Page 1 Operator’s Manual T-680R / T-880R / T-1080R T-680S / T-880S / T-1080S Series with Premium SR-3 HMI TK 55667-1-OP (Rev. 2, 09/16)
Page 4 Disclaimer This manual is published for informational purposes only. Thermo King Corporation makes no representations or warranties, express or implied, with respect to the information, recommendations and descriptions contained in this manual and such information, recommendations and descriptions should not be regarded as all-inclusive or covering all contingencies. In the event you have any questions or require further information, please contact your local Thermo King dealer.
Page 5: Table Of Contents
Table of Contents Manufacturer’s Warranty Coverage ...19 Table of Contents ......3 Owner’s Warranty Responsibilities .
Page 6 Table of Contents CYCLE-SENTRY™ Start/Stop System ... . 30 Switching from Diesel to Electric ....49 Defrost .
Page 7 Table of Contents Displaying and Clearing Alarm Codes ... . 67 Loading and Enroute Inspections ....98 SR-3 Alarm Codes ......69 Pre-Loading Inspection .
Page 8 Table of Contents Maintenance Inspection Schedule ... . . 114 Warranty ........120 Serial Number and Refrigerant Label Locations .
Page 9: Introduction
Introduction There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational your Thermo King unit, but a few minutes studying this purposes only and the information furnished herein should manual will be time well spent. not be considered as all-inclusive or meant to cover all contingencies.
Page 10: Safety Precautions
Safety Precautions Thermo King recommends that all services be performed by a CAUTION: Use extreme caution when drilling holes Thermo King dealer. However, there are several general safety in the unit. Drilling into electrical wiring or practices which you should be aware of: refrigerant lines could cause a fire.
Page 11: Battery Installation And Cable Routing
Safety Precautions Battery Installation and Cable CAUTION: Set all unit electrical controls to the Routing OFF position before connecting battery cables to the battery to prevent unit from starting WARNING: Improperly installed battery could unexpectedly and causing personal injury. result in a fire or explosion! A Thermo King approved battery must be installed and properly CAUTION: Always wear protective clothing, secured to the battery tray.
Page 12: Electrical Hazard
Safety Precautions Electrical Hazard WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally CAUTION: Be sure to turn off the high voltage released into the atmosphere from the liquid state. power supply, and disconnect the electric cable before working on the unit.
Page 13: First Aid
Safety Precautions First Aid Safety Decals and Locations First Aid–Refrigerant Eyes: For contact with liquid, immediately flush eyes with large amounts of water. Get prompt medical attention. Skin: Flush areas with large amounts of warm water. Do not apply heat. Wrap burns with dry, sterile, bulky dressing to protect from infection or injury.
Page 14 Safety Precautions Figure 3: Belt Caution (Locations vary depending on Figure 2: Clearing Alarms Caution model. Decals are located near areas that contain (Typically located near the HMI Controller) belts and fans which can cause severe injuries if hands or clothing become tangled.)
Page 15 Safety Precautions CAUTION FAN ATTENTION VENTILATEUR ACHTUNG VENTILATOR ATTENZIONE VENTILATORE CUIDADO VENTILADOR Figure 4: Automatic Start Caution (Locations vary Figure 5: Fan Caution (Locations vary depending on depending on model. Decals are located near areas model. Decals are located near areas that contain that contain moving parts which can cause severe fans which can cause severe injuries if hands or injuries if hands or clothing become tangled when the...
Page 16: Model 50 Units (Electric Standby)
Safety Precautions Model 50 Units (Electric Standby) Figure 7: High Voltage Caution Figure 6: Electrical Hazard (Locations vary (Located near high voltage box.) depending on model. Typically located near power receptacle, high voltage tray cover and interface board.)
Page 17: Emission Control
Emission Control 2-4. Fuel Oil System: Fuel oil system must remain intact In compliance with the California ULG (Utility, Lawn and Garden) Rules, the following information is provided: and receive regular prescribed maintenance. Example: Fuel filter replacement at required operation hour interval. 1.
Page 18 Emission Control Emission control label: a new label, shown in b. Engine Family Name, as assigned by the California Figure 8, contains important engine information. Air Resources Board, identifies engine family group, by largest displacement, within an engine family, and is shown in Figure 9.
Page 19 Emission Control 3-1 Emission Control Labels: Emission control labels are All engine labels and supplementary labels will contain the a requirement of the California ULG Rules. In the event the following information: emission control label provided on the engine is inaccessible, •...
Page 20: California Emission Control System Warranty
Emission Control 4. Emission Control Related Parts: The California ULG 5. Maintenance Schedule: To maintain optimum engine Rules require a manufacturing defect warranty on all emission performance and compliance with the California ULG Rules, control parts, including: the maintenance schedule must be adhered to. •...
Page 21: Manufacturer's Warranty Coverage
Emission Control Owner’s Warranty Responsibilities (ULG) engine for the time listed below, provided there has been no abuse, neglect or improper maintenance of your utility As the utility equipment (ULG) engine owner, you are equipment (ULG) engine. responsible for the performance of the required maintenance Your California emission control system includes parts such as listed in this Operator’s Manual.
Page 22: Manufacturer Explanation Of Emission Control System Warranty Coverage
Emission Control Manufacturer Explanation Of at a Thermo King authorized service dealer. To obtain the phone number of your nearest Thermo King authorized Emission Control System service dealer, call the Cold Line at: 952-887-2202. Warranty Coverage Warranty Period: Any warranted California emission control system part or component that is not scheduled for A.
Page 23 Emission Control D. What is Not Covered G. Maintenance, Replacement and Repair of Emission Control System Related Parts 1. Failures caused by abuse, neglect, or improper Any Thermo King approved replacement part can be used in maintenance. the performance of any warranty maintenance or repairs on 2.
Page 24: Epa Emission Control System Warranty Statement
Emission Control EPA Emission Control System In an emergency, repairs can be performed at any service establishment, or by the owner, using any replacement part. Warranty Statement Thermo King will reimburse the owner for their expenses, including diagnostic charges, for such emergency repair. These Thermo King warrants to the initial owner and each subsequent expenses shall not exceed Thermo King’s suggested retail price owner that the certified non-road diesel engine in your unit is:...
Page 25: Responsibilities
Emission Control Owner Responsibilities • Intake Manifold • Exhaust Manifold During the emission warranty period, the owner is responsible for: • Miscellaneous hoses, clamps, connectors and sealing devices used in the above systems. • The performance of all required maintenance. A warranty claim will not be denied because the scheduled If failure of one of these parts or components results in failure maintenance was not performed.
Page 26 Emission Control • Attachments, accessory items, or parts not authorized for use by Thermo King. • Improper off-road engine maintenance, repair, or abuse. • Owner’s unreasonable delay in making the product available after being notified of a potential product problem. This warranty is in addition to Thermo King’s standard warranty applicable to the off-road engine product involved.
Page 27: Unit Description
Unit Description General Description Units are offered as Model 30 or Model 50: Model 30: Cooling and hot gas heating on engine operation. This manual covers the following Thermo King models: Model 50: Cooling and hot gas heating on engine operation •...
Page 28: Design Features
Unit Description Design Features • Bypass Oil Filter • Coolant Expansion Tank with Overflow Bottle • Microprocessor Controller, SR-3 Truck • Diesel/Electric Autoswitching (Model 50) • Alarm Code Display • Economy Mode • Battery Voltage Display • Fahrenheit and Celsius Scales •...
Page 29: Unit Options
Unit Description • Stainless Steel Condenser and Evaporator Hardware • Quick Oil Drain Kit • TK374F Tier 4 Diesel Engine (T-680R, T-680S, T-880R • Rear Remote Control (flushmount) and T-880S) • Remote Indicator Light • TK380F Tier 4 Diesel Engine (T-1080R and T-1080S) •...
Page 30: Engine
Unit Description Engine Engine power for the T-680R, T-680S,T-880R and T-880S is provided by the TK374F, a three-cylinder, EPA Tier 4, special clean and quiet diesel engine rated at 11.7 continuous horsepower (8.7 kW) at 2200 RPM. A belt drive system transfers energy to the compressor, unit fans, and alternator.
Page 31: Clutch
Unit Description Scroll Compressor NOTE: The use of 50/50% pre-mixed ELC is recommended to ensure that deionized water is being used. If 100% full The T-680S and T-880S feature the TK04 scroll compressor. strength concentrate is used, deionized or distilled water is recommended instead of tap water to ensure the integrity of The T-1080S features the TK06 scroll compressor.
Page 32: Cycle-Sentry Start/Stop System
Unit Description CYCLE-SENTRY Start/Stop Defrost ™ System Frost will gradually build up on the evaporator coils as a result of normal operation. Periodically this frost must be melted to The CYCLE-SENTRY Start/Stop fuel saving system provides prevent a loss of cooling and airflow. optimum operating economy.
Page 33: Das - Data Acquisition System (Optional)
Unit Description DAS - Data Acquisition System TK 55151 the Truck and Trailer Edition CargoLink Installation Manual for information about installing the CargoLink system (Optional) and sensors, and troubleshooting problems with the system. The DAS (Data Acquisition System) monitors and records the temperatures of (up to) six additional sensors.
Page 34: Standard Model 50 Features
Unit Description Standard Model 50 Features Engine Compartment Components The following features are standard equipment on units equipped with Electric Standby. Coolant Expansion Tank: The coolant level and Automatic Diesel/Electric Selection: The unit will temperature inside the expansion tank are monitored by the automatically switch to electric operation when a power cord is base controller.
Page 35: Unit Protection Devices
Unit Description Engine Oil Dipstick: Use the engine oil dipstick to check Engine Oil Pressure Switch/Sensor: The engine oil the engine oil level. pressure switch/sensor is located on the filter head above the bypass oil filter. Engine oil pressure should rise immediately Receiver Tank Sight Glass: The receiver tank sight glass on starting.
Page 36 Unit Description Figure 14: T-680S Front View (T-680R, T-880S and T-880R are similar)
Page 37 Unit Description Figure 15: T-1080S Front View (T-1080R is similar)
Page 38 Unit Description Engine (oil dipstick on side of engine) Alternator Coolant Overflow Bottle Compressor (reciprocating shown) Coolant Expansion Tank Dehydrator (Filter-Drier) Electric Motor On/Off Switch Figure 16: Main Components...
Page 39: Unit Operation
Unit Operation Premium HMI Control Panel The Premium Truck HMI (Human/Machine Interface) Control Panel is available as an option on SR-3 Truck applications. It is used to operate the unit, display unit information and access all SR-3 Maintenance and Guarded Access Menus. The Premium HMI Control Panel communicates with the base controller via the CAN (Controller Area Network) bus.
Page 40: Controller Features
Unit Operation Controller Features The Standard Display of box temperature and setpoint is shown here. The CYCLE-SENTRY Icon in the upper right of • Displays Box Temperature and Setpoint in Fahrenheit or the display shows the unit is running in CYCLE-SENTRY Celsius (Start-Stop) Mode.
Page 41: Keys
Unit Operation Keys Hard Key Description This key is used to turn the unit on. First the display will briefly show the Thermo King Logo and then the statement "Configuring System - Please Wait". When the power-up sequence is complete the display shows the Standard Display of box temperature and setpoint.
Page 42: Soft Keys
Unit Operation Soft Keys Hard Key Description This key is used to initiate a manual Soft Key Description defrost cycle. For more information see The four "soft" keys under the display "Initiating a Manual Defrost Cycle" later are multi-purpose keys. Their function in this section.
Page 43: Turning The Unit On And Off
Unit Operation Turning the Unit On and Off NOTE: With extremely cold ambient temperatures it may take up to 15 seconds for the display to appear on initial IMPORTANT: Verify the Base Controller On/Off Switch is startup. turned on before turning on the HMI Control Panel. The Base Controller On/Off switch is located on the outside of the control box side of the unit.
Page 44: If More Than One Language Is Enabled
Unit Operation If More Than One Language is Enabled If more than one language has been enabled, a prompt will appear to allow the desired language to be chosen as shown below. Only languages enabled from the Guarded Access Menu are available. If a different language is desired, press the NO key as shown in Figure 23.
Page 45 Unit Operation The Language Menu will appear in the current language as shown in Figure 28. Press the + or - keys to select the desired language. When the desired language is shown press the YES key to confirm the choice. Note that all languages in the installed software can be selected using this method.
Page 46: The Standard Display
Unit Operation The Standard Display Pressing the OFF key stops unit operation. The unit shuts down immediately and the display briefly shows the power down The Standard Display is the default display that appears if no message. other display function is selected. The Standard Display shows the box temperature and setpoint.
Page 47: Changing The Setpoint
Unit Operation Pressing the left soft key allows the user to change the SETPOINT, and pressing the right soft key accesses the MAIN MENU. The other two soft keys access the GAUGES menu and the SENSORS menu. Changing the Setpoint From the Standard Display, press the SETPOINT soft key.
Page 48 Unit Operation The YES and NO soft keys confirm the setpoint change. When After the YES soft key has been pressed, the display briefly the desired setpoint has been selected using the "+" and/or "-" shows PROGRAMMING NEW SETPOINT - PLEASE WAIT. keys, press the YES soft key to confirm and load the new The display then confirms the new setpoint for several setpoint.
Page 49: Starting The Diesel Engine
Unit Operation Setpoint Display. The display briefly shows [SETPOINT NOT CHANGED] and Alarm Code 127 Setpoint Not Entered is set, to indicate that a setpoint change was started but not completed. Starting the Diesel Engine Diesel engine preheats and starts are automatic in both Figure 38: Standard Display, New Setpoint Continuous Mode and CYCLE-SENTRY Mode.
Page 50: Starting The Electric Motor
Unit Operation Starting the Electric Motor When the engine is preparing to start the HMI control panel will display the engine start screen, as shown in Figure 39. The Units equipped with the Electric Standby option only. preheat buzzer sounds during the engine preheat and crank sequence.
Page 51: Switching From Diesel To Electric
Unit Operation After the motor is running the display returns to the Standard Display of temperature and setpoint. Figure 43: Prompt Screen, Guarded Access Set to No If YES is selected then the display will briefly show the screen Figure 42: Standard Display of Temperature and Setpoint in Figure 44.
Page 52: Switching From Electric To Diesel
Unit Operation Switching from Electric to Diesel Turn the unit off and back on using the OFF and ON Keys. This will clear Alarm Code 91 Check Electric Ready Input and Units equipped with the Electric Standby option only. Alarm Code 84 Restart Null. If the Electric to Diesel Autoswitch Enabled feature in NOTE: The CLEAR Soft Key will not clear these two alarms.
Page 53: Initiating A Manual Defrost Cycle
Unit Operation Figure 47: Display is YES is selected Figure 48: Press Defrost Key If unit operation is required the diesel engine will start as The display briefly shows [DEFROST], [PROGRAMMING shown previously in STARTING THE DIESEL ENGINE. DEFROST - PLEASE WAIT] and then [DEFROST STARTED].
Page 54: Terminating A Defrost Cycle
Unit Operation Selecting High Speed Lockout The display then shows the Defrost display. The bar indicator shows approximately how much time remains to complete the Mode (If Enabled) defrost cycle. The bar indicator in Figure 49 shows that the defrost cycle is about 25% complete. High speed operation can be locked out in noise sensitive areas if required.
Page 55 Unit Operation The High Speed Lockout Key is a toggle. If high speed is currently allowed, then pressing the High Speed Lockout Key will disable high speed operation. Pressing the High Speed Lockout Key again will allow high speed operation. To change the setting, press the High Speed Lockout key as shown below.
Page 56: Selecting Cycle-Sentry Or Continuous Mode
Unit Operation Using the Gauges Key The display will then return to the Standard Display. If High Speed Lockout is turned on, the message HIGH SPEED The GAUGES key allows the operator to view the unit gauges. LOCKOUT ACTIVE will be shown at the top of the display. To access the GAUGES menu press the GAUGES key.
Page 57: Gauges Available
Unit Operation Coolant Level - Displays the coolant level in the overflow tank as OK or LOW. Oil Pressure - Displays the engine oil pressure as OK or LOW. Oil Level - Displays the engine oil level as OK or LOW. Amps - Displays the current flow in amps to or from the unit battery.
Page 58: Using The Sensors Key
Unit Operation • High Speed Relay/Electric Heat • Run Relay • Run Relay Feedback • Alternator Excite Output • Defrost Damper • Hot Gas Solenoid Figure 57: Sensors Key • Alternator Frequency The first sensor display will appear. Press the NEXT and •...
Page 59: Sensors Available
Unit Operation The sensors available are shown in the following list. Data Logger Sensor 3 Temperature - Display the temperature of Data Logger Sensor 3. To return to the Standard Display press the EXIT key. Data Logger Sensor 4 Temperature - Display the temperature Sensors Available of Data Logger Sensor 4.
Page 60: Main Menu Choices
Unit Operation See “Main Menu Choices.” For detailed information see the individual explanations of each submenu item on the following pages. To return to the Standard Display press the EXIT key. Main Menu Choices LANGUAGE - If more than one language is enabled, this will Figure 59: Menu Key be the first menu item to appear.
Page 61 Unit Operation HOURMETERS - Allows the operator to view the unit ELECTRIC STANDBY - If the Electric Standby option is hourmeters that have the view feature enabled in the Guarded present and the Diesel to Electric Auto-switch feature is set Access menu.
Page 62: Languages
Unit Operation Languages • Languages currently supported by software revision 67xx are English, Japanese and Chinese. Other than the If the Language feature is enabled, an alternate language can be languages supported, software revisions 65xx, 66xx and selected from the Language Menu. After a new language is 67xx are functionally identical.
Page 63 Unit Operation The display will briefly show PROGRAMMING LANGUAGE - PLEASE WAIT in the new language as shown in Figure 64. Figure 62: Select Key The Language menu will appear as shown in Figure 63. Press the + or - keys to select the desired language. When the desired Figure 64: New Language language is shown press the YES key to confirm the choice.
Page 64: Alarms
Unit Operation Repeat the process to select a different language. To select a press the YES key to confirm the choice. Note that all different Main Menu item press the NEXT key. To return to the languages in the installed HMI Control Panel software (65xx, Standard Display press the EXIT key.
Page 65: Log Alarms
Unit Operation Log Alarms Log Alarms are indicated for 60 seconds each time the unit is turned on. This level of alarm serves as a notice to take corrective action before the condition impacts unit performance. Maintenance items such as maintenance hourmeter time-outs are log alarms.
Page 66: Shutdown Alarms
Unit Operation Shutdown Alarms Prevent Alarms Shutdown alarms will be set if continued operation could cause Prevent Alarms are also indicated by a steady Alarm Icon in damage to the unit or the load. Shutdown Alarms are indicated the display. The remote indicator alarm light (if installed) will by the following: be on.
Page 67: Pretrip Alarm Codes
Unit Operation Alarm Codes When Switching Between possible. The unit will run in this manner for a timed interval. If the unit is successfully able to return to full Diesel and Electric performance for the timed interval without the alarm If a shutdown alarm occurs that affects only diesel mode re-occurring, the alarm is auto cleared and the unit will run operation and the unit is switched to electric, the diesel mode...
Page 68: Clearing Alarm Codes
Unit Operation The following control and display sensor alarm codes can only be cleared from the Maintenance Menu or Guarded Access Menu: • Alarm Code 03 Check Control Return Air Sensor • Alarm Code 04 Check Control Discharge Air Sensor The following alarm codes clear automatically.
Page 69: Displaying And Clearing Alarm Codes
Unit Operation If the Limited Alarm Restarts feature is enabled the following The Language Menu or Alarms Menu will appear. If the additional alarm codes may only be cleared from the Guarded Language Menu appears press the NEXT key to show the Access Menu.
Page 70 Unit Operation If alarms are present, the quantity of alarms (if more than one) and the most recent alarm code number will be shown. In the example in Figure 73, there are two alarms present. The most recent is Alarm Code 5 (Figure 74). It indicates a problem with the ambient temperature sensor.
Page 71: Sr-3 Alarm Codes
Unit Operation • 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. • All alarms must be viewed before any of the alarms can be cleared.
Page 72 Unit Operation Code Description Operator Help Code Description Operator Help Check Ambient Air Report alarm at end of Manually monitor load Sensor the day. Sensor Check temperature. Report alarm at end of the day. Check Coolant Temp Report alarm at end of Sensor the day.
Page 73 Unit Operation Code Description Operator Help Code Description Operator Help If unit is shut down repair Manually monitor load Check Refrigeration immediately. Otherwise, temperature. Report Engine Failed to Start Capacity report alarm at end of the alarm at end of the day. day.
Page 74 Unit Operation Code Description Operator Help Code Description Operator Help Report alarm at end of If unit is shut down repair Check Engine RPM the day. Check High Speed immediately. Otherwise, Circuit report alarm at end of the If unit is shut down repair day.
Page 75 Unit Operation Code Description Operator Help Code Description Operator Help If unit is shut down repair If unit is shut down repair immediately. Otherwise, immediately. Otherwise, Check Air Flow Low Battery Voltage report alarm at end of the report alarm at end of the day.
Page 76 Unit Operation Code Description Operator Help Code Description Operator Help If unit is shut down repair If unit is shut down repair Check Liquid Line immediately. Otherwise, High Compressor immediately. Otherwise, Solenoid Circuit report alarm at end of the Temp report alarm at end of the day.
Page 77 Unit Operation Code Description Operator Help Code Description Operator Help If unit is shut down repair If unit is shut down repair Check Electronic immediately. Otherwise, Check Loader #1 immediately. Otherwise, Throttling Valve report alarm at end of the Circuit report alarm at end of the Circuit day.
Page 78 Unit Operation Code Description Operator Help Code Description Operator Help Unit Not Configured Report alarm at end of If unit is shut down repair Correctly the day. Check Alternator immediately. Otherwise, Excite Circuit report alarm at end of the If unit is shut down repair day.
Page 79 Unit Operation Code Description Operator Help Code Description Operator Help Electric Run Time Autoswitch Diesel to Report alarm at end of Report alarm at end of Maintenance Electric Disabled the day. the day. Reminder #1 If unit is shut down repair Loss of Controller Electric Run Time immediately.
Page 80: Datalogger
Unit Operation The ServiceWatch Data Logger and DAS Data Logger (if Code Description Operator Help equipped) are accessed using the Data Logger Menu. From the Manually monitor load Standard Display, press the MENU key. Out of Range High temperature. Report alarm at end of the day.
Page 81: Hourmeters
Unit Operation The first feature that appears is the Start of Trip. To send a Start of Trip to the ServiceWatch Data Logger and DAS Data Logger (if equipped), press the SELECT key to select the feature, and then press it again to send the Start of Trip. The display will briefly show START OF TRIP COMPLETE to confirm that a Start of Trip marker was set in the data logger(s).
Page 82: Hourmeter Names And Definitions
Unit Operation The Language Menu or Alarm Menu will appear. Press the Hourmeter names and definitions are shown in the table below NEXT key as required to display the Hourmeter Menu. When in the order they appear. Only hourmeters enabled in the the Hourmeter Menu is shown press the SELECT key.
Page 83: Mode
Unit Operation Controller Power On: Total hours the controller and HMI Mode control panel have been turned on. Various operating modes can be selected using the Mode Pretrip Reminder : User Programmable - number of hours menu. Not all modes may be available, depending on settings before a Pretrip Reminder occurs.
Page 84: Start Sleep Mode
Unit Operation Start Sleep Mode Hour to Wake Up: This feature allows the hour the unit is to wake up to be specified. If enabled in Guarded Access, Sleep Mode is used to keep the Minute to Wake Up: This feature allows the minute the unit engine warm and the battery charged when the unit is not in is to wake up to be specified.
Page 85: Selecting Cycle-Sentry Or Continuous Mode
Unit Operation Selecting CYCLE-SENTRY or Continuous Mode When CYCLE-SENTRY mode is selected the unit will start and stop automatically to maintain setpoint, keep the engine warm and the battery charged. When Continuous Mode is selected, the unit will start automatically and run continuously to maintain setpoint and provide constant airflow.
Page 86 Unit Operation Figure 87: Select Key Figure 89: Select Key The Turn Off/Turn On CYCLE-SENTRY screen will appear. The display will confirm the change as shown below. In the display shown below, the unit is operating in CYCLE-SENTRY mode. Turning CYCLE-SENTRY mode off will result in the unit running in Continuous mode.
Page 87: Selecting Sleep Mode
Unit Operation Selecting Sleep Mode Normal CYCLE-SENTRY mode starts and stops the unit as required to maintain the desired setpoint temperature, maintain the unit battery in a charged condition and keep the unit engine warm in cold ambient conditions. Sleep mode does not consider setpoint or maintain cargo temperatures - it only Figure 91: Mode Confirmed keeps the engine warm and the unit battery charged.
Page 88 Unit Operation Figure 95: Sleep Mode Menu Figure 93: Menu Key The screen shown in Figure 96 will appear. The Language Menu or Alarm Menu will appear. Press the NEXT key as required to show the Mode Menu. When the Mode Menu is shown press the SELECT key.
Page 89 Unit Operation To enter a Wake-up Time, verify the unit clock is set properly. Then press the YES key at the Sleep Mode menu. Figure 97: Select No to Enter Sleep Mode The display will show SLEEP and the unit will start and stop as Figure 99: Yes Key required to keep the engine warm and/or the battery charged.
Page 90 Unit Operation The display will now prompt the operator for the Hour the unit The display will now prompt for a Pretrip Test on Wake-up. is to restart in normal operation. In Figure 101 4:00 am has Press the YES key to perform a Pretrip Test on Wake-up. If the been chosen.
Page 91: Pretrip
Unit Operation Test is entered with the unit running in either diesel or electric mode a Running Pretrip Test is performed, but the device amps checks are not performed. Test results are reported as PASS, CHECK or FAIL when the Pretrip Test is completed. If an alarm occurs during a Pretrip Test the alarm code will be displayed as Pretrip Alarm XX, where XX is the alarm code.
Page 92: Pretrip Test Sequence
Unit Operation Pretrip Test Sequence Pretrip Test Considerations Pretrip tests proceed in the order shown below. A Full Pretrip When performing a Pretrip Test, the following issues should be Test includes all tests. A Running Pretrip Test is started with considered.
Page 93: Performing A Pretrip Test
Unit Operation Performing a Pretrip Test The Language Menu or Alarm Menu will appear. Press the NEXT key as required to display the Pretrip Menu. When the If a Pretrip Test is initiated with the engine shut down a Full Pretrip Menu is shown press the SELECT key.
Page 94 Unit Operation If all alarms were not cleared a prompt appears as shown in • The top line of the display indicates the unit is performing Figure 108. Exit the Pretrip Test, clear all alarms and restart the the non-running portion of the Pretrip Test. Pretrip Test.
Page 95: Diesel/Electric Menu
Unit Operation If the Pretrip Test results are CHECK or FAIL the problem should be diagnosed and corrected before the unit is released for service. Diesel/Electric Menu The Diesel Mode/Electric Standby menu allows the operator to manually select diesel or electric mode operation. The unit can Figure 110: Performing Cool Test also be programmed to automatically select electric mode When all tests are complete, the results are reported as PASS,...
Page 96: Switching From Electric To Diesel - Units Equipped With The Electric Standby Option Only
Unit Operation Switching from Electric to Diesel - Units If the Diesel to Electric Autoswitch Enabled feature in Guarded Access is set NO then the prompt screen shown in equipped with the Electric Standby option Figure 112 will appear when standby power is connected and only available.
Page 97: Adjust Brightness
Unit Operation Turn the unit off and back on using the OFF and ON Keys. This will clear Alarm Code 91 Check Electric Ready Input and Alarm Code 84 Restart Null. NOTE: The CLEAR Soft Key will not clear these two alarms. Then the prompt screen shown in Figure 115 will appear.
Page 98 Unit Operation The Display Brightness menu will appear as shown below. Press the + or - keys to select the desired display brightness. When the desired brightness is shown press the YES key to confirm the choice. Figure 117: Menu Key The Language Menu or Alarm Menu will appear.
Page 99: Time
Unit Operation Time The system time and date is viewed using the Main Menu. Time and Date cannot be changed from the Main Menu. From the Standard Display, press the MENU key. Figure 122: Select Key The current time and date will appear. Figure 121: Menu Key The Language Menu or Alarm Menu will appear.
Page 100: Loading And Enroute Inspections
Loading and Enroute Inspections Thermo King refrigeration units are designed to maintain the 4. Pre-cool the cargo compartment. Adjust the setpoint to the required temperature for the product being carried during its desired cargo temperature and allow the unit to run a time in transit.
Page 101: Inspecting The Load
Loading and Enroute Inspections Inspecting the Load 3. While inspecting to see that the cargo is loaded properly, make sure the evaporator inlets and outlets are not Never assume that the product has been loaded properly. Watch blocked. for and perform the following tasks. It takes only a few 4.
Page 102: Enroute Inspections
Loading and Enroute Inspections Enroute Inspections The evaporator is plugged with frost. Initiate a manual defrost cycle. The defrost cycle will be automatically NOTE: Enroute inspections are recommended every four terminated. hours for the prevention of damage to the cargo. d.
Page 103 Loading and Enroute Inspections The unit may have a low refrigerant charge. If liquid CAUTION: Stop the unit if the compartment is not showing in the unit receiver tank sight glass, the temperature remains outside the desired temperature refrigerant charge may be low. Adding refrigerant or range from the setpoint on two consecutive 30 minute repairing the refrigeration system requires a inspections.
Page 104: Specifications
Specifications Engine Model: T-680R, T-680S, T-880R & T-880S TK374F (Tier 4) T-1080R & T-1080S TK380F (Tier 4) Fuel Type No. 2 Diesel fuel under normal conditions No. 1 Diesel fuel is acceptable cold weather fuel Oil Capacity:T-680S and T-880S Crankcase & Oil Filter 9.0 quarts (8.5 liters) T-680S and T-880S w/Bypass Oil Filter 10.0 quarts (9.5 liters) Fill to full mark on dipstick...
Page 105 Specifications Engine (Continued) Engine rpm: Low Speed Operation 1625 ± 25 rpm High Speed Operation Reciprocating Compressor: 2200 ± 25 rpm Scroll Compressor: 2200 ± 25 rpm Engine Oil Pressure 20 to 50 psig (138 to 345 kPa) in low speed 40 to 60 psig (276 to 414 kPa) in high speed Intake Valve Clearance 0.006 to 0.010 in.
Page 106 Specifications Engine (Continued) Engine Coolant Type ELC (Extended Life Coolant), which is “RED” Use a 50/50 concentration of any of the following equivalents: Chevron Dex-Cool Texaco ELC Havoline Dex-Cool® Havoline XLC for Europe Shell Dexcool® Shell Rotella Saturn/General Motors Dex-Cool® Caterpillar ELC Detroit Diesel POWERCOOL®...
Page 107: Belt Tension
Specifications Engine (Continued) Units Built Prior to October 2016 Units with coolant expansion tank only Coolant System Capacity: T-680R, T-680S, T-880R, T-880S 6.0 quarts (5.7 liters) T-1080R, T-1080S 6.5 quarts (6.2 liters) 15 psig (103 kPa) Coolant Expansion Tank Cap Pressure 7 psig (48 kPa) after November 2015 Units Built After October 2016 Units with coolant expansion tank and overflow bottle...
Page 108: Engine Clutch
Specifications Engine Clutch Engagement 600 ± 100 RPM Dynamic Torque 66 ft-lb (89.5 N•m) minimum @ 1600 RPM Refrigeration System Reciprocating Compressor Compressor Model: Unit Model: T-680R and T-880R Thermo King X214 T-1080R Thermo King X426 Refrigerant Charge: T-680R 8.0 lb (3.6 kg) R-404A T-880R 8.5 lb (3.9 kg) R-404A T-1080R...
Page 109: Scroll Compressor
Specifications Refrigeration System Suction Pressure Regulator Valve Setting: T-680R 28 to 31 psig (193 to 214 kPa) T-880R 35 to 37 psig (241 to 255 kPa) T-1080R 21 to 23 psig (145 to 159 kPa) High Pressure Cutout Switch: Open 470 ±...
Page 110: Electrical Control System
Specifications Refrigeration System Compressor Oil Type Ester base P/N 203-516 required for Scroll compressor Discharge Pressure Regulator Valve Setting 350 ± 5 psig (2413 ± 34 kPa) High Pressure Cutout Switch: Open 470 ± 7 psig (3241 ± 48 kPa) Close 375 ±...
Page 111: Fuses
Specifications Fuses Fuse Size Function Power to On/Off Switch Fuel Sol Pull-In/Starter Circuit None No Fuse - All Bosch and Thermo King Alternators 2A Fuse - All Prestolite Alternators Preheat Circuit Damper and High Speed Circuits 8XP Circuit - Controller On Feedback to HMI 2A Power to CAN Connector J12 2A Power to CAN Connector J14 8X Power (Install fuse in right position)
Page 112: Electrical Components
Specifications Fuses (Continued) Fuse Size Function 7.5A HPCO Switch Circuit Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with Prestolite Alternator. F10 When fuse F10 is installed in the right position the On/Off keys on the HMI turn the unit on and off. When fuse F10 is installed in the left position the unit will start and run without the HMI control panel.
Page 113 Specifications Electrical Components (Continued) Component Current Draw (Amps) Resistance at 12.5 Vdc (Ohms) Condenser Inlet Solenoid (CIS) Hot Gas Solenoid (HGS) 11.3 Purge Valve (PV) 11.3 Liquid Injection Solenoid (LIS) (Scroll Compressor 11.3 only) Electronic Throttling Valve (ETV) if used: Coil A (Red [EVA] and Blue [EVB] Wires) —...
Page 114: Smartpower Electrical Standby (Model 50 Units Only)
Specifications SmartPower Electrical Standby (Model 50 Units Only) T-680R, T-680S, T-880R, T-880S Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts Full Load Overload Relay (amps) Setting (amps) 230/3/50 1460 17.0 230/3/60 1765 19.4 400/3/50 1460 460/3/60 1765 T-1080R & T-1080S Electric Motor and Overload Relay Voltage/Phase/Frequency Horsepower Kilowatts...
Page 115: Electric Heater Strips (Optional)
Specifications Electric Heater Strips (Optional) Number Watts 750 watts (each) Resistance 71 ohms (each) SmartPower Standby Power Requirements Supply Circuit Breaker: T-680R, T-680S, T-880R & T-880S 230/3/60 30 amps T-1080R & T-1080S 50 amps 230/3/60 20 amps All 380-460/3/50-60 Extension Cord Size: Up to 50 ft—10 gauge 75 ft—8 gauge...
Page 116: Maintenance Inspection Schedule
Maintenance Inspection Schedule A closely followed maintenance program will help to keep After first week of operation: your Thermo King unit in top operating condition. The • Check belt tension. following general schedule is provided to assist in monitoring • Tighten unit mounting bolts.
Page 117 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours • • Check condition of belts. • • Check engine oil pressure hot, on high speed. • • • • Listen for unusual noises, vibrations, etc. •...
Page 118 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours • Check coolant levels (cool) Coolant Expansion Tank: The expansion tank must always be completely full of coolant when cool. Coolant Overflow Bottle: Coolant level in overflow bottle must always be at or above the FULL COLD mark of the bottle when cool.
Page 119 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Electrical • Check controller for alarms. • Run pretrip test • Check battery voltage. • Inspect battery terminals and electrolyte level. • Inspect wire harness for damaged wires or connections. •...
Page 120 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Refrigeration • • Check refrigerant level. • Check compressor oil level. • Check suction pressure regulator setting on Defrost or Heat. • Check discharge and suction pressures. •...
Page 121 Maintenance Inspection Schedule Pretrip 1,200 2,000 Annual/ Inspect/Service These Items Hours Hours 3,000 Hours Structural • • Visually inspect unit for fluid leaks. • • Visually inspect unit for damaged, loose or broken parts (includes air ducts and bulkheads). • •...
Page 122: Warranty
Warranty Terms of the Thermo King Warranty are available on request. Please reference document TK 50047 for the Thermo King Self-Powered Truck Unit Warranty.
Page 123: Serial Number And Refrigerant Label Locations
Serial Number and Refrigerant Label Locations Write the unit model and unit serial number in the spaces provided in the following Emergency Cold Line chapter. This information is needed to service the unit. Figure 125: Scroll Compressor Serial Number Location, Figure 124: Engine Serial Number Location...
Page 124 Serial Number and Refrigerant Label Locations AQA183 Figure 127: X426 Reciprocating Compressor Serial Figure 126: X214 Reciprocating Compressor Serial Number Location Number Location...
Page 125 Serial Number and Refrigerant Label Locations Figure 129: Laminated Unit Serial Number Plate Unit Serial Plate Refrigerant Type Figure 128: Label Locations Figure 130: Refrigerant Type Label...
Page 126: 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 127: Emergency Cold Line
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 128: California Proposition 65 Warning
CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
Page 132 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. ©2013 Ingersoll-Rand Company Printed in U.S.A.

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