL UNIT RUN HOURS TOTAL ENGINE RUN HOURS Hourmeter Definition...
Page 106: Mode Menu
Operating Instructions Mode Controller Total hours the controller and HMI Control Power On Panel have been turned on. The Mode Menu allows the operator to change the unit operating modes that have been enabled in Guarded Access. Pretrip User Programmable - number of hours Reminder before a Pretrip Reminder occurs.
Page 107 Operating Instructions When shipped from the factory, only the Cycle The Main Menu will appear. Press the UP or DOWN Key as Sentry/Continuous Mode is enabled. required to choose the Mode Menu. When the Mode Menu is selected, press the SELECT Key to choose the Mode Menu If OptiSet Plus is in use some modes may not be available.
Page 108: Turn Cycle Sentry On Or Off
Operating Instructions Turn Cycle Sentry On or Off CHANGE MODE Cycle Sentry Mode can be turned On or Off if Cycle Sentry TURN ON CYCLE SENTRY MODE Mode is allowed by OptiSet Plus. If Cycle Sentry is turned off FAHRENHEIT KEYPAD LOCKOUT the unit runs in Continuous mode, unless Continuous Mode is START SLEEP MODE...
Page 109: Select Temperature Units
Operating Instructions Select Temperature Units If the unit is running in Cycle Sentry Mode, press the SELECT Soft Key (Figure 134) to turn off Cycle Sentry Mode as shown If this feature enabled in Guarded Access > Main Menu below. Configuration, the operator can select temperature units to be displayed as either degrees Fahrenheit or degrees Celsius.
Page 110: Fresh Air Exchange Open Or Closed
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 111: Keypad Lockout
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 112: Start Sleep Mode
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 113: 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 114: Switching From Diesel To Electric
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 115: Electric Standby Power Fails Or Is Disconnected
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 116: Adjust Brightness
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 117: 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 118: 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 130: Menu Key The Main Menu will appear.
Page 119 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 120 Operating Instructions CLEAR ALL ECU FAULTS CLEAR ALL ECU FAULTS EXIT CLEAR Figure 135: 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 121: Rear Remote Control Panel (Optional)
Rear Remote Control Panel (Optional) 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 122: Rear Remote Control Action Set To Stand By
Rear Remote Control Panel (Optional) 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 123 Rear Remote Control Panel (Optional) 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 124: Keypad
Rear Remote Control Panel (Optional) 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 125: Display
Rear Remote Control Panel (Optional) 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 126: Reading A Typical Remote Standard Display
Rear Remote Control Panel (Optional) Reading a Typical Remote Remote Control Panel Lockout Standard Display The remote control panel may be locked out during some control system functions such as Service Test Mode, Interface The Remote Standard Display shows the temperature and Board Test Mode and while setting programmable features.
Page 127: Turning The Unit On Or Off (Configured For Stand By Operation)
Rear Remote Control Panel (Optional) 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 128: Changing The Setpoint
Rear Remote Control Panel (Optional) 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 10: Standard Display Figure 11: Press Up or Down Arrow Keys...
Page 129: Selecting Cycle-Sentry Or Continuous Mode
Rear Remote Control Panel (Optional) 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 130: Displaying The Discharge Air Temperature
Rear Remote Control Panel (Optional) 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 14: Press Up or Down Arrow Keys shown in the display for about 10 seconds.
Page 131: Viewing And Clearing Alarm Codes
Rear Remote Control Panel (Optional) 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 18: Press Enter Key shown first.
Page 132: Starting A Manual Defrost Cycle
Rear Remote Control Panel (Optional) 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 21: Press Enter Key The display will return to the Remote Standard Display.
Page 133: Sending A Start Of Trip Marker
Rear Remote Control Panel (Optional) 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 134: Running A Pretrip Test
Rear Remote Control Panel (Optional) 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 135 Rear Remote Control Panel (Optional) 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 136: 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 137 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 1: Loading Considerations...
Page 138: 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 139: 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 140 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 141 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 142: 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 143 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 2: Alarm Display Prevent Alarms: Prevent Alarms are also indicated by the Alarm Display as shown in Figure 185.
Page 144: Pretrip Alarm Codes
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 shutdown normal video to reverse video and back to normal video (light...
Page 145: 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 146 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 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 If unit is shut down repair immediately. Otherwise, report High Discharge Pressure alarm at end of day.
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 shutdown repair immediately. Otherwise, report Engine Failed to Start 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 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 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 If unit is shutdown, repair immediately. Otherwise, report Electric Motor Failed to Run 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 Unit Forced to Low Speed Report alarm at end of day. Modulation Check Fuel System Add fuel as necessary.
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 Service Test or Interface Board Test time out after 15 Test Mode Time-out minutes.
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 Abnormal Temperature If unit is shutdown, repair immediately. Otherwise, report Differential alarm at end of day Check engine oil level.
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 If unit is shutdown repair immediately. Otherwise, report Low Engine Coolant Temperature alarm at end of day.
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 Low Compressor Suction If unit is shutdown, repair immediately. Otherwise, report Pressure 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 108 Door Open Time-out Close Doors. Report alarm at end of day. If unit is shutdown, repair immediately.
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 Auto switch from Electric to Report alarm at end of day. Diesel 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 Electric Run Time Maintenance Report alarm at end of day. Reminder #1 Electric Run Time Maintenance Report alarm at end of day.
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 Lost Expansion Module CAN If unit is shut down repair immediately. Otherwise, report Communication alarm at end of the 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 Expansion Module Flash Load If unit is shut down repair immediately. Otherwise, report Failure 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 230 Future REB Alarm 231 Future REB Alarm 232 Future REB Alarm REB Transitioning From 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 Host Evaporator Fan RPM If unit is shutdown, repair immediately. Otherwise, report Sensor alarm at end of 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 Engine Control Unit (ECU) Failed If unit is shutdown, repair immediately. Otherwise, report to Enable 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 I/O Controller to Application If unit is shutdown, repair immediately. Otherwise, report Controller Communication 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 Battery Temperature Sensor If unit is shutdown, repair immediately. Otherwise, report Alarm 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 If unit is shutdown, repair immediately. Otherwise, report 529 Check Fuel Pump Circuit 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 601 Check Camshaft Speed Sensor Report alarm at end of the day. Check Intake Throttle Position If unit is shut down repair immediately.
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 If unit is shut down repair immediately. Otherwise, report 609 Check Intake Pressure Sensor alarm at end of the day.
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 616 Engine Overspeed 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 Check Intake Air Temperature If unit is shut down repair immediately. Otherwise, report Sensor alarm at end of the day.
Page 171: 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 172 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 173 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 174 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 2: Sequence for Disconnecting Jumper Cables...
Page 175: Specifications
Specifications Engine Model: S-600 TK488CR (Tier 4) S-700 TK488CRH (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 No. 2 diesel fuel under normal conditions Fuel Type No.
Page 176 Specifications Engine (Continued) API Classification CJ-4 or better ACEA Classification E6 or better Oil Type NOTE: This oil type must be used together with ULSD fuel to prevent damage to the DOC. 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...
Page 177 Specifications Engine (Continued) Intake Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm) Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm) Valve Setting Temperature 70 F (21 C) Low Oil Pressure Switch (Normally Closed) 17 ± 3 psig (117 ± 21 kPa) Engine Coolant Thermostat 160 F (71 C) Engine Coolant Type...
Page 178 Specifications Engine (Continued) CAUTION: Do not add “GREEN” or “BLUE-GREEN” conventional coolant to cooling systems using “RED” Extended Life Coolant, except in an emergency. If conventional coolant is added to Extended Life Coolant, the coolant must be changed after 2 years instead of 5 years.
Page 179: Belt Tension
Specifications Belt Tension Belt Use of Frequency Gauge P/N 204-1903 to measure frequency (Hz) is recommended. New Belt Field Reset AC Generator and Alternator Belt - Standard Units: 37 or 65 Amp Alternator 106 Hz (111 lbs) 92 Hz (84 lbs) 120 Amp Alternator 121 Hz (144 lbs) 105 Hz (108 lbs)
Page 180: Refrigeration System
Specifications 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 Heat/Defrost Method: Engine Operation Hot gas Electric Operation Hot gas and optional electric heater strips...
Page 181: Electrical Control System
-15 F [-26 C]) Fuses See See “Fuses” on page 31. Battery Charging 12 volt, 37 amp, brush type, Thermo King Alternator Voltage Regulator Setting 13.95 to 14.35 volts @ 77 F (25 C) Electrical Components NOTE: Disconnect components from unit circuit to check resistance.
Page 182 Specifications Electrical Components (Continued) Electronic Throttling Valve: Coil A (Red [EVA] and Blue [EVB] Wires) — 20 to 35 Coil B (Black [EVC] and White [EVD] Wires) — 20 to 35 Hot Gas Bypass Valve (if used) 11.1 Starter Motor 350-475* * On-the-engine cranking check.
Page 183 Specifications Electrical Components (Continued) S-600 Fan Motors - Engine Operation Evaporator Fan Motor: Low Speed Power Rating 1.20 hp (0.90 kW) High Speed Power Rating 1.75 hp (1.31 kW) High Fan Speed at Low Engine Speed 1650 rpm at low engine speed (1250 rpm) Low Fan Speed at High Engine Speed 1800 rpm at high engine speed (2050 rpm) Low Fan Speed at Low Engine Speed...
Page 184 Specifications Electrical Components (Continued) S-700 Fan Motors - Engine Operation Evaporator Fan Motor: Low Speed Power Rating 1.60 hp (0.45 kW) High Speed Power Rating 1.20 hp (0.90 kW) High Fan Speed at Low Engine Speed 990 rpm at low engine speed (1450 rpm) High Fan Speed at High Engine Speed 1750 rpm at high engine speed (2600 rpm) Low Fan Speed at Low Engine Speed...
Page 185 Specifications Electrical Components (Continued) Fan Motors — Electric Standby Operation 230/3/60 or 460/3/60 (Unit transformer reduces 460/3/60 input voltage to 230/3/60 applied to fan motors.) S-600 Evaporator Fan Motor: Low Speed Power Rating 1.20 hp (0.90 kW) High Speed Power Rating 1.75 hp (1.31 kW) High Fan Speed 1750 rpm...
Page 186: Electric Heater Strips
Specifications Electrical Standby (Smart Power Units Only) NOTE: A transformer is used to convert 460 Vac to 230 Vac for the condenser and evaporator fan motors in units configured to use electric standby input voltage of 460 Vac. Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts...
Page 187: 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, up to 50-foot length 12 HP Motor 230/3/60 6 AWG Power Cable, 75-foot length 12 HP Motor 460/3/60...
Page 188: 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 189: 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 190 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 191 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 192 550 foot-pounds per second. truck or trailer. See bulkhead. HPCO (High Pressure Cut Out Switch): A Multi-Temp: A Thermo King truck or trailer unit capable of pressure-operated switch that opens to stop unit operation maintaining different set-points in multiple compartments.
Page 193 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 194 Glossary short cycling: When a refrigeration unit cycles between the heat and cool modes more often than normal. sight glass: A system component that permits visual inspection of oil or refrigerant level and condition. thermostat: A device that controls unit modes of operation to maintain a selected box temperature.
Page 195: 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 196 Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours • • • Drain water from fuel tank and check vent. • • • Inspect/clean electric fuel pump filter. • • • Check condition of drive coupling bushings per Service Bulletin T&T 171. •...
Page 197 Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours — Change ELC (red) engine coolant every 5 years or 12,000 hours. Units equipped with ELC have an ELC nameplate on the expansion tank (see page 23).
Page 198 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 199 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 200: Serial Number Locations
Serial Number Locations Unit: Nameplates on the frame near the battery 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 1: Compressor Serial Number Location...
Page 201 Serial Number Locations Figure 2: Engine Serial Number Location Figure 3: Unit Serial Number Plate Locations (inside unit)
Page 202 Serial Number Locations ARA793 Unit Serial Number Bill of Material Number Unit Model Unit ID Figure 4: Unit Serial Number Plate...
Page 203: 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 204 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 205 CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
Page 206 Index alarm codes 141 data logging 27 corrective action 144 defrost 28 types 141 defrost drain inspection 38 amber status light 35 Defrost key 41, 42, 50, 83 automatic start/stop safety precautions 13 door inspection 38 battery inspection 37 ELC (extended life coolant) 23 belt tension, specifications 178 electrical components, specifications 180 belts inspection 37...
Page 207 engine oil dipstick 30 engine oil level 37 jump starting 170 engine, specifications 174 enroute inspections 138 loading procedures ETV (electronic throttling valve) 24 enroute inspections 138 extended life coolant (ELC) 23 post-loading inspection 137 pre-loading inspection 135 first aid for refrigerant 15 low oil level switch 31 first aid for refrigerant oil 15 low oil pressure switch 31...
Page 208 refrigerant 13 post-loading inspection 137 refrigerant oil 15 preheat buzzer 31 Serial Number Locations 199 pre-loading inspection 135 smart FETs 31 pretrip inspection, manual 37 SMART REEFER 2 (SR-2) Controller 25, 39 protection devices 30 soft keys 42 specifications rear remote control panel 120 electric fuel heater 186 receiver tank sight glass 30 SR-2 Controller 25, 39...

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