T-570R - Thermo King
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
T-570R
TK 55179-1-OP (Rev. 1, 05/2012)
©2011 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2011 Ingersoll-Rand Company
Printed in U.S.A.
T-570R
TK 55179-1-OP (Rev. 1, 05/2012)
T-570R
TK 55179-1-OP (Rev. 1, 05/2012)
Copyright© 2011 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
2
Introduction
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a
regular basis will minimize on-the-road operating problems. A
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
IMPORTANT: This manual is published for informational
purposes only and the information furnished herein should
not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Thermo King Service Directory for the location and
telephone number of the local dealer.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
•
They are equipped with the factory recommended tools to
perform all service functions
•
They have factory trained and certified technicians
•
They have genuine Thermo King replacement parts
•
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
3
Introduction
4
Table of Contents
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 9
Battery Installation and Cable Routing . . . . . . . . . . . . 10
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 12
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 12
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 13
Model 50 Units (Electric Standby) . . . . . . . . . . . . 15
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . .
17
17
17
18
19
19
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Reciprocating Compressor . . . . . . . . . . . . . . . . . .19
TSD Control Panel . . . . . . . . . . . . . . . . . . . . . . . .19
CYCLE-SENTRYTM Start/Stop System . . . . . . . .20
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Electric Standby (Model 50 Units Only) . . . . . . . . . . . .21
Standard Model 50 Features . . . . . . . . . . . . . . . . .21
Engine Compartment Components . . . . . . . . . . . .21
Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Standard Display (TSD) Control Panel . . . . . . . . .25
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Keys and LED Indicators . . . . . . . . . . . . . . . . . . . . . . .27
Turning the Unit On and Off . . . . . . . . . . . . . . . . . . . . .33
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . .34
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . .35
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . .36
Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . .37
Switching from Diesel to Electric . . . . . . . . . . . . . . . . .38
5
Table of Contents
Switching from Diesel Mode to Electric Mode . . . . 38
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . 39
Switching from Electric to Diesel Mode . . . . . . . . . . . . 39
Selecting CYCLE-SENTRY or Continuous Mode . . . . 41
Diesel Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Electric Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Selecting the High Speed Lock-Out Feature . . . . . . . . 42
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . 43
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TSR Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sending a Servicewatch Data Logger Start of Trip . . . 56
Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Pretrip Test Conditions . . . . . . . . . . . . . . . . . . . . . 56
Conditions where Pretrip Tests are not allowed . . 56
Pretrip Test Sequence . . . . . . . . . . . . . . . . . . . . . 56
Pretrip Test Considerations . . . . . . . . . . . . . . . . . 58
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . 58
Starting a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . 58
Pretrip Test Results . . . . . . . . . . . . . . . . . . . . . . . 60
TSD Control Panel Display Brightness . . . . . . . . . . . . 61
Keypad Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checking TSD Control Panel Software Revision and
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Checking or Setting Unit Time and Date . . . . . . . . . . . 63
6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control System . . . . . . . . . . . . . . . . . . . . . .
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Standby (Model 50 Units Only) . . . . . . . . . .
Electric Motor and Overload Relay . . . . . . . . . . .
Standby Power Requirements . . . . . . . . . . . . . . .
65
65
68
68
68
70
71
72
74
74
74
Maintenance Inspection Schedule . . . . . . . . . . . . . 75
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 89
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 90
CALIFORNIA Proposition 65 Warning . . . . . . . . . . 91
Safety Precautions
Safety Precautions
Thermo King recommends that all services be performed by a
Thermo King dealer. However, there are several general safety
practices which you should be aware of:
WARNING: Always wear goggles or safety glasses
when working with or around the refrigeration
system or battery. Refrigerant or battery acid can
cause permanent damage if it comes in contact with
your eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating
or when opening or closing compressor service
valves.
WARNING: Exposed coil fins can cause painful
lacerations. Service work on the evaporator or
condenser coils is best left to a certified Thermo King
technician.
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Never drill into
structural components.
Automatic Start/Stop Operation
This unit is capable of automatic operation and may start at any
time without prior warning.
WARNING: The unit may start at any time when the
controller is turned on. The controller display lights
up when the controller is turned on.
WARNING: Units equipped with electric standby may
start at any time when the unit is connected to live
electric power and the controller is turned on.
9
Safety Precautions
WARNING: Be sure to press the OFF key to turn the
controller off before opening doors or inspecting any
part of the unit.
Battery Installation and Cable
Routing
WARNING: Improperly installed battery could
result in a fire or explosion! A Thermo King
approved battery must be installed and properly
secured to the battery tray.
WARNING: Improperly installed battery cables
could result in fire or explosion! Battery cables
must be installed, routed and secured properly to
prevent them from rubbing, chaffing or making
contact with hot, sharp or rotating components.
WARNING: Do not attach fuel lines or any
additional wiring harnesses to the battery cables as
this could cause an electrical fire!
10
CAUTION: Do not connect other manufacturer’s
equipment or accessories to the Thermo King unit.
This could result in severe damage to equipment
and void the warranty!
CAUTION: Set all unit electrical controls to the
OFF position before connecting battery cables to
the battery to prevent unit from starting
unexpectedly and causing personal injury.
CAUTION: Always wear protective clothing,
gloves and eye wear when handling and installing
batteries. Battery acid can cause serious burns
when exposed to eyes or skin. If battery acid
contacts skin or clothing, wash immediately with
soap and water. If acid enters your eye,
immediately flood it with running cold water for at
least twenty minutes and get medical attention
immediately.
Safety Precautions
CAUTION: Always cover battery terminals to
prevent them from making contact with metal
components during battery installation. Battery
terminals grounding against metal could cause the
battery to explode.
Electrical Hazard
CAUTION: Be sure to turn off the high voltage
power supply, and disconnect the electric cable before
working on the unit. Units with electric standby
present a potential electrical hazard.
Refrigerant
Although fluorocarbon refrigerants are classified as safe,
observe caution when working with refrigerants or around
areas where they are being used in the servicing of your unit.
DANGER: Fluorocarbon refrigerants may produce
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
11
Safety Precautions
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
First Aid
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. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until arrival of emergency medical
personnel.
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.
12
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until arrival of emergency
personnel.
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Safety Precautions
Safety Decals and Locations
Figure 1: Antifreeze Caution
(Attached near radiator fill cap.)
ARB108
Figure 2: ELC (Extended Life Coolant) Nameplate
(Located On Expansion Tank In Units Equipped With
ELC)
13
Safety Precautions
AKA99
AKA98
Figure 3: Belt Caution (Locations vary depending on
model. Decals are located near areas that contain
belts and fans which can cause severe injuries if
hands or clothing become tangled.)
14
Figure 4: Automatic Start Caution (Locations vary
depending on model. Decals are located near areas
that contain moving parts which can cause severe
injuries if hands or clothing become tangled when the
unit automatically starts.)
Safety Precautions
Model 50 Units (Electric Standby)
CAUTION FAN
ACHTUNG VENTILATOR
91-4815
ATTENTION VENTILATEUR
ATTENZIONE VENTILATORE
CUIDADO VENTILADOR
AKB01
ARA183
Figure 5: Fan Caution (Locations vary depending on
model. Decals are located near areas that contain
fans which can cause severe injuries if hands or
clothing become tangled.)
Figure 6: Electrical Hazard (Locations vary
depending on model. Typically located near power
receptacle, high voltage tray cover and interface
board.)
AKB02
Figure 7: High Voltage Caution
(Located near high voltage box.)
15
Safety Precautions
16
Unit Description
Introduction
The T-570R is a microprocessor based transport temperature
control system that uses the TSD Control Panel to manage
system functions.
The unit is a one-piece, front-mounted, diesel powered cooling
and heating system designed for straight trucks. The unit
mounts on the front of a truck with the evaporator portion
protruding into the box. It is designed for use with chlorine free
refrigerants. The basic models provide the following:
Model 30: Cooling and hot gas heating on engine operation.
Model 50: Cooling and hot gas heating on engine
operationand electric standby operation. Electric evaporator
heaters are optional.
Engine power for the unit is provided by a diesel engine.
Optional electric standby power (Model 50) is provided by an
electric motor. A clutch on the diesel engine isolates the engine
during electric standby operation.
The continuous monitoring function of the TSD
microprocessor optimizes the unit’s performance, reducing fuel
consumption and unit down time. The unit has a self check
feature that can be run before the daily distribution route to
identify possible malfunctions.
The built-in CYCLE-SENTRY, an exclusive Thermo King
feature, automatically starts and stops the unit according to
temperature demands.
Design Features
•
Microprocessor Controller, TSD
•
Alarm Code Display
•
Continuous System Monitoring
•
CYCLE-SENTRYTM Start/Stop Controls
•
Engine and Electric (Model 50) Hour Display
•
In-Cab Remote
17
Unit Description
•
Smart Defrost
•
X214 Compressor
•
Symbolic Controller Interface
•
Stainless Steel Condenser and Evaporator Hardware
•
Unit Self Check-pretripping
•
TK370 Tier 4 Diesel EngineOptional Features
•
Aerodynamic Thermo Plastic Recyclable Injection
Molded Skins with In-mold Color
Unit Options
•
Air Cleaner, Dry Type Alternator, 12 Volt, 37 Amp
•
Easy-Read Thermometer
•
Automatic Phase Correction (Model 50)
•
Electric Standby Operation (Model 50)
•
Bypass Oil Filter
•
Engine Block Heater
•
Coolant Expansion Tank
•
Fuel Tank
•
Fahrenheit and Celsius Scales
•
Hose Management System
•
Fuel Filter, Spin On
•
Quick Oil Drain Kit
•
Low Decibel Kit
•
Remote Indicator Light
•
Oil Filter, Full Flow
•
Top Cover System
•
Poly-V Stretchy Belt System with Quiet Channel
Technology
•
R-404A Chlorine-free Refrigerant
•
Robotic Welded Steel Frame with Automotive Grade 2
Coat Paint Finish
18
Unit Description
Engine
Clutch
Engine Engine power is provided by the TK370, a
three-cylinder, EPA Tier 4, special clean and quiet diesel
engine rated at 15.0 continuous horsepower (11.2 kW) at 2200
RPM. A belt drive system transfers energy to the compressor,
unit fans, and alternator.
The centrifugal clutch engages fully at 600 ± 100 RPM on
engine operation, constantly turning the compressor, alternator,
and fans at both high and low speed. The clutch isolates the
engine from the belt drive system during electric standby
operation on Model 50 units.
ELC (Extended Life Coolant)
Reciprocating Compressor
The maintenance interval for ELC is five years or 12,000
hours. A nameplate on the coolant expansion tank identifies
units with ELC (see “Safety Decals and Locations”). The new
engine coolant, Texaco Extended Life Coolant, is Red instead
of the previous Green or Blue-Green coolants.
The unit features the X214, 2 cylinder reciprocating
compressor with 13.92 cu in (229 cc) displacement.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to ensure that deionized water is being used. If 100% full
strength concentrate is used, deionized or distilled water is
recommended instead of tap water to ensure the integrity of
the cooling system is maintained.
TSD Control Panel
The TSD Control Panel is used to operate the unit and display
unit information. The Control Panel is typically located in the
vehicle driver's compartment and communicates with the base
controller using a connection on the interface board.
19
Unit Description
The system monitors and maintains the compartment
temperature, the engine block temperature, and battery charge
levels at a point where quick, easy starts are possible.
Defrost
Figure 8: TSD Control Panel
Frost will gradually build up on the evaporator coils as a result
of normal operation. Periodically this frost must be melted to
prevent a loss of cooling and airflow.
The CYCLE-SENTRY Start/Stop fuel saving system provides
optimum operating economy.
Defrost is accomplished by passing hot refrigerant gas through
the evaporator coil, thus melting the frost (or ice). Melted frost
drains out of the unit onto the ground through the drain tubes.
The defrost damper closes during defrost to prevent warm air
from entering the cargo area. The optional electric heater strips
are also energized in defrost during electric standby operation.
WARNING: Turn the unit off by pressing the OFF key before
opening doors or inspecting any part of the unit. The unit can
start at any time without warning if it has been turned on by
pressing the ON key.
Defrost can be initiated at any time the evaporator coil
temperature is below 42 F (5.5 C).
CYCLE-SENTRYTM Start/Stop System
The CYCLE-SENTRY system automatically starts the unit on
microprocessor demand and shuts down the unit when all
demands are satisfied.
20
There are two methods of defrost initiation:
TSD Controller: The Microprocessor Controller is
programmed to automatically initiate timed and forced defrost
cycles. The TSD uses temperature sensors to determine if
forced defrost is required.
Unit Description
Manual Defrost: Manual Defrost allows the operator to
initiate a defrost cycle by pressing the DEFROST key. See
“Initiating a Manual Defrost Cycle.”
Electric Standby (Model 50 Units
Only)
The Electric Standby option allows the unit to be operated on
either the diesel engine or external electric power.
DANGER: High voltage AC power is present whenever the
unit is operating in the Electric mode and whenever the unit
is connected to external standby power. Voltages of this
magnitude can be lethal. Exercise extreme caution when
working on the unit.
Standard Model 50 Features
The following features are standard equipment on units
equipped with Electric Standby.
Automatic Diesel/Electric Selection: The unit will
automatically switch to electric operation when a power cord is
connected and the standby power is switched On.
Overload Relay: The overload relay is self-resetting.
Hot Gas Heat: Hot gas heat is utilized on all units.
Automatic Phase Correction: The control system
features two motor contactors. This allows correct motor
rotation regardless of phase rotation on the incoming power.
Engine Compartment Components
Coolant Expansion Tank: The coolant level and
temperature are monitored by the base controller. If the coolant
temperature becomes too high or the level becomes too low, an
alarm will occur.
The engine must have antifreeze protection to –30 F (–34 C).
Check and add coolant in the expansion tank as needed.
CAUTION: Do not remove expansion tank cap while the
coolant is hot.
CAUTION: Do not add Green or Blue-Green coolants to
cooling systems that use Red Extended Life Coolants.
21
Unit Description
Engine Oil Dipstick: Use the engine oil dipstick to check
the engine oil level. Receiver Tank Sight Glass: The receiver
tank sight glass is used to assist in checking the amount of
refrigerant in the system.
Preheat Buzzer: The preheat buzzer sounds when the
CYCLE-SENTRYTM system energizes the glow plugs. This
should warn anyone near the unit that the CYCLE-SENTRY
system is about to start the diesel engine.
Compressor Oil Sight Glass: The compressor oil sight
glass is used to check the relative level of compressor oil in the
compressor sump.
Coolant Temperature Sensor: This sensor provides an
engine coolant temperature input to the microprocessor. If the
engine coolant temperature is too high, the controller stops the
unit and records an alarm.
Protection Features
Electric Motor Overload Relay (Model 50): The
overload relay protects the electric standby motor.
High Pressure Cutout Switch (HPCO): This normally
closed switch monitors the discharge pressure at the
compressor. It opens on high discharge pressure to shut the unit
down to prevent damage.
Suction Pressure Regulator (SPR): This component is a
mechanical control device used to limit the suction pressure to
the compressor. The valve controls suction pressure based on
the actual system pressure.
Engine Oil Pressure Switch/Sensor: Engine oil
pressure should rise immediately on starting. If engine oil
pressure drops below the acceptable level, the switch/sensor
signals the microprocessor to stop the engine.
22
Fuses: Sizes and functions are described in the
Specifications section of this manual.
Unit Description
Figure 9: T-570R Front View
23
Unit Description
1
2
3
4
5
6
7
8
Figure 10: Main Components
24
1.
Engine Oil Dipstick (on
side of engine)
2.
Engine
3.
Coolant Expansion Tank
4.
Electric Motor
5.
Alternator
6.
Compressor
7.
Dehydrator (Filter-Drier)
8.
On/Off Switch
Unit Operation
Standard Display (TSD) Control Panel
The Truck Standard Display (TSD) Control Panel is supplied
as standard equipment on TSR Single Temperature Truck
applications. It is used to operate the unit and display some unit
information. The Truck Standard Display (TSD) Control Panel
is typically located in the vehicle driver's compartment. It may
be located in the truck dashboard using a DIN mounting ring or
under the dashboard using an under dash mounting kit.
•
The Truck Standard Display (TSD) Control Panel consists
of a display and nine touch-sensitive keys.
•
The display is capable of showing numbers and lighting
several icons. It does not display text, thereby making it
suitable for use with any language.
•
Amber indicator LED's are located next to each of the four
function keys below the display. The LED will light when
that function is active.
•
A red indicator LED is located between the ON Key and
OFF Key. This indicator will glow if Alarm Code 91
Check Electric Ready Input occurs. It will also glow if a
15 pin Thermo King data cable is connected to the serial
port on the back of the controller (DPD).
Controller Features
Figure 11: Truck Standard Display (TSD)
Control Panel
•
Displays Box Temperature and Setpoint in Fahrenheit or
Celsius
•
Displays Engine Running and Motor Running Hourmeters
25
Unit Operation
•
Changes Setpoint
•
Selects and Indicates CYCLE-SENTRY or Continuous
Mode Operation
•
Selects and Indicates High Speed Lock-Out Operation
•
Initiates and Indicates a Defrost Cycle
•
Indicates an Alarm Condition Exists, Displays and Clears
Alarms
•
Initiates and Indicates a Pretrip Test
•
Sends a Start of Trip to the ServiceWatch data logger.
•
Changes Display Brightness
•
Shows TSD Control Panel Serial Number and Software
Revision.
Figure 12: Display
The upper row of numbers can display the Box Temperature,
Engine Run Time Hourmeter or Alarm Code(s).
The lower row of numbers can display the Setpoint, Electric
Run Time Hourmeter or Total Number of Alarms.
The meaning of the display icons are shown in the table below.
Display
The display presents information to the operator. This
information includes setpoint and box temperature, hourmeter
readings, alarms and several icons as shown below. All display
segments and icons are shown in Figure 12.
26
When this icon is present the upper
display is showing the actual box
temperature inside the truck box.
Unit Operation
When this icon is present the lower
display is showing the current setpoint.
When this icon is present the upper
display is showing the diesel engine
run time.
When this icon is present the lower
display is showing the electric motor
run time (if the unit equipped with
optional ELECTRIC STANDBY).
When this Alarm Icon is present one or
more alarm conditions have occurred.
If the display is not flashing any alarms
are Check Alarms. If the display is
flashing on and off a shutdown alarm
has occurred and the unit has been
shut down. Immediate action must be
taken.
Keys and LED Indicators
There are nine touch sensitive keys. Some of these keys have
more than one function as shown in Figure 13.
Figure 13: Keys and LED Indicators
27
Unit Operation
There are amber indicator LED's located next to each of the
four function keys below the display. The LED will glow
amber when that function is active.
The primary and secondary key uses are shown in the table
below. If the key has more than one use the primary use is
shown first.
A red indicator LED is located between the ON Key and OFF
Key at the left side of the display. This indicator will glow if
Alarm Code 91 Check Electric Ready Input occurs. It will also
light if a 15 pin Thermo King data cable is connected to the
serial port on the back of the controller (DPD).
ON Key
Pressing the ON Key will turn the unit on.
Secondary Use - When the unit is on, pressing this key and the PRETRIP Key at the same time will
display any alarm codes that are present.
Secondary Use - When the unit is on, pressing and holding this key allows the UP ARROW Key
and DOWN ARROW Key to increase or decrease the display brightness.
Secondary Use - When the unit is on, pressing this key will return to the Standard Display of box
temperature and setpoint.
28
Unit Operation
POWER OFF Key
Pressing the OFF Key will turn the unit off.
UP ARROW Key
Primary Use - When the unit is turned on and the Standard Display is shown, pressing the UP
ARROW Key will increase the setpoint.
Secondary Use - When alarms are being displayed, pressing this key will scroll thru the alarms (if
more than one alarm is present).
Secondary Use - While holding ON Key down with the unit turned on, pressing this key will increase
the display brightness (Low, Medium, High).
DOWN ARROW Key
Primary Use - When the unit is turned on and the Standard Display is shown, pressing the DOWN
ARROW Key will decrease the setpoint.
Secondary Use - While holding ON Key down with the unit turned on, pressing this key will
decrease the display brightness (High, Medium, Low).
29
Unit Operation
ENTER Key
If the setpoint has been changed using the UP ARROW Key and/or DOWN ARROW Key, pressing
the ENTER Key enters the setpoint into the base controllers memory.
Secondary Use - When alarms are being displayed, pressing this key will clear the alarm shown on
the display.
Secondary Use - When the unit is turned on, press and hold this key for 5 seconds to send a Start
of Trip (SOT) to the data logger.
CYCLE-SENTRY/Continuous Key
Primary Use - If the unit is turned on and is in Continuous Mode, pressing the
CYCLE-SENTRY/CONTINUOUS Key will switch operation to CYCLE-SENTRY Mode and the
amber LED indictor will glow. If the unit is running in CYCLE-SENTRY Mode, pressing this key will
switch operation to Continuous Mode and the amber LED will turn off.
30
Unit Operation
HIGH SPEED LOCK-OUT Key
Primary Use - If the unit is turned on, pressing the HIGH SPEED LOCK-OUT Key will activate High
Speed Lock-Out. The unit will switch to low speed operation and the amber LED indictor will glow.
No further high speed operation is allowed until this feature is turned off. Unit may automatically
return to high speed operation after a programmed time limit if timer feature is enabled.This feature
is typically used in noise sensitive areas to reduce unit noise.
NOTE: The HIGH SPEED LOCK-OUT Key is only used when the unit is operating in Diesel Mode. The
HIGH SPEED LOCK-OUT Key does not have any effect in Electric Mode operation.
DEFROST Key
Primary Use - If the unit is turned on, pressing the DEFROST Key will initiate a manual defrost
cycle if conditions allow. If the evaporator coil temperature less than 45 F (7 C) the unit will enter a
defrost cycle. The amber LED will flash while the defrost cycle is initialized and will glow during the
defrost cycle. The defrost cycle will terminate automatically and the amber LED will turn off when
the evaporator coil temperature is greater than 52 F (11 C). To manually terminate a defrost cycle
turn the unit off and back on.
31
Unit Operation
PRETRIP TEST Key
Primary Use - Pressing and holding the PRETRIP TEST Key for 5 seconds will initiate either a Full
Pretrip Test or Engine Running Pretrip Test so long as no alarm conditions exist. If the Alarm Icon is
glowing, record and clear the alarms before starting the Pretrip Test.
Press and hold the PRETRIP TEST Key for 5 seconds. If the unit is not running when the PRETRIP
TEST Key is pressed the unit will perform a Full Pretrip that includes circuit amps and running
system checks. If the unit is running when the PRETRIP TEST Key is pressed the unit will perform
the running system checks only. The amber LED may flash while the Pretrip Test is initialized and
will glow steady while the Pretrip Test is running. When the Pretrip Test is complete the amber LED
will turn off.
• If there are no alarm codes set when the Pretrip Test is complete, the unit passed.
• If there are alarm codes set when the Pretrip Test is complete, the unit failed. Check and correct
the alarm conditions and repeat the test.
• If a shutdown alarm occurred, Alarm Code 28 Pretrip Abort will be set and the unit will be shut
down. Check and correct the alarm conditions and repeat the test.
Secondary Use - When the unit is turned off press and hold this key for 5 seconds to show the TSD
Control Panel Serial Number (in the upper display) and the HMI Control Panel Software Revision
(in the lower display).
32
Unit Operation
Turning the Unit On and Off
The unit is turned on by pressing the ON Key and off by
pressing the OFF Key. When the ON Key is pressed the
display briefly shows dashes as the display initializes.
Figure 15: Electric Motor Run Time Hours
and Electric Icon
Figure 14: Keys and LED Indicators
Then the unit running time hourmeters are shown for 30
seconds. The diesel engine run time hours and Diesel Icon are
shown in the upper display. If the optional Electric Standby
Feature is installed, the electric motor run time hours and
Electric Icon are shown in the lower display.
When the unit is ready to run the Standard Display of box
temperature and setpoint appears. The box temperature and
Box Temp Icon are shown in the upper display. The setpoint
and Setpoint Icon are shown in the lower display. The box
temperature shown in Figure 16 is 35.8 F (2.1 C) with a 35 F
(1.6 C) setpoint.
33
Unit Operation
The Standard Display
Figure 16: Standard Display of Box temperature and
Setpoint
The Standard Display is the default display that appears if no
other display function is selected. The Standard Display shows
the box temperature and setpoint. The box temperature is that
measured by the return air sensor. The box temperature and
Box Temperature Icon are shown in the upper display. The
setpoint and Setpoint Icon are shown in the lower display. The
box temperature in Figure 18 is 35.8 F (2.1 C) with a 35 F (1.6
C) setpoint.
Pressing the OFF Key stops unit operation. The unit shuts
down immediately and the display goes blank. To start the unit
again, press the ON Key.
Figure 18: Standard Display
Figure 17: ON Key
34
Unit Operation
Changing the Setpoint
From the Standard Display, press the UP ARROW Key and/or
DOWN ARROW Key until the desired setpoint is shown. In
Figure 19 the setpoint has been increased to 40 F (4.4 C) using
the UP ARROW Key.
•
If the setpoint is changed using the UP ARROW Key and
DOWN ARROW Key, the setpoint display will begin to
flash 10 seconds after the last press of the UP ARROW or
DOWN ARROW key as a reminder to press the ENTER
Key.
•
The setpoint display will flash for 10 additional seconds. If
at the end of this time the ENTER Key still has not been
pressed to complete the setpoint change, the setpoint will
return to the old setpoint and Alarm Code 127 Setpoint
Not Entered will be set. The Alarm Icon will appear in the
display.
Figure 19: UP ARROW Key
When the desired setpoint has been selected using the UP
ARROW Key or DOWN ARROW Key, the ENTER Key must
be pressed within about 20 seconds to confirm and load the
new setpoint.
Figure 20: ENTER Key
The new setpoint of 40 F (4.4 C) will remain on the display
after the ENTER Key has been pressed.
35
Unit Operation
Failure to confirm the new setpoint by pressing the ENTER
Key within 20 seconds of changing the setpoint will result in
no setpoint change. In addition, Alarm Code 127 Setpoint Not
Entered is set, to indicate that the setpoint change was started
but was not completed.
Figure 21: Alarm Icon and Setpoint
Notice that the setpoint has returned to the old setpoint of 35 F
(1.6 C) and the Alarm Icon has lighted indicating that Alarm
Code 127 Setpoint Not Entered is set.
IMPORTANT: If the setpoint is changed using the UP
ARROW Key or DOWN ARROW Key, the change must be
confirmed by pressing the ENTER Key within 20 seconds of
changing the setpoint.
36
•
If the ENTER Key is pressed, the setpoint change made
with the UP ARROW Key and/or DOWN ARROW Key is
accepted, the setpoint is changed, and the display returns
to the Standard Display showing the new setpoint.
•
If the ENTER Key is not pressed within 20seconds of
making a change with the UP ARROW Key and/or
DOWN ARROW Key, the setpoint is not changed and the
display returns to the Setpoint Display showing the old
setpoint. Alarm Code 127 Setpoint Not Entered is set and
the Alarm Icon will appear on the display, to indicate that
the setpoint change was started but not completed.
Starting the Diesel Engine
Verify the Base Controller On/Off switch is in the ON position.
Diesel engine preheats and starts are automatic in both
Continuous Mode and CYCLE-SENTRY Mode. The engine
will preheat and start as required when the unit is turned on.
The engine pre-heat and start sequence will be delayed in
Cycle Sentry mode if there is no current need for the engine to
run.
Unit Operation
NOTE: If the unit is equipped with optional Electric Standby
there may be some additional prompts before the engine will
start. See STARTING THE ELECTRIC MOTOR on the
following pages for details.
CAUTION: The engine may start automatically any time the
unit is turned on.
WARNING: Never use starting fluid.
When the engine is preparing to start, the TSD Control Panel
will continue to display the Standard Display as shown in
Figure 22. The preheat buzzer at the unit (located on the unit
Interface Board) sounds during the engine pre-heat and crank
sequence.
Starting the Electric Motor
Units equipped with the Electric Standby option only.
Verify the Base Controller On/Off switch is in the ON position.
Electric motor starting is automatic in both Continuous Mode
and CYCLE-SENTRY Mode. The motor will start as required
when the unit is turned on in Standby Mode and standby power
is connected.
CAUTION: The motor may start automatically any time the
unit is turned on.
When the motor is preparing to start, the TSD Control Panel
will continue to show the Standard Display as shown in Figure
23. The preheat buzzer at the unit (located on the Base
Controller) sounds for 20 seconds before the electric motor
starts.
Figure 22: Standard Display
37
Unit Operation
•
When running in Diesel Mode, a TSR unit can operate in
either Cycle Sentry or Continuous. Cycle Sentry or
Continuous operation is selectable by the operator in
Diesel Mode.
•
When a TSR unit is switched from Diesel Mode to
Electric Mode, the unit is forced to Cycle Sentry
operation. Continuous operation is not available in
Electric Mode. However, the previous Diesel Mode
operating condition (Cycle Sentry or Continuous) is held
in memory. This information is retained even if the unit is
turned off.
•
When a TSR unit is switched from Electric Mode to
Diesel Mode, the unit is forced to the previous Diesel
Mode operating selection, either Cycle Sentry or
Continuous. Cycle Sentry or Continuous operation is
selectable by the operator in Diesel Mode.
Figure 23: Standard Display
Switching from Diesel to Electric
IMPORTANT: Applies to units with the Electric Standby
Option only.
IMPORTANT: Diesel to Electric Auto Switch
IMPORTANT: and Electric to Diesel Auto Switch are not
IMPORTANT: programmable features on TSR Truck units.
Diesel to Electric Auto Switch is set [YES] on TSR units and
cannot be changed. Electric to Diesel Auto Switch is set [NO]
on TSR units and cannot be changed.
IMPORTANT: Cycle Sentry and Continuous operating
modes are allowed as shown below.
38
Switching from Diesel Mode to
Electric Mode
The unit will switch automatically from Diesel Mode to
Electric Mode when standby power is connected and present.
Unit Operation
Switching from Electric to Diesel
IMPORTANT: Applies to units with the Electric Standby
Option only.
IMPORTANT: Cycle Sentry and Continuous operating
modes are allowed as shown below.
•
When running in Diesel Mode, a TSR unit can operate in
either Cycle Sentry or Continuous. Cycle Sentry or
Continuous operation is selectable by the operator in
Diesel Mode.
•
When a TSR unit is switched from Diesel Mode to
Electric Mode, the unit is forced to Cycle Sentry
operation. Continuous operation is not available in
Electric Mode. However, the previous Diesel Mode
operating condition (Cycle Sentry or Continuous) is held
in memory. This information is retained even if the unit is
turned off.
•
When a TSR unit is switched from Electric Mode to
Diesel Mode, the unit is forced to the previous Diesel
Mode operating selection, either Cycle Sentry or
Continuous. Cycle Sentry or Continuous operation is
selectable by the operator in Diesel Mode.
Switching from Electric to Diesel
Mode
If the unit is operating in Electric Mode and standby power is
disconnected or fails, the unit will not automatically switch to
Diesel mode. This is primarily designed to prevent
unauthorized diesel engine starts when the truck is indoors or
on a ferry where engine operation is strictly prohibited.
If the unit is operating in Electric Mode and standby power is
disconnected or fails, Alarm Code 91 Check Electric Ready
Input will be set. The red LED between the ON key and OFF
Key will glow, the Alarm Icon will glow and the box
temperature and setpoint displays will disappear as shown in
Figure 24.
Figure 24: Alarm Icon
39
Unit Operation
Alarm Code 91 Check Electric Ready Input will be cleared and
the unit will restart automatically if power is restored.
3.
Pressing the ON Key will clear Alarm Code 91 Check Electric
Ready Input and turn the unit back on in Diesel Mode. If unit
operation is required, the diesel engine will start as shown
previously in STARTING THE DIESEL ENGINE.
Press the TSD Control Panel ON Key to turn the unit on.
The Hourmeters display will briefly appear and then the
screen will appear as shown in Figure 26.
Figure 26: Display, Preferred Method for Manually
Switching from Electric Mode to Diesel Mode
4.
Figure 25: Press ON Key
Preferred Method for Manually Switching
from Electric Mode to Diesel Mode
1.
Press the TSD Control Panel OFF Key to turn the unit off.
2.
Turn off the standby power and disconnect the cord.
40
Press the TSDControl Panel ON Key again to clear Alarm
Code 91 Check Electric Ready Input and turn the unit
back on in Diesel Mode.
IMPORTANT: When the display shown in Figure 26 is
present, do not press the TSD Control Panel OFF Key to turn
the unit off. Press the TSD Control Panel ON Key again to
clear Alarm Code 91 Check Electric Ready Input and turn
the unit back on in Diesel Mode.
Unit Operation
If the TSD Control Panel OFF Key is pressed when the display
shown in Figure 26 is present, the unit will turn off and the
display will be blank.
To restart the unit in Diesel Mode, proceed as follows:
•
Press the TSD Control Panel ON Key. The Hourmeters
display and a blinking Alarm Icon will appear.
•
When the Hourmeters display and a blinking Alarm Icon
is shown, press the TSD Control Panel ON Key again. The
display will go blank but the blinking Alarm Icon will
remain on and blinking.
•
When the display goes blank and the blinking Alarm Icon
is shown, press the TSD Control Panel ON Key again. The
box temperature and setpoint will appear, the blinking
Alarm Icon will disappear and the unit will start in Diesel
Mode.
selected, the unit starts automatically and runs continuously to
maintain setpoint and to provide constant airflow throughout
the truck box.
Diesel Mode
When running in Diesel Mode, CYCLE-SENTRY Mode or
Continuous Mode is selected by pressing the
CYCLE-SENTRY/CONTINUOUS Key when the unit is
turned on. If the unit is running in Continuous Mode, pressing
this key will switch operation to CYCLE-SENTRY Mode and
the amber LED indictor will glow. If the unit is running in
CYCLE-SENTRY Mode, pressing this key will switch
operation to Continuous Mode and the amber LED will turn
off.
The unit shown in Figure 27 is running in CYCLE-SENTRY
Mode.
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
41
Unit Operation
When switched to Electric Mode, the previous Diesel Mode
operating condition (Cycle Sentry or Continuous) is held in
memory. This information is retained even if the unit is turned
off. When the unit is switched back to Diesel Mode, the unit
will operate in the previous Diesel Mode condition.
Figure 27: CYCLE-SENTRY/Continuous Key
CAUTION: The engine may start automatically any time the
unit is turned on.
CAUTION: If the unit is in CYCLE-SENTRY null and the
mode is switched to Continuous Mode, the unit will start
automatically.
Electric Mode
When running in Electric Mode, the unit is forced to Cycle
Sentry operation. Continuous operation is not available when
the unit is running in Electric Mode.
42
Selecting the High Speed
Lock-Out Feature
If the High Speed Lock-Out feature is enabled and turned on,
the unit will run only in low speed until the High Speed
Lock-Out feature is turned off or the High Speed Lockout
Timer is exceeded. This feature is typically used in noise
sensitive areas to reduce unit engine noise.
High Speed Lock-Out is turned on or off by pressing the HIGH
SPEED LOCKOUT Key when the unit is turned on. Pressing
this key will turn High Speed Lock-Out on, pressing it again
will turn High Speed Lockout off. If High Speed Lockout is
turned on, unit will switch to low speed operation and the
amber LED indictor will glow. No further high speed operation
is allowed until this feature is turned off or the High Speed
Lockout Timer is exceeded.
Unit Operation
IMPORTANT: HIGH SPEED LOCKOUT TIMER: If High
Speed Lockout Mode is selected, the High Speed Inhibit
Timeout feature may be enabled to return the unit to normal
operation after a set time period has expired. This prevents
unintended extended operation with high speed operation
locked out. The time period may be set from 15 minutes to 2
hours. If a time period is set and exceeded, the unit will
return to normal operation with high speed operation allowed
and the amber LED indicator will turn off. If necessary to
return to High Speed Lockout Mode, press the HIGH
SPEED LOCKOUT Key again.
The unit shown in Figure 28 has High Speed Lockout turned
on.
NOTE: The HIGH SPEED LOCK-OUT Key is only used
when the unit is operating in Diesel Mode. The HIGH
SPEED LOCK-OUT Key does not have any effect in Electric
Mode operation.
Initiating a Manual Defrost Cycle
Defrost cycles are usually initiated automatically based on time
or demand. Manual defrost may also be available. Defrost is
only available if the unit is running and the evaporator coil
temperature is less than 45 F (7 C). Other features such as door
switch settings may not allow manual defrost under some
conditions.
To initiate a manual defrost cycle, press the DEFROST Key as
shown in Figure 29. If conditions allow, the unit will enter a
defrost cycle and the amber LED next to the DEFROST Key
will glow.
.
Figure 28: HIGH SPEED LOCKOUT Key
43
Unit Operation
Terminating a Defrost Cycle
Figure 29: DEFROST Key
IMPORTANT: During the defrost cycle, the box temperature
will rise toward 50 F (10 C). This is normal and is caused by
the defrost cycle warming the evaporator coil. Since the
damper door is closed during the defrost cycle, this warm air
is not allowed to pass into the truck box.
Figure 30: Box temperature will rise toward
50 F (10 C)
44
The defrost cycle terminates automatically when the coil
temperature is greater than or equal to 52 F (11 C) or the
maximum defrost timer expires. Alarm code 14, Defrost
Terminated by Time, will generate if the maximum defrost
time is exceeded. When the defrost cycle is completed the
amber LED next to the DEFROST Key will turn off. Defrost
can also be terminated by turning the unit off and back on.
Alarms
Alarm Code Notification
If an alarm condition occurs, the Alarm Icon will appear on the
display. If the alarm is a Check Alarm, the Alarm Icon will turn
on but the unit will continue to run. If the alarm is a Shutdown
Alarm, the Alarm Icon and the display will flash on and off and
the unit will shut down.
Unit Operation
.
Figure 31: Alarm Icon
Displaying Alarm Codes
Alarms are displayed by simultaneously pressing and holding
the ON Key and PRETRIP TEST Key. The alarm display will
appear as shown below. The upper display shown in Figure 32
indicates that Alarm Code 127 Setpoint Not Entered has been
set. The lower display indicates that only one alarm code
exists.
Figure 32: ON and PRETRIP TEST Keys
If more than one alarm code has been set, they are displayed
with the most recent alarm shown first. Use the UP ARROW
Key to scroll through the alarms.
Clearing Alarm Codes
After the alarm situation is resolved, press the ENTER Key to
clear the alarm code currently being shown. When all alarms
have been cleared the display will show all zeros to indicate
that no alarm codes exist.
45
Unit Operation
Important Alarm Notes
Figure 33: ENTER Key
•
All alarms must be viewed before any of the alarms can be
cleared.
•
If an alarm will not clear, it may still exist. If the alarm is
not corrected, it will not clear or may be immediately set
again.
•
Some alarms cannot be cleared using the TSD Control
Panel. These alarms must be cleared by maintenance
personnel from the Maintenance or Guarded Access
Menus.
•
Alarm Code 91 Check Electric Ready Input is cleared by
turning the unit off and back on. See SWITCHING FROM
ELECTRIC TO DIESEL in this section.
The display will return to the Standard Display about 30
seconds after all alarms have been cleared.
TSR Alarm Codes
NOTE: Not all alarm codes are used with all applications.
Figure 34: Standard Display
Code
0
46
Description
No Alarms Exist
Operator Help
Unit Operation
Code
Description
Operator Help
2
Check Evaporator
Coil Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
3
Check (Control)
Return Air Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
4
Manually monitor load
Check (Control)
temperature. Report
Discharge Air Sensor
alarm at end of the day.
5
Check Ambient Air
Sensor
Report alarm at end of
the day.
6
Check Coolant Temp Report alarm at end of
Sensor
the day.
7
Check Engine RPM
Sensor
Report alarm at end of
the day.
9
High Evaporator
Temperature
Manually monitor load
temperature. Report
alarm at end of the day.
Code
Description
Operator Help
10
High Discharge
Pressure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
11
Unit Controlling on
Alternate Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
12
Sensor or Digital
Input Shutdown
The indicated zone is not
longer able to operate
and has been shut down.
Repair immediately.
13
Sensor Check
Manually monitor load
temperature. Report
alarm at end of the day.
15
If unit is shut down repair
Check Glow Plugs or immediately. Otherwise,
report alarm at end of the
Intake Air Heater
day.
47
Unit Operation
Code
Description
Operator Help
17
Engine Failed to
Crank
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
18
If unit is shut down repair
High Engine Coolant immediately. Otherwise,
Temperature
report alarm at end of the
day.
19
Low Engine Oil
Pressure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
20
If unit is shut down repair
immediately. Otherwise,
Engine Failed to Start
report alarm at end of the
day.
21
Manually monitor load
Cooling Cycle Check temperature. Report
alarm at end of the day.
48
Code
Description
Operator Help
22
Manually monitor load
Heating Cycle Check temperature. Report
alarm at end of the day.
23
Cooling Cycle Fault
The indicated zone is not
longer able to operate
and has been shut down.
24
Heating Cycle Fault
The indicated zone is not
longer able to operate
and has been shut down.
25
Alternator Check
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
26
Check Refrigeration
Capacity
Manually monitor load
temperature. Report
alarm at end of the day.
28
Pretrip or Self Check Report alarm at end of
Abort
the day.
Unit Operation
Code
Description
Operator Help
29
Defrost Damper
Circuit Check
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
30
Defrost Damper
Stuck
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
31
Check Oil Pressure
Switch
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
32
33
Refrigeration
Capacity Low
Check Engine RPM
The indicated zone is not
longer able to operate
and has been shut down.
Repair immediately.
Report alarm at end of
the day.
Code
Description
Operator Help
35
Check Run Relay
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
36
If unit is shut down repair
Electric Motor Failed immediately. Otherwise,
to Run
report alarm at end of the
day.
37
Check Engine
Coolant Level
Report alarm at end of
the day.
38
Electric Phase
Reversed
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
39
Check Water Valve
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
49
Unit Operation
Code
Description
Operator Help
40
Check High Speed
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Description
Operator Help
46
Check Air Flow
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
41
If unit is shut down repair
Check Engine
immediately. Otherwise,
Coolant Temperature report alarm at end of the
day.
48
If unit is shut down repair
immediately. Otherwise,
Check Belts or Clutch
report alarm at end of the
day.
42
Unit Forced to Low
Speed
Report alarm at end of
the day.
50
Reset Clock
Report alarm at end of
the day.
43
Unit Forced to Low
Speed Modulation
Report alarm at end of
the day.
Check Heat Circuit
Check Fuel System
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Test Mode Timeout
Hot Gas or Hot Gas
Bypass Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Service Test or Interface
Board Test timed out
after 15 minutes. Report
alarm at end of the day.
44
45
50
Code
52
54
Unit Operation
Code
Description
Operator Help
61
Low Battery Voltage
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
62
Ammeter Out of
Calibration
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Engine Stopped
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
63
Report alarm at end of
the day.
64
Pretrip Reminder
66
Check engine oil level. If
unit is shut down repair
Low Engine Oil Level immediately. Otherwise,
report alarm at end of the
day.
Code
Description
Operator Help
67
Check Liquid Line
Solenoid Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
68
Internal Controller
Fault Code
Report alarm at end of
the day.
70
Hourmeter Failure
Report alarm at end of
the day.
74
Controller Reset to
Defaults
Report alarm at end of
the day.
77
Controller EPROM
Checksum Failure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
79
Internal Data Logger Report alarm at end of
Overflow
the day.
80
Check Compressor
Temp Sensor
Report alarm at end of
the day.
51
Unit Operation
Code
Description
Operator Help
81
High Compressor
Temp
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
82
High Compressor
Temp Shutdown
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
83
Low Engine Coolant
Temperature
84
Code
Description
Operator Help
89
Check Electronic
Throttling Valve
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
90
Electric Overload
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
91
If unit is shut down repair
Check Electric Ready immediately. Otherwise,
Input
report alarm at end of the
day.
Restart Null
Report alarm at end of
the day.
92
Sensor Grades Not
Set
Report alarm at end of
the day.
85
Forced Unit
Operation
Report alarm at end of
the day.
Check Discharge
Pressure Sensor
Report alarm at end of
the day.
93
86
Low Compressor
Suction Pressure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
87
Check Suction
Pressure Sensor
Report alarm at end of
the day.
52
Unit Operation
Code
Description
Operator Help
94
Check Loader #1
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
95
96
Check Loader #2
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Low Fuel Level
Check engine fuel level.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Check Fuel Level
Sensor
Report alarm at end of
the day.
99
High Compressor
Pressure Ratio
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
108
Door Open Timeout
Close Doors. Report
alarm at end of the day.
98
Code
Description
Operator Help
111
Unit Not Configured
Correctly
Report alarm at end of
the day.
113
Check Electric Heat
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
114
If unit is shut down repair
Multiple Alarms - Can immediately. Otherwise,
Not Run
report alarm at end of the
day.
115
If unit is shut down repair
Check High Pressure immediately. Otherwise,
Cut Out Switch
report alarm at end of the
day.
116
Check High Pressure Report alarm at end of
Cut In Switch
the day.
117
Auto Switch from
Diesel to Electric
Report alarm at end of
the day.
118
Auto Switch from
Electric to Diesel
Report alarm at end of
the day.
53
Unit Operation
Code
Description
Operator Help
120
Check Alternator
Excite Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Check Liquid
Injection Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
121
122
If unit is shut down repair
Check Diesel/Electric immediately. Otherwise,
Circuit
report alarm at end of the
day.
127
Be sure the setpoint is
Setpoint Not Entered set to the required
temperature.
128
Engine Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
Engine Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
129
54
Code
Description
Operator Help
130
Electric Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
131
Electric Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
132
Total Unit Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
133
Total Unit Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
134
Controller Power On
Hours
Report alarm at end of
the day.
135
Check Spare Digital
Inputs
Report alarm at end of
the day.
136
Check Spare Digital
Outputs
Report alarm at end of
the day.
137
Check Damper Motor Report alarm at end of
Heater Output
the day.
Unit Operation
Code
Description
Operator Help
Code
Description
Operator Help
141
Autoswitch Diesel to
Electric Disabled
Report alarm at end of
the day.
151
Out of Range High
145
Loss of Controller
"On" Feedback
Signal
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Manually monitor load
temperature. Report
alarm at end of the day.
203
Check Display
Return Air Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
146
Software Version
Mismatch
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
204
Manually monitor load
Check Display
temperature. Report
Discharge Air Sensor
alarm at end of the day.
148
Autoswitch Electric to Report alarm at end of
Diesel Disabled
the day.
149
Alarm Not Identified
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
150
Out of Range Low
Manually monitor load
temperature. Report
alarm at end of the day.
55
Unit Operation
Sending a Servicewatch Data
Logger Start of Trip
When the unit is turned on, press and hold the ENTER Key for
5 seconds to send a Start of Trip (SOT) marker to the unit
ServiceWatch Data Logger and the optional DAS Data Logger
(if equipped).
Pretrip Test Conditions
•
The current unit settings are saved and restored at the end
of the Pretrip Test or if the unit is turned off and back on.
•
The Pretrip Test can be run in either Diesel or Electric
Mode.
•
The unit will auto switch from Diesel Mode to Electric
Mode or from Electric Mode to Diesel Mode during a
Pretrip Test if these features are enabled and the auto
switch conditions occur.
Conditions where Pretrip Tests are
not allowed
Figure 35: ENTER Key
Pretrip Test
A Pretrip Test verifies unit operation. The PRETRIP Key
allows either a Full Pretrip Test or an Engine Running Pretrip
Test to be initiated by the operator.
56
•
Pretrip Tests are not allowed if any shutdown alarms are
present.
•
Pretrip tests are allowed with some Check and Log alarms
present.
Pretrip Test Sequence
Pretrip tests proceed in the order shown below.
Unit Operation
Full Pretrip Test
Engine Running Pretrip Test
Full Pretrip Tests include all of the tests shown below.
Engine Running Pretrip Tests include all of the tests shown
below. They do not include the Amps Check or the Engine
Start tests.
•
Amp Checks - Each electrical control component is
energized and the current drawn is confirmed as within
specification.
•
Engine Start - The Engine will start automatically.
•
Defrost - If the coil temperature is below 45 F (7 C), a
defrost cycle is initiated.
•
RPM Check - The engine RPM in high and low speed is
checked during the Cool Check.
•
Cool Check - The ability of the unit to cool in low speed is
checked.
•
Heat Check - The ability of the unit to heat in low speed is
checked.
•
Report Test Results - The test results are reported when the
Pretrip Test is completed. If the Pretrip Test fails, alarm
codes will exist to direct the technician to the source of the
problem.
•
Defrost - If the coil temperature is below 45 F (7 C), a
defrost cycle is initiated.
•
RPM Check - The engine RPM in high and low speed is
checked during the Cool Check.
•
Cool Check - The ability of the unit to cool in low speed is
checked.
•
Heat Check - The ability of the unit to heat in low speed is
checked.
•
Report Test Results - The test results are reported when the
Pretrip Test is completed. If the Pretrip Test fails, alarm
codes will exist to direct the technician to the source of the
problem.
57
Unit Operation
Pretrip Test Considerations
Performing a Pretrip Test
When performing a Pretrip Test, the following issues should be
considered.
Starting a Pretrip Test
•
Whenever possible, run the Pretrip Test with an empty
truck box.
The Full Pretrip Test must be started with the unit not running.
Turn the unit on and clear all alarm codes. Turn the unit off.
•
If running a Pretrip Test on a truck loaded with dry cargo,
insure that proper airflow can occur around the load. If the
load restricts airflow, false test results may occur. Also,
units have high refrigeration capacity which results in
rapid temperature change. Sensitive dry cargo may be
damaged as a result.
Turn the unit on and wait for the unit running time hourmeters
to be shown on the display. When the unit running time
hourmeters are shown on the display, press and hold the
PRETRIP Key for 5 seconds.
•
If running a Pretrip Test on a truck that has just been
washed down, the extremely high humidity inside the
truck box may result in false test results.
•
If running a Pretrip Test on a truck loaded with sensitive
cargo, monitor the load temperature during the test as
normal temperature control is suspended during pre-trip
operation.
•
58
Always perform Pretrip Tests with the cargo doors closed
to prevent false test results.
Figure 36: Pretrip Test
•
A flashing Pretrip LED indicates that the Pretrip Test is
being initialized. When the Pretrip Test starts, the Pretrip
LED will glow steady amber. The display will show the
Standard Display.
Unit Operation
•
The Amps Check Test will be preformed and then the unit
will start automatically. The balance of the tests will be
completed.
•
The Pretrip Test will take about 20 - 30 minutes,
depending on conditions.
IMPORTANT: The box temperature will vary during the
Pretrip Test. This is normal operation.
•
When the Pretrip Test is complete or if a Shutdown Alarm
occurs, the amber Pretrip LED will turn off.
•
Stopping a Pretrip Test: To stop a Pretrip Test at any time,
press the POWER OFF Key to turn the unit off. This 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.
Starting a Engine Running Pretrip Test
The Engine Running Pretrip Test must be started with the unit
running. Turn the unit on and clear all alarm codes. Allow the
unit to start.
Figure 37: PRETRIP Key
•
A flashing Pretrip LED indicates that the Pretrip Test is
being initialized. When the Pretrip Test starts, the Pretrip
LED will glow steady amber to indicate the test is in
progress. The display will show the Standard Display.
•
The Pretrip Test will take about 20 - 25 minutes,
depending on conditions.
IMPORTANT: The box temperature will vary during the
Pretrip Test. This is normal operation.
When the Pretrip Test is complete or if a Shutdown Alarm
occurs, the amber Pretrip LED will turn off.
With the unit running, press and hold the PRETRIP Key for 5
seconds.
59
Unit Operation
Stopping a Pretrip Test: To stop a Pretrip Test at any time,
press the POWER OFF Key to turn the unit off. This 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.
Pretrip Test Results
•
The amber Pretrip Test LED will turn off at the completion
of the test, but the Alarm Icon will remain lit. This
indicates that one or more Check Alarm conditions
occurred during the Pretrip Test. More than one alarm may
be present.
•
View and record the alarm(s), correct as necessary, clear
the alarm(s) and repeat the Pretrip Test.
Pass Pretrip Test
Fail Pretrip Test with Shutdown Alarms
•
•
If the unit fails the Pretrip Test with a Shutdown alarm, the
Alarm Icon will appear when the alarm condition occurs,
the unit will immediately shut down and the amber Pretrip
Test LED will turn off.
•
The Pretrip Test will be aborted.
•
Alarm Code 28 Pretrip Abort will be set along with the
Shutdown Alarm that was detected. This signifies that a
Shutdown Alarm occurred during the Pretrip Test and that
the test was aborted. Other alarms may also be present.
•
View and record the alarm(s), correct as necessary, clear
the alarm(s) and repeat the Pretrip Test.
If the unit passes the Pretrip Test, the amber Pretrip Test
LED will turn off at the completion of the test and the unit
will continue to run as required. This signifies that the unit
passed the Pretrip Test.
Fail Pretrip Test with Check Alarms
•
60
If the unit fails the Pretrip Test with Check alarms, the
Alarm Icon will appear when the alarm condition occurs.
The Pretrip Test will continue to run unless a Shutdown
Alarm occurs.
Unit Operation
TSD Control Panel Display
Brightness
The brightness of the TSD Control Panel display can be
adjusted to allow for changing ambient light conditions. The
choices available to the operator are HIGH, MEDIUM and
LOW.
To change the display brightness press and hold the ON key
then press the UP ARROW Key to increase display brightness
and the DOWN ARROW Key to decrease display brightness.
Keypad Lockout
The Keypad Lockout feature allows the operator to lock the
keypad to prevent tampering. If the Keypad Lockout feature is
turned on, all keys except the ON Key and OFF Key are
prevented from functioning. The unit can still be turned On and
Off, but doing so does not clear Keypad Lockout.
To turn Keypad Lockout on, simultaneously press and hold the
ON Key, CYCLE SENTRY Key and HIGH SPEED
LOCK-OUT Key for 5 seconds. The display shown in Figure
36 will appear, with [0 - - - n] replacing the box temperature.
When the three keys are released, the display will return to the
Standard Display of box temperature and setpoint.
Figure 38: ON Key, UP/DOWN Arrow Keys
Figure 39: [0 - - - n] Replaces Box Temperature
61
Unit Operation
When Keypad Lockout is turned on, only the ON and OFF
Keys are functional. All other keys are locked out. Pressing
any key other than the ON Key and OFF Key will cause the
box temperature to display [0 - - - n]. When the key is released,
the display will return to the Standard Display of box
temperature and setpoint.
To turn Keypad Lockout off, simultaneously press and hold the
ON Key, CYCLE SENTRY Key and HIGH SPEED
LOCK-OUT Key for 5 seconds. The display shown above will
appear, with [0 - - - n] replacing the box temperature. When the
three keys are released, the display will return to the Standard
Display of box temperature and setpoint. All keys will function
normally.
Checking TSD Control Panel
Software Revision and Serial
Number
The TSD Control Panel serial number and software revision
can be displayed if necessary.
62
To display the serial number and software revision press and
hold the PRETRIP key for 5 seconds when the unit is turned
off.
Figure 40: PRETRIP Key
The TSD Control Panel serial number is shown at the top of the
display and the software revision is shown at the bottom of the
display. The TSD Control Panel Serial Number shown in
Figure 41 is 00186. The software revision shown below is
Revision 2202.
Unit Operation
Figure 41: Software Revision and Serial Number
Checking or Setting Unit Time
and Date
The system time and date is maintained by the TSD Control
Panel. The time and date held by the TSD Control Panel cannot
be viewed using the TSD Control Panel itself. See the unit
maintenance manual for procedures to check and change the
date and time.
63
Unit Operation
64
Specifications
Engine
Model
TK370 (Tier 4)
Fuel Type
No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity:
Crankcase & Oil Filter
w/Bypass Oil Filter
9.0 quarts (8.5 liters)
10.0 quarts (9.5 liters) Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better
(ACEA Rating E3 or better for Europe)
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)
Engine rpm:
Low Speed Operation
High Speed Operation
1650 ± 25 rpm
2200 ± 25 rpm
65
Specifications
Engine (Continued)
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
Low Oil Pressure Switch/Sensor
10 ± 2 psig (69 ± 14 kPa)—shutdown
High Coolant Temperature Sensor
220 ± 5 F (104 ± 3 C)—shutdown
Engine 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®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
66
Specifications
Engine (Continued)
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life
Coolant, the coolant must be changed after 2 years
instead of 5 years.
Coolant System Capacity:
With Tube and Fin Radiator Coil (ending 6/12)
With Micro-Channel Radiator Coil (starting 6/12)
4.5 quarts (4.3 liters) with coolant expansion tank
4.9 quarts (4.6 liters) with coolant expansion tank
Coolant Expansion Tank Cap Pressure
15 psig (103 kPa)
67
Specifications
Belt Tension
Belt
Tension No. on TK Gauge
P/N 204-427
New Belt
Field Reset
Water Pump Belt
40
40
Engine/Electric Motor (Jackshaft)
81
77
Electric Motor (Jackshaft)/Compressor
Frequency Gauge P/N 204-1903
Setting Where Applicable
New Belt
Field Reset
62 Hz
55 Hz
Automatically tensioned by tensioner position. See “Belts” in Engine
Maintenance Chapter.
Engine Clutch
Engagement
600 ± 100 RPM
Dynamic Torque
66 ft-lb (89.5 N•m) minimum @ 1600 RPM
Refrigeration System
Compressor Model
68
Thermo King X214
Specifications
Refrigeration System (Continued)
Refrigerant Charge:
With Tube and Fin Condenser Coil (ending 6/12)
7 lbs (3.2 kg) R-404A
With Micro-Channel Condenser Coil (starting 6/12)) 6 lbs (2.7 kg) R-404A
*Compressor Oil Charge
3.2 quarts (3.0 liters)
Compressor Oil Type
Ester base P/N 203-513 required
Suction Pressure Regulator Valve Setting
28 to 31 psig (193 to 214 kPa)
High Pressure Cutout Switch:
Open
Close
470 ± 7 psig (3241 ± 48 kPa)
375 ± 38 psig (2586 ± 262 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured. This is to be sure that the same amount of oil can be added before placing the
replacement compressor in the unit.
69
Specifications
Electrical Control System
Control System Voltage
12.5 Vdc
Battery Charging System
12 volt, 37 amp, brush type, Thermo King alternator
Voltage Regulator Setting
13.95 to 14.35 volts @ 77 F (25 C)
NOTE: Fuse F14 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King
Alternator.
70
Specifications
Fuses
Fuse
Size
Function
F1
5A
2P Circuit - Battery Power to TSD CAN Connector
F2
2A
8XP Circuit - Switch On Power to TSD CAN Bus
F3
2A
8FC Circuit - Remote Light
F4
15A
Power to On/Off Switch
F5
7.5A
HPCO/PHPCO Circuit
F6
40A
Preheat Circuit
F7
40A
Starter Solenoid Circuit
F8
15A
Damper Solenoid Circuit
F11
10A
8X Circuit - Power From On Relay (K4) - Install fuse in
upper position.
F13
15A
High Speed (Throttle) Solenoid Circuit
F14
None
2A
No Fuse - All Bosch and Thermo King Alternators
2A Fuse - All Prestolite Alternators
F20
2A
Battery Power to Alternator Sense Circuit
71
Specifications
Fuses (Continued)
Fuse
Size
Function
F21
60A
Main Fuse (2 Circuit)
F11 When fuse F11 is installed in the lower position the On/Off keys on the TSD Control Panel turn the unit on
and off. When fuse F11 is installed in the upper position the unit will start and run without the TSD control panel.
F14 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with
Prestolite Alternator.
Electrical Components
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance
(Ohms)
4.3
2.3 ± 0.2
35 to 45
0.5
0.2 to 0.3
24 to 29
High Speed (Throttle) Solenoid
3.3
3.8
Damper Solenoid
5.7
2.2
Condenser Inlet Solenoid (CIS)
1.8
6.9
Glow Plugs (3) Each
Fuel Solenoid:
72
Pull In Coil
Hold In Coil
Specifications
Electrical Components (Continued)
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance
(Ohms)
Hot Gas Solenoid (HGS)
1.1
11.3
Purge Valve (PV)
1.1
11.3
Starter Motor (No Load Bench Test)
90
73
Specifications
Electrical Standby (Model 50 Units Only)
Electric Motor and Overload Relay
Voltage/Phase/Frequency
Horsepower
Kilowatts
rpm
Full Load
(amps)
Overload Relay
Setting (amps)
230/3/60
7.2
5.4
1765
19.4
22
460/3/60
7.2
5.4
1765
9.7
11
Standby Power Requirements
Supply Circuit Breaker:
Extension Cord Size:
74
230/3/60
460/3/60
30 amps
20 amps
Up to 50 ft—10 gauge
75 ft—8 gauge
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
After first week of operation:
For more specific detail, see the maintenance manual for your
unit and to the PreTrip Inspection chapter in this manual.
Pretrip
1,200
Hours
2,400
Hours
•
Check belt tension.
•
Tighten unit mounting bolts.
•
Check refrigerant level.
Annual/
3,000
Hours
Inspect/Service These Items
Microprocessor
Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).
Engine
•
Check fuel supply.
•
•
Check engine oil level.
•
•
Check engine oil pressure hot, on high speed.
•
•
•
•
•
Listen for unusual noises, vibrations, etc.
Check air cleaner hose for damage.
75
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,400
Hours
Annual/
3,000
Hours
•
76
Inspect/Service These Items
Inspect and clean electric fuel pump filter.
•
Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year
(whichever occurs first)
•
Change EMI 2000 (black) fuel filter.
•
Change engine oil and oil filters (hot). Requires oil with API Rating
CI-4 or better (ACEA Rating E3 for Europe) and EMI 2000 bypass oil
filter.
•
Adjust electric motor (jackshaft)/compressor belt to field reset
position. See “Electric Motor (Jackshaft)/Compressor Belt” in
maintenance manual.
•
Check restraining mount (snubber) pre-load adjustment.
•
Drain water from fuel tank and check vent.
•
Check and adjust engine speeds (high and low speed).
•
Check condition of engine mounts.
•
Maintain year round antifreeze protection at –30 F (–34 C).
•
Test fuel injection nozzles at least every 3,000 hours.*
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,400
Hours
Annual/
3,000
Hours
Inspect/Service These Items
--
Replace the fuel return lines between fuel injection nozzles every
10,000 hours or sooner as required.
--
Change ELC (red) engine coolant every 5 years or 12,000 hours.
Units equipped with ELC have an ELC nameplate on the expansion
tank.
* Based on EPA 40 CFR Part 89.
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.
•
Inspect alternator bearings and brushes.**
•
Inspect electric motor bearings (Model 50).**
** With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
77
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,400
Hours
Annual/
3,000
Hours
Inspect/Service These Items
•
•
Check refrigerant level.
•
Check compressor oil level.
REFRIGERATION
•
Check suction pressure regulator setting on Defrost or Heat.
•
Check discharge and suction pressures.
•
Check compressor efficiency.
--
Replace dehydrator every two (2) years.
STRUCTURAL
•
•
Visually inspect unit and refrigerant hoses for fluid leaks.
•
•
Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
•
78
•
Inspect clutch for shoe and anchor bushing wear with a mirror. Check
bearings.**
•
Inspect idlers, fan shafts and jackshaft (if so equipped) for leakage
and bearing wear.**
•
Clean entire unit including condenser coils, evaporator coils, and
defrost drains.
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,400
Hours
Annual/
3,000
Hours
•
•
•
Inspect/Service These Items
Check all unit, fuel tank, engine, and electric motor mounting bolts,
brackets, lines, hoses, etc.
** With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
79
Maintenance Inspection Schedule
80
Warranty
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 51350 for the Thermo King
Self-Powered Truck Unit Warranty.
81
Warranty
82
Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
NOTE: Additional terms not found in the glossary may be
located in the index section of this manual.
accumulator: A device located in the suction line to collect
liquid refrigerant and meter it safety back to the compressor as
gas.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Battery Sentry: Part of the CYCLE-SENTRY™ system. The
Battery Sentry module monitors alternator charge rate and will
keep the unit running until the battery is adequately charged.
box temperature: The temperature within a
temperature-controlled compartment.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
bulkhead: 1) return air bulkhead. A metal or plastic “wall”
placed at the front of the box to prevent loading of product
tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
divider. A thick, insulated “wall” used to separate
compartments of a multi-temperature truck or trailer.
calorie: The amount of heat required to raise temperature of
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
83
Glossary
CFC: Chlorofluorocarbon. A chlorine-based refrigerant
consisting of chlorine, fluorine and carbon. Example: R12. In
many countries it is illegal to release this type of refrigerant to
the atmosphere because chlorine damages the earth’s
atmosphere. CFC refrigerants are not used in modern Thermo
King units.
circuit breaker: A thermal device that automatically
interrupts an electrical circuit when the current in the circuit
exceeds the predetermined amperage rating of the breaker. See
amp.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
cold curtains: Flexible vinyl curtains used to reduce air
exchange between the refrigerated compartment and the
outside during door openings.
compound gauge: A gauge calibrated in psig (or kPa) to
measure pressure, and in inches of mercury (Kg/cm2) to
measure vacuum.
compressor: The refrigeration component that compresses
refrigerant vapor and creates refrigerant flow.
84
condenser: An arrangement of tubing in which the
vaporized and compressed refrigerant is liquefied as heat is
removed.
cycles per second: See Hertz.
damper door: A door on the evaporator section that closes
during defrost to prevent hot air from entering the refrigerated
cargo compartment.
data logger: An electronic device that monitors and stores
unit operating and temperature data for later review. Examples:
DMS, DAS, DRS and AccuTrac.
defrost: The removal of accumulated ice from an evaporator
coil. Periodic defrost is necessary when the evaporator coil is
operating below freezing. Defrost is required more frequently
when the air passing through the evaporator has a high
moisture content.
defrost termination switch: A component that terminates
defrost operation at a specific temperature.
defrost timer: A solid state module that initiates defrost at
selected intervals. Also establishes a maximum defrost
duration if normal circuits malfunction.
Glossary
dehydrator: A device used to remove moisture from
refrigerant. Also called a drier.
discharge air temperature: The temperature of air leaving
the evaporator.
drier: See dehydrator.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
F: See Fahrenheit.
Fahrenheit: A unit of temperature measurement used in the
United States. Abbreviated “F.”
freeze up: 1) Failure of a refrigeration system to operate
normally due to moisture in the refrigerant and the formation
of ice at the expansion valve. The expansion valve may be
frozen shut or open, causing improper unit operation in either
case. 2) The formation of a solid ice mass over the evaporator
coil reducing air flow.
fuse: An electrical safety device (typically a cartridge)
inserted into an electrical circuit. It contains material that will
melt or break when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
refrigerant containing hydrogen, chlorine, fluorine and carbon.
Example: R22. Because chlorine damages the earth’s
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not
used in modern Thermo King units.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HFC: A refrigerant consisting of hydrogen, fluorine and
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the
environment.
85
Glossary
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the
system if pressure exceeds a predetermined value.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
load: 1) The product being refrigerated and transported.
2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
when expected to cool a very warm box.)
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
86
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit.
pre-cooling: 1) To cool down an empty box
(temperature-controlled area) to the desired load temperature
prior to loading. 2) To cool cargo to a desired temperature
before loading.
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
Glossary
receiver tank: A refrigerant storage device included in
nearly all Thermo King units.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
refrigerant: The medium of heat transfer in a refrigeration
system which absorbs heat by evaporating at a low temperature
and releases heat by condensing at a higher temperature.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
return air bulkhead: A structure (metal or plastic) mounted
in the front of a trailer and designed to prevent restriction of
return air flow to the Thermo King unit due to improper
loading. See bulkhead.
return air temperature: The temperature of the air
returning to the evaporator. See box temperature.
rpm: Revolutions per minute.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
87
Glossary
88
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AKB12
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.
89
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.
In addition, service personnel must be aware of Federal regulations
concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local THERMO KING dealer.
90
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
91
92
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
T-570R
TK 55179-1-OP (Rev. 1, 05/2012)
©2011 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2011 Ingersoll-Rand Company
Printed in U.S.A.
T-570R
TK 55179-1-OP (Rev. 1, 05/2012)
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