Page 1 Operator’s Manual Precedent S-600 and S-700 TK 55538-2-OP (Rev. 3, 01/2014)
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
Unit Description ......21 Thermo King Corporation Responsibilities ..10 Unit Overview .
Page 5 Opening the Front Doors ..... . . 30 Changing The Setpoint ......56 Engine Compartment .
Page 6 Pretrip Test Sequence ......82 Displaying and Clearing Alarm Codes ... . .97 Pretrip Test Considerations .
Page 7 Electric Standby Power Fails or is Disconnected . . . 118 Running a Pretrip Test ..... . . 138 Switching from Electric to Diesel ....118 Adjust Brightness .
Page 8 Electric Motor and Overload Relay ... 191 Electric Heater Strips ..... 191 Standby Power Cord Requirements .
Page 10: 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 11 Introduction...
Page 12: Epa Emission Control System
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 13: Responsibilities
Thermo King parts. However, warranty. Thermo King is not liable for parts that are not genuine Thermo King parts. Responsibilities A part not being available within 30 days or repair not being This warranty is subject to the following: completed within 30 days constitutes an emergency.
Page 14: Owner Responsibilities
• Premium of overtime cost. Remedies under this warranty are limited to the provision of material and services as specified herein. Thermo King is not • Cost to investigate complaints that are not caused by responsible for incidental or consequential damages such as defects in Thermo King material or workmanship.
Page 15 EPA Emission Control System Warranty Statement...
Page 16: 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 17: Automatic Start/Stop Operation
Safety Precautions Electrical Hazard CAUTION: Use extreme caution when drilling holes in the unit. Drilling into electrical wiring or DANGER: Dangerous three phase AC electric power refrigerant lines could cause a fire. Do not drill into is present whenever the unit is operating in either structural components.
Page 18: Battery Installation And Cable Routing
WARNING: Improperly installed battery could result causing personal injury. in a fire or explosion. A Thermo King approved battery must be installed and properly secured to the CAUTION: Always wear protective clothing, gloves battery tray.
Page 19: Refrigerant
Safety Precautions Refrigerant WARNING: Always wear goggles or safety glasses to protect eyes from refrigerant oil contact. Although fluorocarbon refrigerants are classified as safe, use caution when working with refrigerants or in areas where they are being used. WARNING: Protect skin and clothing from prolonged or repeated contact with refrigerant oil.
Page 20: First Aid-Refrigerant Oil
Safety Precautions Safety Decals and Locations Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until emergency personnel arrive. First Aid–Refrigerant Oil Eyes: Immediately flush eyes with large amounts of water for at least 15 minutes while holding the eyelids open. Get prompt medical attention.
Page 21: Condenser And Evaporator Fans
Safety Precautions Condenser and Evaporator Fans High Voltage Components Be aware of the warning nameplates near the condenser fans Various components on the Precedent unit operate using and evaporator fans (example in Figure 2). 220/3/60 or 460/3/60 high voltage and are identified by warning nameplates (examples in Figure 3).
Page 22 Safety Precautions 1. Condenser Motors 4. High Voltage Control Box 2. Evaporator Motor 5. AC Generator Evaporator Motor High Voltage Junction 3. High Voltage 6. Electric Standby Motor & Distribution Box Power Receptacle High Voltage Heater All ORANGE conduiting ™ (SmartPower Option) Strips...
Page 23: Do Not Use Ether Starting Aids
Safety Precautions Do Not Use Ether Starting Aids Figure 6: Do Not Use Ether Starting Aids (Near Engine)
Page 24: 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 25: 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 26 Unit Description Precedent S-600 & S-700 Key Features & Options Anti-Siphon Device REB Wireless Communication Platform TracKing Telematics m / o PrimAir™ bulkhead and duct system Rear Remote Control Humidity Sensor Battery Charger Reliamax Battery, 12 Volt, Wet Cell EON Battery,...
Page 27: Diesel Engine
Unit Description Diesel Engine ELC (Extended Life Coolant) The S-600 uses the TK488CR. The S-700 uses the ELC (Extended Life Coolant) is standard equipment. The TK488CRH. These are 4-cylinder, water cooled, direct maintenance interval for ELC is five years or 12,000 hours. A injection diesel engines.
Page 28: 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 29: Smart Reefer Tm 4 (Sr-4) Control System
Unit Description Diesel Operation SMART REEFER 4 (SR-4) Control 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 30: Cycle-Sentrytm Start-Stop Controls
Unit Description • Modulated Heat (Hot Gas only) Your Thermo King unit provides a wide range • Hot Gas Heat of control and programming flexibility. However, pre-programming of the unit SR-4 • Full Heat (Hot Gas and Electric Heat) microprocessor may prohibit operation in •...
Page 31: Data Logging
ThermoServ™ software. ServiceWatch™: ServiceWatch is standard equipment. It records operating events, alarm codes and compartment temperatures as they occur and at preset intervals. This THERMO KING information is typically used to analyze unit performance. °F USB PORT CargoWatch™: CargoWatch data logging requires the...
Page 32: Optiset Tm Plus
30 minutes if maximize protection of cargo, while keeping operating costs to required. a minimum. Contact your Thermo King dealer for information about programming FreshSet. Manual Defrost: In Manual Defrost mode, the operator initiates a defrost cycle.
Page 33: Opening The Front Doors
Unit Description NOTE: The unit will not perform a Manual Defrost Cycle unless the unit has been turned on with the O key, the unit is running in Continuous or CYCLE-SENTRY Mode (or shut down in CYCLE-SENTRY Null Mode), and the coil temperature is below 45 F (7 C).
Page 34: Engine Compartment
Unit Description Engine Compartment The following maintenance items can be checked visually. WARNING: The unit can start at any time without warning. Press the O key on the control panel and place the microprocessor On/Off switch in the Off position before inspecting any part of the unit. Compressor Oil Sight Glass: Use this sight glass to check the compressor oil level.
Page 35: Unit Protection Devices
High Pressure Relief Valve: This valve is designed to relieve excessive pressure in the refrigeration system. It is located on the receiver tank. If the high pressure relief valve opens, much of the refrigerant will be lost. Take the unit to a Thermo King dealer if this occurs.
Page 36 Preheat Buzzer: The preheat buzzer sounds when the base Fuel Solenoid/Starter Circuit controller energizes the preheat relay. This warns anyone near None No Fuse - All Bosch and Thermo King the unit that the controller is about to start the engine. Alternators (Note 1) 2A Fuse - All Prestolite Alternators Overload Relay—Automatic Reset (SmartPower): An...
Page 37 Unit Description Fuse Size Function Fresh Air Door Circuit 7.5A High Pressure Cutout Circuit NOTE: Fuse F4 must be in place for Prestolite alternators to charge. Fuse F4 must be removed for Bosch and Thermo King alternators. Service Parts Base Controllers are shipped without the F4 fuse NOTE: The F5 preheat fuse is a “slow blow”...
Page 38 Unit Description Figure 13: SR-4 Controller...
Page 39 Unit Description...
Page 40: 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 41 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 42 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 43 Remote Status Display (Optional)
Page 44: Manual Pretrip Inspection (Before Starting The Unit)
Manual Pretrip Inspection (Before Starting the Unit) Pretrip inspections are an important part of a preventative Engine Coolant: The engine coolant must have antifreeze maintenance program designed to minimize operating protection to -30 F (-34 C). Add coolant if Alarm Code 37 is problems and breakdowns.
Page 45 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 46: 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 47: Control Panel
Operating Instructions Control Panel Interface (HMI) Control Panel. It is used to operate the unit. The USB ports are used to retrieve data from the data logging The control panel has a display and eight touch sensitive keys. system. The display is capable of showing both text and graphics. The Microprocessor On/Off Switch: This switch supplies or four keys on the left and right sides of the display are “hard”...
Page 48: 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 49: 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 Soft Keys and then the statement “Configuring System - Please Wait”. When the power-up sequence is The four “soft”...
Page 50: Turning Unit On
THERMO KING Logo as the display initializes. 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 Figure 22: ON Key flicker but the unit will not start up.
Page 51: 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 Only USB Port on the Control Panel when the unit FLASH DRIVE DETECTED is turned on, the display (Figure 24) will briefly show FLASH EXIT DOWN FLASH...
Page 52 Operating Instructions Configurable Soft Keys • DOWNLOAD • “Download the ServiceWatch Data Logger When the Standard Display is shown, the default functions of • “Download the CargoWatch Data Logger the two center soft keys are GAUGES and SENSORS. (Figure 26) •...
Page 53: 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 54 Operating Instructions languages 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 55: 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 56: Turning The Unit Off
Operating Instructions °F SYSTEM IS POWERING DOWN GAUGES SENSORS MENU POINT Figure 33: Standard Display Figure 34: 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 57: 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 58: 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 TemperatureWatch Display will remain on until any key is MENU pressed or a check, prevent or shutdown alarm occurs.
Page 59: 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 60: 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 61 Operating Instructions NEW SETPOINT WILL BE NEW SETPOINT WILL BE 40 F 40 F +/- TO CHANGE +/- TO CHANGE Figure 43: Yes and No Keys Figure 42: 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 62 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 63: 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 64 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 47: Product Displayed...
Page 65 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 POTATO, LATE CROP Entered is set, to indicate that the product change was initiated but not completed.
Page 66 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 67: 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 68 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 Setpoint - Named Product change as shown previously. PRODUCT/ GAUGES SENSORS...
Page 69: 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 70: 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 71: 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 72: Switching From Electric To Diesel
Operating Instructions Switching from Electric to Diesel Units equipped with the SMARTPOWER option only. ELECTRIC STANDBY NOT DETECTED DO YOU WISH TO SWITCH TO If the Electric to Diesel Auto-Switch Enabled feature in DIESEL? 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 73: 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 74 Operating Instructions The display briefly shows [DEFROST], [PROGRAMMING DEFROST - PLEASE WAIT] and then [DEFROST STARTED] (Figure 64). GAUGES SENSORS MENU POINT DEFROST STARTED Figure 65: Bar Indicator If conditions do not allow a defrost cycle, the display shown in Figure 66 will briefly appear.
Page 75: Terminating A Defrost Cycle
Operating Instructions See Figure 67 for an overview of the Initiating a Manual Defrost Cycle procedure. °F GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT DEFROST STARTED DEFROST NOT AVAILABLE Figure 67: Initiating a Manual Defrost Cycle Terminating a Defrost Cycle NOTE: If Rail Alternate is set YES the defrost cycle terminates at 70 F (21 C) or if the defrost timer expires.
Page 76: 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 77 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 78 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 79: Using The Gauges Key
Operating Instructions Using the Gauges Key The GAUGES Key allows the operator to view the unit BATTERY VOLTAGE 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 80 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 81: 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 82: 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 83: Using The Main Menu
Operating Instructions Using the Main Menu MAIN MENU The Main Menu contains several additional submenus that PRETRIP allow the operator to view information and modify unit LANGUAGE ALARMS operation. To access the Main Menu press the MENU Key GAUGES EXIT SELECT DOWN (Figure 78).
Page 84: 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 85: Pretrip Test Conditions
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 86: Pretrip Test Considerations
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 87 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 shown press the SELECT Key to start a Pretrip Test (Figure PROGRAMMING PRETRIP MODE 81). MAIN MENU PRETRIP LANGUAGE...
Page 88 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 89 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 90: Flash Drive
Operating Instructions Flash Drive • RETRIEVE • Retrieve OptiSet Plus files If a properly configured USB Flash Drive is currently connected to the USB Port on the unit Control Panel, the Flash If a USB Flash Drive is not connected to the unit, this feature Drive Menu will appear as a Main Menu selection.
Page 91: Selecting The Flash Drive Menu From The Main Menu (If Already Connected)
Operating Instructions Selecting the Flash Drive Menu from the Main Menu (If Already Connected) MAIN MENU FLASH DRIVE PRETRIP To select the Flash Drive Menu, press the MENU Key (Figure LANGUAGES 89). The Main Menu will appear. ALARMS EXIT SELECT DOWN °F Figure 90: Flash Drive Menu...
Page 92: Removing The Flash Drive
Operating Instructions FLASH DRIVE DETECTED FLASH DRIVE REMOVED EXIT DOWN FLASH OPTISET EXIT HELP LOAD LOAD PLUS Figure 91: Flash Drive Figure 92: Flash Drive Removed If the HELP Soft Key is pressed the display shown in Figure 93 Removing the Flash Drive will appear.
Page 93: 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 94 Operating Instructions MAIN MENU PRETRIP LANGUAGE ALARMS GAUGES EXIT SELECT DOWN Figure 95: Main Menu Figure 96: 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 95 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 96: Language Menu Quick Access
Operating Instructions °F GAUGES SENSORS MENU POINT MAIN MENU PRETRIP LANGUAGE ALARMS GAUGES EXIT SELECT DOWN Figure 99: 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 then press and hold the first and last soft keys for 5 seconds as shown below.
Page 97: 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 98: Shutdown Alarms
Operating Instructions GAUGES SENSORS MENU GAUGES SENSORS MENU POINT POINT Figure 103: Alarm Icon Figure 104: 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 99: Clearing Alarm Codes
Operating Instructions shutdown alarm that is preventing diesel mode operation. If the • Alarm Code 204 Check Display Discharge Air Sensor unit is switched back to diesel mode, the alarm again become a The following alarm codes clear automatically: diesel mode shutdown alarm and prevents unit operation. •...
Page 100: Displaying And Clearing Alarm Codes
Operating Instructions • Alarm Code 24 Heating Cycle Fault • Alarm Code 32 Refrigeration Capacity Low MAIN MENU PRETRIP LANGUAGE ALARMS Displaying and Clearing Alarm Codes GAUGES EXIT SELECT DOWN Alarms are displayed and cleared using the Alarm Menu. From the Standard Display, press the MENU Key (Figure 105).
Page 101 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 using the CLEAR Key.
Page 102: Important Alarm Notes
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 103 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 EXIT CLEAR HELP DOWN GAUGES SENSORS MENU GAUGES SENSORS...
Page 104: 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 105: Sensors
Operating Instructions Displaying Sensors Sensors are displayed using the Sensors Menu. From the BATTERY VOLTAGE Standard Display, press the MENU Key (Figure 118). EXIT LOCK BACK NEXT °F GAUGES SENSORS MENU Figure 117: Next, Back, Lock Keys POINT The gauges and I/O conditions available are described in this section of the manual.
Page 106: 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 107: 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 108: 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 109 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 110: 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 111: Hourmeter Names And Definitions
Operating Instructions Press the NEXT or PREVIOUS Key to scroll through the To return to the Main Menu press the EXIT Key. To return to hourmeters (Figure 129). the Standard display press the EXIT Key again. Hourmeter Names and Definitions HOURMETERS TOTAL UNIT RUN HOURS Only configured hourmeters that have been enabled in the...
Page 112: Mode
Operating Instructions IMPORTANT: If a programmable hourmeter is not enabled Total Run User Programmable - The number of hours or the view for that hourmeter is not turned on it will not Reminder 2 before a Total Unit Run Time Maintenance Reminder 2 occurs.
Page 113: Using The Change Mode Menu
Operating Instructions • Allows Keypad Lockout to be selected (if enabled from the Guarded Access > Main Menu Configuration Menu). • Start Sleep Mode (if enabled from the Guarded Access > °F Main Menu Configuration Menu). GAUGES SENSORS MENU POINT When shipped from the factory, only the Cycle Sentry/Continuous Mode is enabled.
Page 114: Turn Cycle Sentry On Or Off
Operating Instructions The first enabled Change Mode Menu selection will appear. To • The modes shown on the following pages may be choose that function, press the SELECT Soft Key. To Scroll available. through the enabled features in the Change Mode Menu, press the UP and DOWN Soft Keys (Figure 132).
Page 115: Select Temperature Units
Operating Instructions If the unit is running in Cycle Sentry Mode, press the SELECT NOTE: Cycle Sentry Mode can also be turned on and off Soft Key (Figure 134) to turn off Cycle Sentry Mode as shown using the Cycle Sentry Key on the HMI Control Panel unless below.
Page 116: Fresh Air Exchange Open Or Closed
Operating Instructions Choose the desired Temperature Units using the UP and interior air to be exhausted by opening the Fresh Air Exchange DOWN Soft Keys and press the SELECT Soft Key to select door. This feature is beneficial when hauling loads that release the choice (Figure 136).
Page 117: Keypad Lockout
Operating Instructions IMPORTANT: The Fresh Air Exchange feature should be used exactly as specified by the customer. CHANGE MODE TURN ON CYCLE SENTRY MODE • The Fresh Air Exchange door will only be open when the FAHRENHEIT KEYPAD LOCKOUT unit engine is running. The door will close when the START SLEEP MODE engine shuts down to preserve unit battery life.
Page 118: 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 119: 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 120: 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 then the unit will automatically switch to Electric Mode MAIN MENU HOURMETERS...
Page 121: 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 122: 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 the unit is switched back to Electric Mode these alarms again GAUGES SENSORS MENU...
Page 123 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 124: Time
Operating Instructions The date and time held in the HMI Control Panel will be shown on the display (Figure 151). Time and Date cannot be changed from the Main Menu. °F GAUGES SENSORS MENU POINT TIME MENU 01:18 MONDAY 10 DEC 2012 EXIT Figure 149: Menu Key The Main Menu will appear.
Page 125: Clear All Ecu Faults
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 126 Operating Instructions CLEAR ALL ECU FAULTS CLEAR ALL ECU FAULTS EXIT CLEAR Figure 154: Clear Key All Engine Control Unit (ECU) Faults and associated Thermo King Faults will be cleared. To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
Page 127 Operating Instructions...
Page 128: Optional Rear Remote Control Panel
Optional Rear Remote Control Panel Rear Remote Control Panel The optional Rear Remote Control Panel is connected to the control system and is used to operate the unit from a remote Functionality location, typically at the rear of the trailer. In the illustration below all display segments are turned on.
Page 129: Rear Remote Control Action Set To Stand By
Optional Rear Remote Control Panel Rear Remote Control Action Set to If the control system is powered up from the Rear Remote Control Panel the Standard Display will appear in both the Stand By Rear Remote Control Panel display and the unit Control Panel If the Rear Remote Control Action is set to STAND BY, display.
Page 130 Optional Rear Remote Control Panel When in STAND BY, the unit will not start and run and a When the StAnd bY display is shown, press the Select Key to defrost cycle or Pretrip Test cannot be started. show the Remote Standard Display. When the remote standard Display is shown, the setpoint and operating mode can be If the control system is powered up from the remote control changed, the discharge air temperature can be displayed and...
Page 131: Keypad
Optional Rear Remote Control Panel Keypad Turns the unit on as determined ON Key by the setting of Rear Remote The nine touch sensitive keys are used to turn the unit on and Control Action. off. They also allow the setpoint to be changed, Cycle Sentry or Continuous Mode to be selected, Alarm Codes and other OFF Key Turns the unit off.
Page 132: Display
Optional Rear Remote Control Panel TK Logo Sends a Start of Trip marker to This icon appears when the unit is Cool Icon the data logger. cooling. This icon appears when the unit is Heat Icon Initiates a defrost cycle if heating.
Page 133: Reading A Typical Remote Standard Display
Optional Rear Remote Control Panel Reading a Typical Remote • The unit is cooling as shown by the icon at the upper left side of the display. Standard Display • The unit is operating in Cycle Sentry mode as shown by The Remote Standard Display shows the temperature and the icon at the upper right side of the display.
Page 134: Turning The Unit On Or Off (Configured For Stand By Operation)
Optional Rear Remote Control Panel Turning the Unit ON or OFF (Configured for STAND BY Operation) The control system is turned on by pressing the ON Key and off by pressing the OFF Key. When the On Key is pressed the remote display briefly shows all segments and then StAnd by as shown in Figure 163.
Page 135: Changing The Setpoint
Optional Rear Remote Control Panel Changing the Setpoint The setpoint can be changed when the Remote Standard Display is shown. When the Remote Standard Display is shown, press the Up or Down Arrow Keys to select the desired setpoint (Figure 165). Figure 164: Standard Display Figure 165: Press Up or Down Arrow Keys...
Page 136: Selecting Cycle-Sentry Or Continuous Mode
Optional Rear Remote Control Panel Selecting Cycle-Sentry or When the desired setpoint is shown on the display, immediately press the Enter Key to load the new setpoint. Continuous Mode The display will briefly show [Lod] and then the new setpoint will reappear in the display. Cycle Sentry or Continuous Mode operation can be changed using the Select Key.
Page 137: Displaying The Discharge Air Temperature
Optional Rear Remote Control Panel Displaying the Discharge Air Temperature The discharge air temperature can be shown using the Select Key. When the Remote Standard Display is shown, press the Select Key twice. The discharge air temperature will be Figure 168: Press Up or Down Arrow Keys shown in the display for about 10 seconds.
Page 138: Viewing And Clearing Alarm Codes
Optional Rear Remote Control Panel Viewing and Clearing Alarm Codes Alarm Codes can be displayed and cleared using the Select Key. When the Remote Standard Display is shown, press the Select Key three times. Any alarm codes present will be shown in the display, with the most recent alarm code Figure 172: Press Enter Key shown first.
Page 139: Starting A Manual Defrost Cycle
Optional Rear Remote Control Panel Starting a Manual Defrost Cycle If conditions allow, a manual defrost cycle can be initiated using the Defrost Key. Press the Defrost Key. The defrost prompt [EnTEr dEF] will appear in the display. Figure 175: Press Enter Key The display will return to the Remote Standard Display.
Page 140: Sending A Start Of Trip Marker
Optional Rear Remote Control Panel Sending a Start of Trip Marker When the Start of Trip prompt is shown, press the Enter Key to send a Start of Trip marker to the CargoWatch and A Start of Trip marker can be sent to the data loggers using the ServiceWatch data loggers.
Page 141: Running A Pretrip Test
Optional Rear Remote Control Panel Running a Pretrip Test When the Pretrip prompt is shown, press the Enter Key to start a Pretrip Test. The display will briefly show LOAd A Pretrip Test can be started using the Pretrip Key as long as PrE.
Page 142 Optional Rear Remote Control Panel When the Pretrip Test is running the display will show PrE When the Pretrip Test is complete the display will show trP. The Control Panel will show the Pretrip Test progress. PASS, CHEC or FAIL. Pressing the Select Key will return to the Remote Standard Display.
Page 143 Optional Rear Remote Control Panel...
Page 144: 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 145 Loading and Enroute Inspections Correct load height (trailers without chutes) Tight doors and gaskets Good air circulation around load Proper cargo temperature (prior to loading) Interior/exterior walls and insulation in good condition Clear defrost drains Good outside air circulation Unit inspection Tight seals ADZ30 Figure 183: Loading Considerations...
Page 146: 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 147: 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 148 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 149 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 150: Alarm Codes
Maintenance Menu or the Guarded Access Menu. Contact before the Standard Display appears) each time the unit is your supervisor or a Thermo King dealer about clearing turned on. The Alarm Display must be used to view the those alarms.
Page 151 Alarm Codes corrective action before a problem becomes severe. Maintenance items such as a maintenance reminder hour meter reaching its time limit are log alarms. GAUGES SENSORS MENU POINT LOG ALARMS ACTIVE GO TO MENU TO VIEW EXIT Figure 185: Alarm Display Prevent Alarms: Prevent Alarms are also indicated by the Alarm Display as shown in Figure 185.
Page 152: 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 153: 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 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 No Alarms Exist None required Manually monitor load temperature with independent Evaporator Coil Sensor thermometer.
Page 155 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action If unit is shut down repair immediately. Otherwise, report High Discharge 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 If unit is shutdown repair immediately. Otherwise, report Engine Failed to Start alarm at end of day.
Page 157 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action 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 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 If unit is shutdown, repair immediately. Otherwise, report Electric Motor Failed to Run 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 Unit Forced to Low Speed Report alarm at end of day. Modulation Check Fuel System Add fuel as necessary.
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 Service Test or Interface Board Test time out after 15 Test Mode Time-out minutes.
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 Abnormal Temperature If unit is shutdown, repair immediately. Otherwise, report Differential alarm at end of day Check engine oil level.
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 If unit is shutdown repair immediately. Otherwise, report Low Engine Coolant Temperature 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 Low Compressor Suction If unit is shutdown, repair immediately. Otherwise, report Pressure 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 108 Door Open Time-out Close Doors. Report alarm at end of day. If unit is shutdown, repair immediately.
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 Auto switch from Electric to Report alarm at end of day. Diesel If unit is shutdown, repair immediately.
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 Electric Run Time Maintenance Report alarm at end of day. Reminder #1 Electric Run Time Maintenance Report 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 Lost Expansion Module CAN If unit is shut down repair immediately. Otherwise, report Communication alarm at end of the day.
Page 168 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Expansion Module Flash Load If unit is shut down repair immediately. Otherwise, report Failure 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 230 Future REB Alarm 231 Future REB Alarm 232 Future REB Alarm REB Transitioning From Report 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 Host Evaporator Fan RPM If unit is shutdown, repair immediately. Otherwise, report Sensor alarm at end of day.
Page 171 Alarm Codes Table of Alarm Codes NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software. Level Of Code Description Corrective Action Action Engine Control Unit (ECU) Failed If unit is shutdown, repair immediately. Otherwise, report to Enable alarm at end of day.
Page 172 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 173 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 174 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 175 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 176 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 177 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 178 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 179 Alarm Codes...
Page 180: 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 181 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 (Discharged) it to explode. 12-Volt Remove the red cover from the positive (+) battery Battery terminal on the unit’s battery.
Page 182 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 183 Jump Starting Unit (Discharged) 12-Volt Battery Good 12-Volt Battery Unit Engine Starter Mounting Bolt on Unit Engine Negative (–) Terminal on Good Battery Positive (+) Terminal on Good Battery Positive (+) Terminal on Unit Battery Figure 188: Sequence for Disconnecting Jumper Cables...
Page 184: 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 185 Specifications Engine (Continued) Oil Type API Classification CJ-4 or better Oil Viscosity 14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic) 5 to 104 F (-15 to 40 C): SAE 15W-40 -13 to 104 F (-25 to 40 C): SAE 10W-40 -13 to 86 F (-25 to 30 C): SAE 10W-30 -22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic) Below -22 F (-30 C): SAE 0W-30 (Synthetic)
Page 186 Specifications Engine (Continued) Engine Coolant Thermostat 160 F (71 C) Engine Coolant Type ELC (Extended Life Coolant), which is “RED” Use a 50/50 concentration of any of the following equivalents: Chevron Dex-Cool Texaco ELC Havoline Dex-Cool® Havoline XLC for Europe Shell Dexcool®...
Page 187: Belt Tension
Specifications Engine (Continued) Radiator Cap Pressure 15 psig (103 kPa) Drive: Standard Units Direct to compressor; belts to AC generator, alternator, and water pump Smart Power Units Centrifugal clutch to compressor; belts to electric standby motor, AC generator, alternator, and water pump Belt Tension Belt Use of Frequency Gauge P/N 204-1903 to measure...
Page 188: Refrigeration System
Alternator Belt - Smart Power Units Only: All Alternators 216 Hz (75 lbs) 187 Hz (56 lbs) Refrigeration System Compressor Thermo King X430LSC5 Refrigerant Charge—Type 14.5 lb (6.6 kg)—R404A Compressor Oil Charge 4.3 qt (4.1 liters)* Compressor Oil Type Polyol Ester type P/N 203-513...
Page 189: Electrical Control System
-15 F [-26 C]) See “Base Controller Fuses” on page 101, and other fuses Fuses on pages 105 and 107. Battery Charging 12 volt, 37 amp, brush type, Thermo King Alternator Voltage Regulator Setting 13.95 to 14.35 volts @ 77 F (25 C)
Page 190: 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) Glow Plugs (4) Each Pilot Solenoid 17.0 Electronic Throttling Valve: Coil A (Red [EVA] and Blue [EVB] Wires) — 20 to 35 Coil B (Black [EVC] and White [EVD] Wires) —...
Page 191 Specifications Electrical Components 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 192 Specifications Electrical Components 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 193 Specifications Electrical Components 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 194: Electrical Standby (Smart Power Units Only)
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 195: 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 196: 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 197 Warranty...
Page 198: 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 199 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 200 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 201 550 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 202 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 203 A device that controls unit modes of operation to maintain a selected box temperature. TLE: Thin-line evaporator. A Thermo King remote evaporator designed to be compact (thin) while supplying superior air flow. See ECT and EW.
Page 204: 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 205 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 206 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 117).
Page 207 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 208 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 209 Maintenance Inspection Schedule...
Page 210: 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 189: Compressor Serial Number Location...
Page 211 Serial Number Locations Figure 190: Engine Serial Number Location Figure 191: Unit Serial Number Plate Locations...
Page 212 Serial Number Locations ARA793 Unit Serial Number Bill of Material Number Unit Model Unit ID Figure 192: Unit Serial Number Plate...
Page 213 Serial Number Locations...
Page 214: 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 215: Recover Refrigerant
Recover Refrigerant At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.
Page 216: California Proposition 65 Warning
CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
Page 218: Index
Index alarm codes 147 data logging 28 corrective action 150 defrost 29 types 147 defrost drain inspection 42 amber status light 38 Defrost key 45, 46, 54, 87 automatic start/stop safety precautions 14 door inspection 42 battery inspection 41 ELC (extended life coolant) 24 belt tension, specifications 184 electrical components, specifications 187 belts inspection 41...
Page 219 engine oil dipstick 31 engine oil level 41 jump starting 177 engine, specifications 181 enroute inspections 144 loading procedures ETV (electronic throttling valve) 25 enroute inspections 144 extended life coolant (ELC) 24 post-loading inspection 143 pre-loading inspection 141 first aid for refrigerant 16 low oil level switch 33 first aid for refrigerant oil 17 low oil pressure switch 33...
Page 220 refrigerant 15 post-loading inspection 143 refrigerant oil 16 preheat buzzer 33 Serial Number Locations 207 pre-loading inspection 141 smart FETs 33 pretrip inspection, manual 41 SMART REEFER 2 (SR-2) Controller 26, 43 protection devices 32 soft keys 46 specifications rear remote control panel 125 electric fuel heater 192 receiver tank sight glass 31 SR-2 Controller 26, 43...
Page 221 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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