To verify the accuracy of the data log from the Thermo King Precedent C-600, use the CargoWatch system, which logs data such as setpoint and, if optional sensors are installed, up to six temperature readings and four door switch statuses. Use the USB port to download the data for review. Ensure sensors are correctly installed and readings are consistent with expected values.

If the unit is malfunctioning and shows alarm codes like "Internal ECU Fault" or "Unknown ECU Fault," and the unit is shut down, repair it immediately. Otherwise, report the alarm at the end of the day as specified by the alarm code actions.

This answer is automatically generated

CHUN LING

April 23, 2025

How do we know whether or not reefer unit is running normal operation. Will there be any pre-alert or alarm error whenever unit is malfunction ? If yes, from where can we retreive such data ?

1 comments:

Mr. Anderson

May 12, 2025

To determine if the Thermo King Precedent C-600 reefer unit is operating normally, you can perform a Pretrip Test using the unit's interface:

1. Access the Pretrip Menu and press the SELECT key to start the test.
2. If the unit is off, a Full Pretrip Test will begin. If it's running, a Running Pretrip Test will be performed.
3. The display will show test progress (e.g., Test 1 of 26).
4. When all tests are complete, results will show as PASS, CHECK, or FAIL.
- PASS means normal operation.
- CHECK or FAIL indicates an issue; alarm codes will help identify the cause.

Yes, the unit provides alerts and alarms for malfunctions:

- Log Alarms: Indicate maintenance needs; shown for 30 seconds at startup.
- Check Alarms: Require service within 24 hours; unit continues running but with limited functions.
- Prevent Alarms: Temporarily shut down the unit; may restart with reduced performance.
- Shutdown Alarms: Stop the unit completely until the issue is fixed.

You can retrieve alarm and operation data from the Alarm Menu on the unit display. A connected USB flash drive can also store data if configured.

This answer is automatically generated

Summary of Contents for Ingersoll-Rand Thermo King Precedent C-600

Page 1 Maintenance Manual SB-210+ SB-210+ SB-210+ Precedent™ C-600 Additional text information Additional text information Additional text information to be placed here to be placed here to be placed here TK 55494-2-MM (Rev. 0, 06/13) TK 5XXXX-X-PL TK 5XXXX-X-PL TK 5XXXX-X-PL...
Page 3 The maintenance information in this manual covers unit models: System Precedent C-600 (901819) Precedent C-600 (070008) For further information, refer to: Precedent C-600 Operator’s Manual TK 55692 Precedent C-600 Parts Manual TK 55688 Precedent SR-4 Microprocessor Control System Diagnostic Manual TK 55533 Precedent Single Temperature Systems Installation Manual TK 55496...
Page 4 Recover Refrigerant At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.
Page 5 CHANGES, COMMENTS and SUGGESTIONS You are invited to comment on this manual so it can be updated and improved to better meet you needs. Any corrections, comments or suggestions are welcome. Please complete the following information: Manual Form Number _____________________________________________________ Section and Page # _______________________________________________________ Your Name ______________________________________________________________ Company Name __________________________________________________________...
Page 6: Table Of Contents
Table of Contents Safety Precautions ..............10 General Practices .
Page 7 Table of Contents Configurable Soft Keys ..............36 Display Heater .
Page 8 Table of Contents Evaporator Fans ............... . . 82 Ground Fault Detection Module .
Page 9 Table of Contents Injection Pump Timing ..............108 Injection Pump Removal .
Page 10 Table of Contents Suction Pressure Transducer ............. . 150 Electronic Throttling Valve (ETV) .
Page 11: Safety Precautions
Safety Precautions Thermo King recommends that all service be DANGER: Avoid engine operation in performed by a Thermo King dealer. However, confined spaces and areas or you should be aware of several general safety circumstances where fumes from the practices: engine could become trapped and cause serious injury or death.
Page 12: Battery Installation And Cable Routing
Safety Precautions NOTE: In the USA, EPA Section 608 CAUTION: Always cover battery Certification is required to work on refrigeration terminals to prevent them from making systems. contact with metal components during battery installation. Battery terminals Battery Installation and Cable grounding against metal could cause the Routing battery to explode.
Page 13: Refrigerant Oil Hazards
Safety Precautions Electrical Hazards CAUTION: Refrigerant in a liquid state evaporates rapidly when exposed to the High Voltage atmosphere, freezing anything it contacts. Be careful when handling refrigerant to DANGER: Lethal amounts of voltage are protect your skin from frostbite. present in some electrical circuits.
Page 14: Microprocessor Service Precautions
Safety Precautions Welding Precautions WARNING: Do not wear jewelry, watches or rings because they increase the risk of Take precautions before electrically welding any shorting out electrical circuits and portion of the unit or the vehicle to which it is damaging equipment or causing severe attached.
Page 15: First Aid, Refrigerant Oil
Safety Precautions Move victim to fresh air and use INHALATION: CPR (cardio pulmonary resuscitation) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive. First Aid, Refrigerant Oil Immediately flush with water for at least EYES : 15 minutes.
Page 16: 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 17: Belt Tension
Specifications Engine (Continued) Drive: Standard Units Direct to compressor; belts to AC generator, alternator, and water pump SmartPower™ Units Centrifugal clutch to compressor; belts to electric standby motor, AC generator, alternator, and water pump Belt Tension Belt Use of Frequency Gauge P/N 204-1903 to measure frequency (Hz) is recommended.
Page 18: 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 60-70* 0.14...
Page 19: Electric Heater Strips
Specifications Electric Heater Strips Number Watts 1000 watts (each) Resistance 48 ohms (each) 9 amps, 230V unit Overload Relay Setting 6 amps, 460V unit 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...
Page 20: Maintenance Inspection Schedule
Maintenance Inspection Schedule Pretrip Every Every Annual/ Inspect/Service These Items 1,500 3,000 4,500 Hours Hours* Hours Microprocessor • Run Pretrip Test (see “Performing a Pretrip Test” on page 51). Engine • Check fuel supply. • Check engine oil level. • •...
Page 21 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 22: Unit Description
Unit Description Unit Overview Precedent C-600 Key Features & Options The Thermo King Precedent C-600 is a one piece, SMART REEFER SR-4 Controller self-contained, diesel powered, air ❍ SmartPower™ Electric Standby cooling/heating unit operating under the control of ❍ SmartPower High-Output the SMART REEFER™...
Page 23: Diesel Engine
Unit Description Diesel Engine An optional battery charger is available to replace the alternator. The battery charger converts AC The unit uses the TK486V25, a 4-cylinder, water power from the AC generator (or the electric cooled, direct injection diesel engine. standby power source) to 12 Vdc to charge the The engine is coupled directly to the compressor battery and provide power for the 12 Vdc control...
Page 24: Refrigeration Cluster
Unit Description Thermo King X430L Reciprocating speed windings is energized and the evaporator Compressor fans run at approximately 1800 rpm. This keeps the evaporator air flow consistent regardless of the The unit is equipped with a Thermo King X430L engine speed. In certain cases when the engine is reciprocating compressor with 30.0 cu.
Page 25: Smart Reefer 4 (Sr-4) Control System
Unit Description valve may open. When the return air temperature When CYCLE-SENTRY Mode is selected the begins to move away from the setpoint, the ETV unit will start and stop automatically to maintain begins to open and the hot gas bypass valve closes setpoint, keep the engine warm and the battery (if it was open).
Page 26: Cargolink
Unit Description Refer to TK 55533 the SR-4 Microprocessor Control System Diagnostic Manual and for information about using the USB ports. MICRO PROCESSOR ServiceWatch is standard ServiceWatch™: equipment. It records operating events, alarm codes and compartment temperatures as they THERMO KING occur and at preset intervals.
Page 27: Optiset Plus
Unit Description about installing the CargoLink system and In electric operation (SmartPower units only) the sensors, and troubleshooting problems with the drive motor operates at a single speed. It does not system. run in Null. Electric evaporator heaters are also used to increase the Heat and Defrost capacities OptiSet Plus™...
Page 28: Opening The Front Doors
Unit Description Opening the Front Doors intervals of 2, 4, 6, 8, or 12 hours. Demand defrost cycles occur if the differences between the return Pull the door latch handle to open the doors and air temperature, discharge air temperature, and access the engine compartment.
Page 29: Engine Compartment Components
Unit Description Use the engine oil dipstick to Engine Compartment Engine Oil Dipstick: check the engine oil level. Components CAUTION: Make sure the engine is The following maintenance items can be checked turned off before attempting to check the visually. engine oil.
Page 30: Unit Protection Devices
Unit Description The preheat buzzer sounds when Unit Protection Devices Preheat Buzzer: the controller energizes the preheat relay. This The coolant level switch Coolant Level Switch: warns anyone near the unit that the controller is closes if the coolant level drops below an about to start the engine.
Page 31: Serial Number Locations
Unit Description Serial Number Locations Nameplates on the frame near the battery, Unit: and on the roadside of the evaporator. See the engine identification plate located Engine: on the engine valve cover. Stamped between the cylinders on Compressor: the front end above the oil pump. On Evaporator Housing On Frame In Engine Compartment Figure 11: Unit Serial Number Locations...
Page 32 Unit Description ARA2121 Fan Control Box (High Voltage) High Voltage Box (SmartPower Units Only) Control Box (Low Voltage) Figure 13: Electrical Control Boxes...
Page 33 Unit Description Evaporator Discharge Air Outlet Figure 14: Back View...
Page 34: Operating Instructions
Operating Instructions SMART REEFER 4 (SR-4) Microprocessor On/Off Switch Control System This switch supplies or removes electrical power to the microprocessor. It is located above HMI Thermo King has applied the latest advances in Control Panel. It is hidden when the lower computer technology to develop a device that roadside body panel surrounding the Control Box controls temperature and unit function, and...
Page 35 Operating Instructions Control Panel Display Hard Keys The display is used to supply unit information to The keys on either side of the display are the operator. This information includes setpoint, dedicated or “hard” keys. Their function always current box temperature, operating information, remains the same.
Page 36: Turning Unit On
Operating Instructions Turning Unit On The unit is turned on by pressing the ON Key FLASH DRIVE (Figure 17) and off by pressing the OFF Key. When the On Key is pressed the display briefly shows the THERMO KING Logo as the display initializes.
Page 37: Configurable Soft Keys
Operating Instructions • RETRIEVE • Retrieve OptiSet Plus files °F The Flash Drive is also available from the Main PRETRIP MENU Menu. POINT The Flash Drive Menu will time out about 30 seconds after the engine starts. When the Flash Drive Menu times out, the Standard Display will Figure 22: PRETRIP and SOT appear.
Page 38: If Log Alarms Are Present
Operating Instructions The Language menu will appear as shown in If log alarm(s) are present the Log Alarm notice Figure 24. Press the + or - Keys to select the shown in Figure 27 will appear on the display for desired language.
Page 39: The Standard Display
Operating Instructions The display briefly shows OFF (Figure 30) and Pressing the left soft key allows the user to change then goes blank. To start the unit again, press the the SETPOINT, and pressing the right soft key ON Key. accesses the MAIN MENU.
Page 40: Changing The Setpoint
Operating Instructions Both Numerical Setpoints and If the Defrost Key or Cycle Sentry Key is pressed, Named Products the display will return to the TemperatureWatch Display immediately after the defrost cycle is OptiSet Plus can allow the use of both Numerical initiated or the operating mode is changed.
Page 41 Operating Instructions If the NO Key is pressed the display will briefly show SETPOINT NOT CHANGED and return to NEW SETPOINT WILL BE 40 F the Standard Display. The Standard Display will show the old setpoint. +/- TO CHANGE The display then returns to the Standard Display showing the new setpoint.
Page 42: 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 43 Operating Instructions After the YES Key has been pressed, the display IMPORTANT: If the named product is changed briefly shows PROGRAMMING NAMED using the “+” or “-” Keys, the change must be PRODUCT - PLEASE WAIT. The display then confirmed or rejected by pressing the YES or NO confirms the new setpoint for several seconds.
Page 44: Changing The Setpoint - Both Numerical Setpoint And Named Product Available
Operating Instructions Changing the Setpoint - Both NOTE: If the unit is equipped with optional Numerical Setpoint and Named Electric Standby there may be some additional Product Available prompts before the engine will start. See STARTING THE ELECTRIC MOTOR on the If the TemperatureWatch display is shown, press following pages for details.
Page 45: Switching From Diesel To Electric
Operating Instructions PROGRAMMING ELECTRIC STANDBY PLEASE WAIT Figure 53: Electric Power Receptacle Figure 56: YES Selected When the motor is preparing to start the HMI Control Panel will display the motor start screen Electric Mode operation will briefly be (Figure 54). The preheat buzzer sounds for 20 confirmed.
Page 46: Initiating A Manual Defrost Cycle
Operating Instructions If YES is selected then the display will briefly The display briefly shows [DEFROST], show the screen in Figure 58. [PROGRAMMING DEFROST - PLEASE WAIT] and then [DEFROST STARTED] (Figure 60). PROGRAMMING DIESEL MODE PLEASE WAIT DEFROST STARTED Figure 58: Yes Selected Diesel Mode operation will briefly be confirmed.
Page 47: Terminating A Defrost Cycle
Operating Instructions °F GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT DEFROST STARTED DEFROST NOT AVAILABLE Figure 63: Initiating a Manual Defrost Cycle Terminating a Defrost Cycle The defrost cycle terminates automatically when °F the coil temperature is greater than or equal to 58 F (14 C) or the defrost timer expires.
Page 48 Operating Instructions PROGRAMMING CONT MODE °F PLEASE WAIT GAUGES SENSORS MENU POINT Figure 66: Continuous Mode Figure 68: Cycle Sentry Icon Not Shown = Continuous Mode The new mode is confirmed for 3 seconds (Figure Pressing the Cycle Sentry/Continuous Key again 67).
Page 49: Using The Gauges Key
Operating Instructions Displays the voltage of the unit Using the Gauges Key Battery Voltage: battery. The GAUGES Key allows the operator to view Displays the voltage at Accessory Battery Voltage: the unit gauges. If the function of this key has the alternator.
Page 50: Using The Sensors Key
Operating Instructions Displays the Using The Sensors Key Ambient Air Temperature: temperature of the ambient air sensor. The SENSORS Key allows the operator to view Displays the temperature * Spare 1 Temperature: the unit gauges. If the function of this key has of the spare 1 temperature sensor.
Page 51: Pretrip
Operating Instructions SmartPower™ Electric Standby Option: Diesel/Electric Standby selection from the Main MAIN MENU PRETRIP Menu allows the operator to manually select LANGUAGE ALARMS diesel or electric mode operation on units GAUGES EXIT SELECT DOWN equipped with the electric standby SmartPower option.
Page 52: Performing A Pretrip Test
Operating Instructions • If the unit is in Sleep Mode. • If running a Pretrip Test on a trailer loaded with sensitive cargo, monitor the load • If the unit is in Service Test Mode, Output temperature during the test as normal Test Mode or Evacuation Mode.
Page 53 Operating Instructions When the non-running tests are complete the unit will start automatically and continue with the PROGRAMMING PRETRIP MODE Running Pretrip Test. In the example shown in Figure 81 the unit is in the Running Pretrip and is performing Test 21 of 26, Cool Test. RUNNING PRETRIP TEST 21 OF 26 Figure 78: Programming Trip Mode...
Page 54: Flash Drive
Operating Instructions NON-RUNNING PRETRIP RUNNING PRETRIP PROGRAMMING PRETRIP MODE TEST 1 OF 26 TEST 21 OF 26 °F SENSOR CHECK COOL TEST HOUR SENSORS GAUGES GAUGES SENSORS MENU HOUR SENSORS GAUGES POINT METERS METERS Alarms Cleared? MAIN MENU PRETRIP PRETRIP NO PRETRIP -- ALARM ACTIVE PASS LANGUAGE...
Page 55: Languages (If Enabled)
Operating Instructions If a properly configured USB Flash Drive is If the HELP Soft Key is pressed the display connected to the Flash Drive Only USB Port on shown in Figure 89 will appear. the Control Panel, the Flash Drive Menu will appear as a main Menu selection.
Page 56 Operating Instructions The Main Menu will appear. If more than one language is enabled, the Language Menu will appear as a main Menu selection (Figure 91). Press the UP or DOWN Key as required to choose the Language Menu. When the Language Menu is shown press the SELECT Key to select the Language menu.
Page 57: Alarms
Operating Instructions Language Menu Quick Access Should it be necessary at any time to change to LOG ALARMS ACTIVE English or any other installed language, return to GO TO MENU TO VIEW the Standard Display and then press and hold the EXIT first and last soft keys for 5 seconds as shown below.
Page 58 Operating Instructions Alarm Codes When Switching Between • Alarm Code 85 Forced Unit Operation - Diesel and Electric Clears when the unit is no longer running in a forced mode due to a Prevent Alarm. If a shutdown alarm occurs that affects only diesel mode operation and the unit is switched to •...
Page 59 Operating Instructions The number of alarms (if more than one) and a list If a serious condition occurs, the unit will be shut of the alarms with the most recent alarm first will down to prevent damage to the unit or the load. If be shown.
Page 60: Gauges
Operating Instructions • If an alarm cannot be cleared from the Main menu, the Clear Key will not appear. These alarms must be cleared from the Maintenance or Guarded Access Menus. See Figure 110 for an overview of the Displaying and Clearing Alarm Codes procedure.
Page 61: Sensors
Operating Instructions The gauges and I/O conditions available are described in “Gauges Available” on page 48. Not CONTROL DISCHARGE AIR TEMPERATURE all gauges or I/O conditions may appear °F depending on unit configuration and software EXIT LOCK BACK NEXT revision. To return to the Main Menu press the EXIT Key.
Page 62 Operating Instructions The Main Menu will appear. Press the UP or The Print Data Menu will appear. The first Print DOWN Key as required to choose the Data Data Menu allows the operator to print a Delivery Logger Menu. When the Data Logger Menu is Ticket using a hand held printer.
Page 63: Hourmeters
Operating Instructions The Main Menu will appear. Press the UP or UNIT SERIAL NUMBER: xxxxxxxxxx DOWN Key as required to choose the Hourmeter CONTROLLER SERIAL NUMBER: A00021506190T3 TRAILER ID: xxxxxxxxxx Menu. When the Hourmeter Menu is selected, CONTROLLER VERSION NUMBER: B007 CONTROLLER TYPE: press the SELECT Key to choose the Hourmeter...
Page 64: Mode
Operating Instructions Hourmeter Names and Definitions • Turns Off Cycle Sentry Mode/Turns On Cycle Sentry Mode (If Cycle Sentry is turned Off Only configured hourmeters that have been unit runs in Continuous). Note that selecting enabled in the Viewable Hourmeter Setup Menu Cycle Sentry Mode or Continuous Mode can will be shown: also be accomplished using the Cycle Sentry...
Page 65 Operating Instructions CHANGE MODE MAIN MENU TURN ON CYCLE SENTRY MODE DATA LOGGER FAHRENHEIT HOURMETERS KEYPAD LOCKOUT MODE START SLEEP MODE ELECTRIC STANDBY EXIT SELECT DOWN EXIT SELECT DOWN Figure 129: Up, Down, Select Keys Figure 131: Select Key The first enabled Change Mode Menu selection If the unit is running in Cycle Sentry Mode, press will appear.
Page 66 Operating Instructions Choose the desired Temperature Units using the To open the Fresh Air Exchange door press the UP and DOWN Soft Keys and press the SELECT SELECT Key as shown below. Soft Key to select the choice (Figure 134). FRESH AIR EXCHANGE OPEN FRESH AIR EXCHANGE TEMPERATURE UNITS...
Page 67: Smartpower Electric Standby Option
Operating Instructions CHANGE MODE CHANGE MODE TURN ON CYCLE SENTRY MODE TURN ON CYCLE SENTRY MODE FAHRENHEIT FAHRENHEIT KEYPAD LOCKOUT KEYPAD LOCKOUT START SLEEP MODE START SLEEP MODE EXIT SELECT DOWN EXIT SELECT DOWN Figure 137: Select Key Figure 139: Select Soft Key A Confirmation Request will appear.
Page 68 Operating Instructions • If the unit is currently operating in Electric From the Main Menu choose Electric Standby and Mode the DIESEL MODE selection will press the SELECT Soft Key (Figure 141). appear in the Main Menu. MAIN MENU HOURMETERS Electric Mode Operation MODE ELECTRIC STANDBY...
Page 69: Adjust Brightness
Operating Instructions Switching from Electric to Diesel operator are HIGH, MEDIUM, LOW and OFF. OFF actually results in a very dim screen suitable If the unit is running in Electric Mode and the for low light conditions. Electric to Diesel Auto-Switch Enabled feature in Guarded Access is set YES then the unit will Display brightness is adjusted using the Adjust automatically switch to Diesel Mode operation...
Page 70: Time
Operating Instructions Time Clear All ECU Faults The Time and Date held by the HMI Control NOTE: On C-600 units this menu selection is Panel can be checked. Time and Date cannot be only displayed on early versions of HMI software changed from the Main Menu.
Page 71: Loading Procedure
Operating Instructions Visually inspect the unit for leaks, Structural: Post Trip Checks loose or broken parts and other damage. The 1. Wash the unit. condenser and evaporator coils should be clean and free of debris. Check the defrost drain hoses 2.
Page 72: Alarm Codes
Alarm Codes Thermo King Precedent Unit Alarm Codes COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPECIFIED TAKE IMMEDIATE ACTION Description Operator Action No Alarms Exist No action required. Check Evaporator Coil Sensor Manually monitor load temperature. Report alarm at end of day.
Page 73 Alarm Codes COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPECIFIED TAKE IMMEDIATE ACTION Description Operator Action Check Oil Pressure Switch If unit is shut down repair immediately. Otherwise, report alarm at end of day. Refrigeration Capacity Low The unit is no longer able to operate and has been shut down.
Page 74 Alarm Codes COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPECIFIED TAKE IMMEDIATE ACTION Description Operator Action Internal Controller Fault Code If unit is shut down repair immediately. Otherwise, report alarm at end of the day. Hourmeter Failure Report alarm at end of day. Controller Reset to Defaults Report alarm at end of day.
Page 75 Alarm Codes COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPECIFIED TAKE IMMEDIATE ACTION Description Operator Action Engine Run Time Maintenance Report alarm at end of day. Reminder #2 Electric Run Time Maintenance Report alarm at end of day. Reminder #1 Electric Run Time Maintenance Report alarm at end of day.
Page 76 Alarm Codes COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPECIFIED TAKE IMMEDIATE ACTION Description Operator Action Check Host Evaporator Fan High If unit is shut down repair immediately. Otherwise, report Speed alarm at end of day. Check Roadside Condenser Fan If unit is shut down repair immediately.
Page 77 Alarm Codes COLOR CODE DEFINITIONS OK TO RUN CHECK AS SPECIFIED TAKE IMMEDIATE ACTION Description Operator Action Battery Charger Temp Below Report alarm at end of day. Operating Range Battery Charger Input AC Report alarm at end of day. Overvoltage Battery Charger Internal If unit is shut down repair immediately.
Page 78: Electrical Maintenance
Electrical Maintenance Alternator Diagnostic CAUTION: These units use high voltage Procedures AC from the AC generator for the condenser and evaporator fans. Lethal General Information voltage potentials can exist on connections in the fan control box. Take Poor charging performance may not be caused by appropriate precautions and use extreme a bad alternator.
Page 79: Base Controller Fuse F4
Electrical Maintenance B+ Terminal (Positive Output - 2A Wire) F2 Terminal (Do Not Ground) B- Terminal (Negative Ground - CH Wire) 6. Voltage Regulator and Brush Assembly S Terminal (Regulator Sense - 2Y Wire) W Terminal (AC Output - WRPM Wire on Standard Units) L Terminal (Regulator Excite - EXC Wire) Figure 151: Thermo King Alternator Terminal and Component Locations Base Controller Fuse F4...
Page 80: General Diagnostic And Warranty Evaluation Procedure
Electrical Maintenance To test the alternator under load, Thermo King CAUTION: Energizing the circuit with recommends the use of a clamp-on ammeter to the resistor bypass fuse installed will monitor output current, both on initial startup and damage Thermo King alternators. Be sure under full unit load conditions.
Page 81: Field Current Test
Electrical Maintenance 14. Turn the unit on and allow it to start. Using the If the voltage at the B+ terminal is no more clamp-on ammeter, check the current flow in than 1.0 Vdc higher than the voltage between the 2A wire. the battery terminals, continue with Step 17.
Page 82: Battery
Electrical Maintenance • No field current or a low field current 2. Use the key to check the Amps AUGES indicates an open circuit or excessive Display and the Battery Voltage Display. The resistance in the field circuit. Remove the Amps reading should show a positive value.
Page 83: If Fan Runs Backwards
Electrical Maintenance direction with the engine running in high 8. Turn the unit off and check the T1/L1, T2/L2, speed. If it does not run, go to the next step. If and T3/L3 circuits (including any contactors) it runs backwards, go to “If Fan Runs back to the AC generator for continuity.
Page 84: Ground Fault Detection Module
Electrical Maintenance 2. Use the Service Test Mode to run the unit in 9. Check the continuity of the ET11, ET12, and low speed cool. The evaporator fans should ET13 wires from the EFHC contactor to the run at approximately 1180 rpm with the EFLC fan.
Page 85 Electrical Maintenance F5 – 60A J101 LED09 STATUS LED48 J102 LED45 F15 - 2A F2 - 15A F6 - 15A F25 – 7.5A F22 - 10A F3 - 40A LED04 LED01 F20 - 2A LED07 LED05 LED43 LED44 LED23 FA DMP LED08 ARA1994 Figure 153: Base Controller...
Page 86: Base Controller Leds
Electrical Maintenance Base Controller LEDs Base Controller LED Functions (Continued) LED # Function The base controller has LEDs that indicate which LED 48 Heart Beat outputs are energized. The LED is illuminated when the associated circuit output is energized. LED 49 ETV –...
Page 87: Smart Reefer 4 (Sr-4) Microprocessor Controller
Electrical Maintenance SMART REEFER 4 (SR-4) Microprocessor Controller Refer to the SR-4 Microprocessor Control System Diagnostic Manual TK 55533 for complete service information about the Microprocessor F5 – 60A Controller and the related components. IMPORTANT: A ServiceWatch download can be Card GPRS Holder...
Page 88: Battery Fusing
Electrical Maintenance Battery Fusing Unit Wiring There is a 40A fuse (FS8) that protects the 2 Inspect the unit wiring and the wire harnesses circuit to the relay and fuse assembly in the during scheduled maintenance inspections for control box. loose, chaffed or broken wires to protect against unit malfunctions due to open or short circuits.
Page 89: Transformer Contactor - Trc
Electrical Maintenance ARA1909 – – Compressor Motor Contactor Heater Overload Relay – – Fuse Block 1 Heater Contactor – – Generator Contactor 10. OL Overload Relay (Compressor Motor) – – Battery Charger Contactor 1 (460 Vac Only) 11. Phase Selection Module –...
Page 90: Phase Contactor 2 - Pc2
Electrical Maintenance Phase Contactor 2 – PC2 Auto Phase System Provides corrected 3 phase power to the system. The Auto Phase system automatically adjusts the This is controlled by the Phase Select Module phase sequence of the power supply to correspond (7EB).
Page 91: Evaporator Heaters
Electrical Maintenance h. Wires L1, L2, and L3 should be connected 6. Check the continuity of the RED wires on the respectively to terminals L1, L2, and L3 phase contactors. The RED wires must have on PC1. continuity. i. The 9-pin wire connector between the 7.
Page 92: Ultrasonic Fuel Level Sensor
Electrical Maintenance Ultrasonic Fuel Level Sensor agree closely is at 50% or 1/2 full. The readings at other fuel levels may not agree as closely. If you The ultrasonic fuel level sensor (if used) is think the ultrasonic fuel level sensor is not mounted to a flange on top of the fuel tank.
Page 93: Important Usfls Replacement Information
Electrical Maintenance 5. If the output voltage is incorrect, check the 1. Remove and discard the sensor and the continuity of the wires that go from the J1 gaskets. DO NOT reuse the gaskets. connector on the base controller to the sensor 2.
Page 94: Electric Fuel Heater (Optional)
Electrical Maintenance 4. The UFLS assembly should be pre-assembled IMPORTANT: DO NOT burn the heat before installing it into the fuel tank. shrink. If the heat shrink is burnt, charred, or has bubbles from overheating, the wire a. Slide a gasket up the sensor tube to the connections must be removed and redone flange, making sure the pin hole in the correctly.
Page 95: Diagnosis
Electrical Maintenance 2. Check the resistance of the electric fuel heater by checking the resistance between the two terminals in the 2-pin connector on the wires to the electric fuel heater. The resistance should be 0.9 to 1.1 ohms. NOTE: The temperature of the electric fuel heater must be below 30 F (-1 C) to verify the internal thermostat closes.
Page 96 Electrical Maintenance 7. If the 2FH and 2HP wires have good continuity, check for battery voltage on the 2A-03 wire at the Fuel Heater Relay. If battery voltage is not present, check the continuity of 2A-03 wire between the Fuel Heater Relay and the 2A (J25) screw terminal on the base controller.
Page 97: Engine Maintenance
Engine Maintenance TK486V25 Diesel Engine NOTE: Units equipped with the EMI 3000 package do require regular inspection in This unit uses a new engine called the TK486V25. accordance with Thermo King's maintenance It is part of the TK486 family of engines, but it recommendations.
Page 98: Low Oil Pressure
Engine Maintenance Low Oil Pressure oil pressure is not normally caused by a faulty oil pump. Use the “Low Oil Pressure Flow Chart” on Oil pressure is affected by oil temperature, oil the following page to help diagnose low oil viscosity, and engine speed.
Page 99: Engine Cooling System
Engine Maintenance Engine Cooling System The engine employs a closed, circulating type, pressurized cooling system. Correct engine temperatures are controlled and maintained by a radiator, fan and thermostat. The coolant is circulated through the system by a belt driven centrifugal pump. The pump draws the coolant from the side of the radiator, circulates it through the cylinder block and head and returns it to the radiator.
Page 100: Antifreeze Maintenance Procedure
Engine Maintenance NOTE: The use of 50/50 percent pre-mixed CAUTION: Avoid direct contact with hot Extended Life Coolant (ELC) is recommended to coolant. assure that de-ionized water is being used. If 100 percent full strength concentrate is used, a. Run clear water into the radiator and allow de-ionized or distilled water is recommended it to drain out of the block until it is clear.
Page 101: Bleeding Air From The Cooling System
Engine Maintenance Bleeding Air from the Cooling 5. Make sure that the amount of coolant that System goes back into the system is approximately equal to the amount of coolant that came out Jiggle pin thermostats are original equipment on of the system.
Page 102: Coolant Level Switch
Engine Maintenance Coolant Level Switch 1. Remove the wire harness connector from the coolant level switch. The plastic expansion tank uses a reed type coolant level switch. The coolant level switch 2. Use an ohmmeter to check the continuity of senses the position of the magnetic float inside the the switch at the connection pins.
Page 103: Engine Fuel System
Engine Maintenance Engine Fuel System IMPORTANT: Do not open the fuel system unless required. TK486V25 engines use a mono-plunger and NOTE: The injection nozzles must be cleaned distributor injection pump. and tested (and repaired if necessary) at least The components of the fuel system are: every 3,000 hours in accordance with EPA 40 CFR Part 89.
Page 104 Engine Maintenance ARA2119 Fuel Filter/Water Separator Feed Line (From Fuel Pump to Fuel Filter) Feed Line (From Fuel Filter to Injection Pump) Electric Fuel Pump (With Prefilter) Injection Pump Return Line Fitting (Bleed Screw Inlet Line (From Fuel Tank) Mono-plunger and Distributor Injection Pump Return Line (To Fuel Tank) Return Line (From Injection Pump to Fuel Filter) Figure 164: Fuel System...
Page 105: Fuel Return Line Replacement
Engine Maintenance Fuel Return Line Replacement 2. Discard the old clamps, end cap, and fuel return lines. The fuel return lines (hoses) and end cap on the fuel injection nozzles should be changed every 3. Install the end cap and clamp. Note that the 10,000 engine operating hours.
Page 106: Draining Water From Fuel Tank
Engine Maintenance Fuel Filter/Water Separator The fuel filter/water separator filters the fuel, and removes water from the fuel and returns it to the fuel tank. Fuel Filter/Water Separator Replacement Replace the fuel filter/water separator at intervals according to the Maintenance Inspection Schedule.
Page 107: Electric Fuel Pump
Engine Maintenance 3. Lubricate the top inside edge of the filter bowl Make sure the CHFP/black wire completes a good with oil. ground with the battery. Check the voltage at the 8DF/red wire in the harness. The pump will not 4.
Page 108: Electric Fuel Heater (Optional)
Engine Maintenance If the pump does not operate, check for: 3. Energize the throttle solenoid by using the Output Test Mode to energize the high speed • A good ground on the black wire pin of the solenoid while the engine is not running. pump harness 4.
Page 109: Injection Pump Timing
Engine Maintenance Injection Pump Timing Use this timing procedure when installing a new injection pump. It is not necessary to use this timing procedure when removing and reinstalling the original injection pump. In that case, align the index marks on the injection pump and the gear case as they were before removing the injection Index Mark on Injection Pump pump.
Page 110 Engine Maintenance 3. Remove the old injection pump. Use the injection pump gear tool P/N 204-1011 to remove the injection pump gear without removing the timing gear cover (see “Injection Pump Removal” on page 111). NOTE: Remove the injection pump gear by removing the nut and lock washer that secure the injection pump gear assembly to the injection pump shaft.
Page 111 Engine Maintenance 5. Record the injection angle marked on the side of the new injection pump. 6. Calculate the injection angle difference by subtracting the injection angle of the old injection pump from the injection angle of the new injection pump. Examples Injection Angle of New Injection Pump (Degrees)
Page 112: Injection Pump Removal
Engine Maintenance Injection Pump Removal 2. Remove the starter for clearance, remove throttle linkage, fuel lines, harness and The injection pump drive gear will not fit through mounting hardware from injection pump. the gear housing when removing the pump, the gear must be separated from the pump.
Page 113: Injection Pump Reinstallation
Engine Maintenance Injection Pump Adapter (Tool) Gear Case Tool Long Screw (Tool) Cover Plate Tool Short Screw (Tool) Cover Plate Bolt Tool Plate (Tool) Figure 185: Injection Pump Gear Tool Injection Pump Reinstallation 5. Fasten cover plate to gear case and reinstall all components removed previously to facilitate 1.
Page 114 Engine Maintenance NOTE: The fuel solenoid may be removed from the injection pump to visually check its operation. The fuel solenoid must be energized when it is re-installed in the injection pump. If it is not, the plunger and the linkage may not line up correctly and the fuel solenoid will not function properly.
Page 115: Trochoid Feed Pump
Engine Maintenance resistance of the pull-in coil should be 0.2 5. Energize the fuel solenoid by energizing the to 0.3 ohms. If the resistance of the pull-in run relay with the Output Test Mode. coil is not in this range, replace the fuel NOTE: The fuel solenoid must be energized solenoid.
Page 116 Engine Maintenance Trochoid Feed Pump Outlet Pressure Port Trochoid Feed Pump Figure 189: Trochoid Feed Pump Location Allen Head Screws (Do Not Remove) Hex Head Screws Trochoid Feed Pump Leaks Figure 190: Trochoid Feed Pump Removal Internal – If the seal in the trochoid feed pump 2.
Page 117: Cold Start Device
Engine Maintenance 5. Place the new trochoid feed pump on the 3. Let the engine start, then check the engine rpm injection pump. in the Gauges Menu. The engine rpm should be approximately 100 rpm higher than normal 6. Install and tighten four hex head screws that (see Specifications).
Page 118: Engine Valve Clearance Adjustment
Engine Maintenance Engine Valve Clearance 3. Remove the cold start device from the injection pump fitting. Use a backup wrench Adjustment on the injection pump fitting if necessary. The valve clearance should be adjusted every 3.000 hours. 1. Remove the rocker arm cover. 2.
Page 119 Engine Maintenance d. If the rocker arms are tight, the engine is at top dead center of the exhaust stroke for the number one cylinder. Rotate the engine 360 degrees to place the engine at top dead center of the compression stroke for the number one cylinder.
Page 120: Crankcase Breather
Engine Maintenance Crankcase Breather damaged. Inspect the insulation to make sure it is in place and undamaged. The insulation is used to Gases formed in the crankcase are directed to the prevent freezing in cold weather. intake manifold. Harmful vapors that would The following items can effect the crankcase otherwise collect in the crankcase and pressure readings.
Page 121: Belts
Engine Maintenance Belts Belts should be regularly inspected during unit pretrip inspections for wear, scuffing or cracking. Belt tension should also be checked during scheduled maintenance inspections. Belts that are too loose will whip and belts that are too tight put too much strain on the belt fibers and bearings.
Page 122: Water Pump Belt
Engine Maintenance AC Generator Belt Replacement 4. Check the belt tension setting and readjust if necessary. NOTE: Do not attempt to remove or install the belts without loosening the adjustments. Belts that are installed by prying over pulleys will fail prematurely due to internal cord damage.
Page 123: Alternator Belt - Smartpower Units Only
Engine Maintenance 5. Remove the belt through the gap between the 4. Move the alternator in the alternator mounting clutch and the flywheel. bolt slot enough to allow you to remove the alternator belt from the pulleys and remove 6. Install the new belt on the clutch pulley the alternator belt.
Page 124: Clutch (Smartpower Units)
Engine Maintenance Clutch (SmartPower Units) NOTE: The refrigeration lines may be removed from the compressor to allow more Periodically inspect the clutch for worn bearings, movement of the compressor for better access worn friction shoes, shoe support bushings, or to the clutch. isolator drive bushings.
Page 125: Drive Bushing Replacement
Engine Maintenance 9. To disassemble the clutch, press the pulley out 16. Reinstall the compressor drive belt on the of the bearing. clutch pulley. 17. Slide the compressor back into position and 10. Inspect the friction shoes and shoe support bushings.
Page 126 Engine Maintenance NOTE: The refrigeration lines may be 11. Clean the holes from which the bushings were removed from the compressor to allow more removed. movement of the compressor for better access 12. “Start fit” the bushing in the clutch to the clutch.
Page 127: Dowel Pin Replacement
Engine Maintenance 14. Use the large diameter end of the Bushing 24. Turn the idler adjuster as needed to adjust the Replacement Tool 204-1955 to press the new belt to the correct belt tension setting. bushing into the hub/coupling until the flange 25.
Page 128 Engine Maintenance Drive Dowel Pin In Until Tool Hits Flywheel Dowel Pin Outer Face Of Flywheel Figure 208: Driving New Dowel Pin Into Flywheel with Impact Pin Tool 4. Install the flywheel and align it with the dowel pin in the end of the crankshaft. 5.
Page 129: Refrigeration Maintenance
Refrigeration Maintenance NOTE: The following procedures involve 8. Under these conditions, refrigerant should be servicing the refrigeration system. Some of these visible in the receiver tank sight glass. If refrigerant is not visible in the receiver tank service procedures are regulated by Federal, and in some cases, by State and Local laws.
Page 130: Moisture Indicating Sight Glass
Refrigeration Maintenance NOTE: If the liquid level in the receiver sight h. Close the hand valve on the refrigerant glass drops during step 4, the unit is not tank when the liquid level approaches the overcharged and it is not necessary to top of the receiver sight glass.
Page 131: Oil Collection Container
Refrigeration Maintenance Oil Collection Container the tube inside the container. It is a very tight fit between the check valve and the grommet in the The oil collection container collects the oil collection container. compressor shaft seal seepage to keep the unit If maintenance in the area requires removal of the clean.
Page 132: High Pressure Cutout Switch (Hpco)
Refrigeration Maintenance To check compressor oil level with an ambient air temperature above 50 F (10 C): Install a gauge manifold on the compressor. Operate the unit on cool with a 20 psig (138 kPa) minimum suction pressure and a 185 psig (1275 kPa) minimum discharge pressure for 15 minutes or more.
Page 133: Three-Way Valve Condenser Pressure Bypass Check Valve
Refrigeration Maintenance Three-Way Valve Condenser Pressure Bypass Check Valve A three-way valve condenser pressure bypass check valve is used in this unit. This check valve controls the bypass flow of refrigerant gas between the condenser inlet line and the compressor discharge line. The check valve is closed when the unit is running on cool, or whenever the discharge pressure is higher than the condenser pressure.
Page 134: Electronic Throttling Valve (Etv)
Refrigeration Maintenance Electronic Throttling Valve (ETV) The Electronic Throttling Valve (ETV) is standard on the these units. The Electronic Throttling Valve (ETV) is a variable position valve operated by a stepper motor. The ETV is located in the suction line between the accumulator and the suction vibrasorber.
Page 135: Refrigeration Service Operations
Refrigeration Service Operations Refrigeration System NOTE: The following procedures involve servicing the refrigeration system. Some of these Component Locations service procedures are regulated by Federal, and The following drawings show the locations of in some cases, by State and Local laws. various refrigeration system components.
Page 136 Refrigeration Service Operations Curbsibe Condenser Coil Road Condenser/Radiator Coil Figure 217: Condenser Coils ARA1985 Figure 216: Curbsibe View of Refrigeration Cluster Curbsibe Condenser Coil Radiator Coil Road Condenser Coil Figure 218: Condenser and Radiator Coils...
Page 137: Compressor
Refrigeration Service Operations Expansion Valve Evaporator Coil Heat Exchanger Figure 219: Evaporator with Access Panel Removed Compressor 6. Disconnect the high pressure cutout switch, the pilot solenoid line (if used), and remove the compressor oil filter. Removal 7. Support the compressor and unbolt the 1.
Page 138: Compressor Coupling Removal (Standard Units)
Refrigeration Service Operations NOTE: When the compressor is removed 2. Attach the tool to the coupling with the from the unit, the oil level should be noted, provided socket head screws and spacers. Two or the oil removed from the compressor sets of spacers are provided with the tool, use should be measured so that the same amount the short spacers with shallow compressor...
Page 139 Refrigeration Service Operations AGA1059 Coupling 10 mm Allen Tool (for large shaft compressor) Long Spacers (supplied with tool) 5/16 Allen Tool (for small shaft compressors) Short Spacers (supplied with tool) Coupling Removal Tool (P/N 204-991) Socket Head Bolts (supplied with tool) Engine Mounting Flange Figure 220: Compressor Coupling Removal Tool 2.
Page 140: Curbside Condenser Coil
Refrigeration Service Operations Curbside Condenser Coil 6. Re-install the coupling and align the keyways with the Keyway Tool. Removal 7. Do not install the key at this time. Install the flat washer and bolt and pre-torque to 20 ft-lb 1. Recover the refrigerant charge. (27 N•m).
Page 141: Roadside Condenser Coil
Refrigeration Service Operations IMPORTANT: This unit uses micro-channel 2. Place the coil in the unit and install the condenser coils. Micro-channel coils are mounting bolts. make of aluminum but have copper stub 3. Solder the inlet and outlet refrigeration line tubes at the inlet and outlet connections.
Page 142: Discharge Vibrasorber
Refrigeration Service Operations Installation In-Line Condenser Check Valve 1. Place the radiator coil in the unit and install This unit uses an in-line condenser check valve. the mounting bolts. The in-line check valve is not repairable and must be replaced if it fails. A heat sink must be used on 2.
Page 143: Bypass Check Valve
Refrigeration Service Operations Installation 6. If no leaks are found, evacuate the system. 7. Recharge the unit with proper refrigerant and 1. Install the high pressure relief valve in the receiver tank. check the compressor oil. 2. Solder the bypass check valve onto the Bypass Check Valve receiver tank.
Page 144: Expansion Valve Assembly
Refrigeration Service Operations Expansion Valve Assembly 5. Replace the access panels. 6. Open the refrigeration valves and place the Removal unit in operation. 1. Pump down the low side and equalize the 7. Test the unit to see that the expansion valve is pressure to slightly positive.
Page 145: Evaporator Coil Assembly
Refrigeration Service Operations 5. Solder the equalizer line to the suction line 3. Replace and reconnect connect the sensors, and the liquid outlet line to the expansion and reconnect defrost drain hoses. valve. 4. Pressurize the low side and test for leaks. If no 6.
Page 146: Three-Way Valve Repair
Refrigeration Service Operations Three-Way Valve Repair 3. Remove the line from the three-way valve to the pilot solenoid. NOTE: The three-way valve can be repaired in 4. Loosen the four 1/4 in. Allen head screws (DO the unit if leakage or damage to the Teflon seals NOT REMOVE OR CAP MAY POP OFF);...
Page 147: End Cap Checks
Refrigeration Service Operations Number 43 Drill Figure 229: Check Bleed Hole Diameter Piston Bleed Orifice Check 1. Use a number 66 (0.033 in. [0.84 mm]) drill bit to check the orifice in the bleed hole from the gasket surface to the groove in the bottom AGA1066 of the piston bore.
Page 148: Assembly/Installation
Refrigeration Service Operations 3. With the piston pushed all the way back in its 3. Install new gaskets on both sides of the seat. bore, use a strong light to look down the Oil the gaskets in compressor oil before 0.089 in.
Page 149: Three-Way Valve Condenser Pressure Bypass Check Valve Repair
Refrigeration Service Operations Installation 9. Install the pilot solenoid line and pressurize the system with refrigerant to check for leaks. 1. Coat the O-ring with compressor oil and 10. If there are no leaks, evacuate the system and install it on the check valve stem. recharge with the proper refrigerant.
Page 150: Suction Vibrasorber
Refrigeration Service Operations High Pressure Cutout Switch 2. Place the valve in the unit and install the mounting bolts. The arrow on the valve indicates the direction of flow through the Removal valve. Make sure that the arrow points in the 1.
Page 151: Discharge Pressure Transducer
Refrigeration Service Operations Electronic Throttling Valve 4. Recharge the unit with the proper refrigerant and check the compressor oil. (ETV) Discharge Pressure Transducer Removal 1. Pump down the low side and equalize the Removal pressure to slightly positive. 1. Recover the refrigerant charge. 2.
Page 152 Refrigeration Service Operations Installation of Service Kit NOTE: Do not connect the ETV harness to main wire harness and turn the unit on before the stepper motor and piston assembly is installed in the valve body. The controller is programmed to close the ETV when the unit is turned on.
Page 153 Refrigeration Service Operations 2. Lubricate the piston and threads on the new 2. Insert the piston into the piston nut. You must stepper motor and piston assembly with align the rectangular shaft on the piston with refrigeration oil. the rectangular hole in the piston nut to allow the piston to be inserted into the piston nut.
Page 154: Hot Gas Bypass Valve
Refrigeration Service Operations Hot Gas Bypass Valve 7. Continue to turn the piston and piston nut onto the stepper motor until they are tight. Torque the piston nut and stepper motor to 37 ft-lb (50 Removal N•m). 1. Recover the refrigerant charge. Installation of Complete ETV Assembly 2.
Page 155: Checking Compressor Oil Pressure
Refrigeration Service Operations 7. Attach and tighten the oil lines to the compressor oil filter. Hold the oil filter with a back-up wrench on the hex behind the ORS fitting. 8. Evacuate the compressor and filter to a maximum of 500 microns to remove trapped air.
Page 156: Structural Maintenance
Structural Maintenance Unit and Engine Mounting Bolts Unit Inspection Check and tighten all unit and engine mounting Inspect the unit during pretrip inspection and bolts during scheduled maintenance inspections. scheduled maintenance inspections for loose or Torque the unit mounting bolts to 60 ft-lb broken wires or hardware, compressor oil leaks, (81 N•m).
Page 157 Structural Maintenance • Use a soft bristled brush (DO NOT USE A WIRE BRUSH) and brush the coil going with the fins, across the tubes. The coil will clean in a manner similar to the way lint cleans from the lint trap of a household clothes dryer. •...
Page 158: Defrost Drains
Structural Maintenance Unit Installation All nuts that hold the unit to the trailer are accessible using an impact wrench with a 10 in. extension, ball-type swivel and a deep-well socket. NOTE: The nuts for mounting the unit should be elastic stop nuts (Nylock type). Condenser Fan Alignment Figure 245: Source Angle for Cleaning with Air or Water...
Page 159: Evaporator Fan/Blower Alignment
Structural Maintenance 4. Use a torque wrench set to 7 ft-lb (9.5 N•m) [Note: 6.43 ft-lb (8.7 N•m) actual required] to complete the tightening sequence on each bolt alternatively. 5. If necessary, loosen the condenser fan orifice mounting bolts, center the orifice around the fan, and tighten the mounting bolts.
Page 160: Mechanical Diagnosis
Mechanical Diagnosis Condition Possible Cause Remedy Engine will not crank Electrical problem Check and repair electrical system Defective starter solenoid Replace solenoid Defective starter Repair starter Water in cylinders Check for hydrostatic lock. Remove injectors and turn engine slowly Starter motor turns but engine Starter clutch defective Replace does not crank...
Page 161 Mechanical Diagnosis Condition Possible Cause Remedy Engine does not develop full Air intake system clogged Clean air intake system power Fuel tank vent clogged Unclog vent Clogged fuel tank or fuel lines Clean fuel tank and fuel lines Insufficient fuel volume leaving filter Check for dirty filter or air in system Air cleaner clogged Replace air filter Delivery of electric fuel pump...
Page 162 Mechanical Diagnosis Condition Possible Cause Remedy Oil pressure low Insufficient oil in pan Add oil Faulty oil pressure switch Check oil pressure switch. Replace if necessary Oil control valve defective Check oil pressure control valve Worn oil pump, camshaft, main or Repair engine connecting rod bearings, loose oil gallery plug...
Page 163: Electric Standby Diagnosis
Electric Standby Diagnosis Condition Possible Cause Remedy Unit turned ON—LCD Blank Battery discharged Charge or replace battery Faulty battery cable connections Clean battery cables Fuse FS8 blown Check for short circuit and replace fuse Fuse F2, F8, or F12 blown Check for short circuits and replace fuse Open circuit...
Page 164: Refrigeration Diagnosis
Refrigeration Diagnosis Possible Causes • • • • Overcharge of refrigerant • • • • • • Shortage of refrigerant • • • • • No refrigerant • Air through condenser too hot (ambient) • Air flow through condenser restricted •...
Page 165 Refrigeration Diagnosis Possible Causes • • Loose or broken electrical connections • • • • • Sensor out of calibration • • • • Compound pressure gauge out of calibration • Leaky receiver tank outlet valve • Leaky bypass check valve •...
Page 166: Refrigeration Diagrams
Refrigeration Diagrams Cool Cycle With Electronic Throttling Valve Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank Sight Glass 12. Receiver Outlet Valve 13.
Page 167: Heat/Defrost Cycle With Electronic Throttling Valve
Refrigeration Diagrams Heat/Defrost Cycle With Electronic Throttling Valve Compressor Discharge Service Valve Discharge Vibrasorber Discharge Line Three-way Valve Three-way Valve Bypass Check Valve Condenser Coil Condenser Check Valve High Pressure Relief Valve 10. Receiver Tank Sight Glass 12. Receiver Outlet Valve 13.
Page 168: Index
Index control panel 33 display 34 AC generator 22, 77 keys 34 test 77 coolant level switch 29, 101 AC generator belt 120 checking the float 101 adjustment 120 replacing 101 replacement 121 testing 101 accumulator, replacement 144 cooling system, engine 98 air cleaner, EMI 3000 119 bleeding air from 100 air heater 87...
Page 169 Index filter-drier, replacement 142 maintenance inspection schedule 19 first aid 13 manual pretrip inspection 69 electrical shock 14 microprocessor On/Off switch 33 engine coolant 14 Mode key 34 refrigerant 13 moisture indicating sight glass 129 refrigerant oil 14 mounting bolts, unit and engine 155 FreshSet 26 front doors opening 27...
Page 170 Index soft keys 34 specifications electric fuel heater 18 SR-4 Control System 33 suction pressure transducer, replacement 150 suction vibrasorber, replacement 149 thermostat, engine 100 three-way valve condenser pressure bypass check valve 132 three-way valve condenser pressure bypass check valve, repair 148 three-way valve, repair 145 transducers, pressure 133 transformer 90...
Page 171: Diagram Index
Diagram Index Drawing No. Drawing Title Page 1H81406 Schematic Diagram 171-176 1H81407 Wiring Diagram 177-183 1H75892 Fuel Line Routing Diagram 184-185...
Page 172 Schematic Diagram - Page 1 of 6 F15-2A...
Page 173 Schematic Diagram - Page 2 of 6...
Page 174 Schematic Diagram - Page 3 of 6...
Page 175 Schematic Diagram - Page 4 of 6...
Page 176 Schematic Diagram - Page 5 of 6...
Page 177 Schematic Diagram - Page 6 of 6...
Page 178 DETAIL A UNIFIED Pg2-[8,F] CARGO WATCH SENSOR WIRES CAD GENERATED DRAWING, DS-INT-01 INGERSOLL-RAND IS THE SOLE OWNER OF THIS DRAWING AND ALL DO NOT MANUALLY UPDATE INFORMATION IN IT, WHICH ARE PROTECTED BY COPYRIGHT AND DS-01 DS-02 UNLESS OTHERWISE SPECIFIED TOLERANCES...
Page 179 Wiring Diagram - Page 2 of 7 UNIFIED Pg1-[1,B] 8S-01 8S-01 DTP-01 DTP-01 DTN-01 DTN-01 CHFP-01 DTRP-01 CHH-01 BAT-01 BAT-01 BAT-01 DTRN-01 CH26-01 CHF-01 CH-01 BAT-01 ENGINE GND CHDS-01 CHHS-01 ST1N-01 CHOLS-01 BAT_NEG BAT_NEG BAT_POS BAT-01 ST1P-01 CHBAT-01 CHBAT-01 CH-02 CHB-01 CHB-01 CHB-01...
Page 180 Wiring Diagram - Page 3 of 7 LV CONTROL (50) Pg1-[1,D],Pg2-[8,B],Pg4-[8,F] POWER TIMER TIMER TIMER G/Y-11 FB-PSM-GND2 PHASE HASE GND-01 CH-25 CH-25 SELECT SELECT SELE BUSS BAR BB3 L1A-03 BB2C BB3A BB3A MODULE MODULE MODULE T1A-01 BB2A BB1A BB1C L2A-03 BB2B BB3B BB3B...
Page 181 Wiring Diagram - Page 4 of 7 ALTERNATOR (50). Pg1-[4,E] LV CONTROL (50). Pg1-[1,D],Pg2-[8,B],Pg3-[8,F] POWER G/Y-11 TIMER TIMER TIMER FB-PSM-GND2 2A-02 PHASE PHASE PHASE CH-25 SELECT SELECT SELECT FB-PSM-GND BUSS BAR BB3 MODULE MODULE MODULE L1A-03 BB2C BB3A BB3A T1A-01 BB2A BB1A BB1C...
Page 182 Wiring Diagram - Page 5 of 7 OPTIONAL HARNESS - FRESH AIR DOOR AFADSP-02 AFADSP-02 TO WIRING AFADS-02 AFADS-02 SHEET 2 AFADE-02 AFA_MAIN OPTIONAL HARNESS - LED AFADE-02 AFAD AFAD CHFA-01 AUTO FRESH AIR DAMPER LED5 SP-03 LEDP-02 LEDP-03 LEDP-01 LEDP-01 LEDP-04 LEDP-04...
Page 183 Wiring Diagram - Page 6 of 7 TELEMATICS OPTIONAL REB BOARD WPAN OPTION RJ98 FUELN-02 FUELN-02 TO FUEL LEVEL SENSOR FUEL-02 FUEL-02 WIRING SHEET 6 8F-02 8F-02 UPDATE UPDATE PDATE PORT PORT DS-04 DS-04 TO DS-INT WIRING SHEET 1 RX2-02 RX2-02 RX2-02 TX2-02...
Page 184 Wiring Diagram - Page 7 of 7 WIRE CODE SIGNAL DESCRIPTION WIRE CODE SIGNAL DESCRIPTION WIRE CODE SIGNAL DESCRIPTION 2-01 FS8 FUSE to SR4 BOARD DSP-01 DOOR SWITCH POSITIVE S2N-01 CARGO WATCH SENSOR 2 NEGATIVE 20B-01 LOW OIL PRESSURE SWITCH DSP-03 WPAN MODULE TO DS-WP S2P-01...
Page 185 Fuel Line Routing Diagram - Page 1 of 2...
Page 186 Fuel Line Routing Diagram - Page 2 of 2...
Page 187 Ingersoll Rand’s Climate Solutions sector delivers energy-efﬁ cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efﬁ cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes.

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Ingersoll-Rand Thermo King Precedent C-600 Maintenance Manual

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