Thermo King T-680S User manual

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Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy effi cient heating, ventilating and air
conditioning systems, building and contracting services, parts support and advanced controls
for commercial buildings and homes.
SB-210+
Additional text information
to be placed here
TK 5XXXX-X-PL
TK 55635-1-MM
©2013 Ingersoll Rand Company
Printed in U.S.A.
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
Distributed by:
SB-210+
Additional text information
to be placed here
TK 5XXXX-X-PL
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
SB-210+
Additional text information
to be placed here
TK 5XXXX-X-PL
Distributed by:
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
Distributed by:
T-680S, T-880S,
T-1080S Series
with SR-3
TK 55635-1-MM (Rev. 5, 11/16)
314 West 90th Street
Minneapolis, MN 55420
Direct [phone]
Thermo King Corporate
Maintenance Manual

T-680S, T-880S,
T-1080S Series
with SR-3
TK 55635-1-MM (Rev. 5, 11/16)
Copyright©2013 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in
U.S.A.

2
Revision History
Rev. 0 – 55635-1-MM (Rev. 0, 02/13) Original release.
Rev. 1 – 55635-1-MM (Rev. 1, 09/13) Revise MIS page 20 and Adjust Engine Valve
Clearance page 103 to indicate engine valve adjustment interval of 1,000 hours.
Rev. 2 – 55635-1-MM (Rev. 2, 06/14) Update Oil Fill Procedure, Coolant MIS, and other
general updates.
Rev. 3 – 55635-1-MM (Rev. 3, 12/14) Update engine oil viscosity specifications.
Rev. 4 – 55635-1-MM (Rev. 4, 03/15) Change voltage/phase/frequency on page 19 from
208-230/3/60 to 230/3/60 for 7.2 hp (5.4 kW) electric motor.
Rev. 5 – 55636-1-MM (Rev. 5, 11/16) Revise for cooling system update and new style ETV.
This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.
The maintenance information in this manual covers unit models:
SYSTEM T-680S 30 SR (902385) SYSTEM T-680S 50 SR 230/3/60 (902386)
SYSTEM T-680S 50 SR 460/3/60 (902387) SYSTEM T-880S 30 SR (902388)
SYSTEM T-880S 50 SR 230/3/60 (902389) SYSTEM T-880S 50 SR 460/3/60 (902391)
SYSTEM T-1080S 30 SR (902392) SYSTEM T-1080S 50 SR 230/3/60 (902393)
SYSTEM T-1080S 50 SR 460/3/60 (902394)
For further information, refer to:
T-680R, T-880R, T-1080R, T-680S, T-880S, T-1080S with Standard Display Operator’s Manual TK 55665
T-680R, T-880R, T-1080R, T-680S, T-880S, T-1080S with Premium Display Operator’s Manual TK 55667
T-680S Parts Manual TK 55630
T-880S Parts Manual TK 55631
T-1080S Parts Manual TK 55632
SR-3 Truck Single Temp Diagnostic Manual TK 55208
T-Series Truck Single Temperature Systems Installation Manual TK 55212
Diagnosing TK Refrigeration System TK 5984
Truck Open Drive Scroll Compressor Diagnostic Manual TK 51205
TK270, TK370, TK374F, TK376, and TK380F Engine Overhaul Manual TK 53163
Tool Catalog TK 5955
Evacuation Station Operation and Field Application TK 40612
The information in this manual is provided to assist owners, operators and service people in the proper upkeep
and maintenance of Thermo King units.

3
Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants as,
in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular
purpose or merchantability, or warranties arising from course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.
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.
R-404A
WARNING: Use only Polyol Ester-based refrigeration compressor oil in
R-404A. See Thermo King Parts Manual for part number.
Do not mix Polyol Ester and standard synthetic compressor oils. Keep Polyol
Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes
contaminated with moisture or standard oils, dispose of properly–DO NOT USE.
When servicing Thermo King R-404A unit, use only those service tools certified
for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Residual non-HFX refrigerants or oils will contaminate R-404A systems.

4
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Scan the Quick Response (QR) code or click or type the web address
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5
Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auto Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Microprocessor Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Welding Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
First Aid, Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
First Aid, Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
First Aid, Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
First Aid, Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
T-680S and T-880S Electric Motor and Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
T-1080S Electric Motor and Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electric Heater Strips (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Standby Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Maintenance Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Standard HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mechanics HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Premium HMI Control Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CYCLE-SENTRYTM Start/Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DAS - Data Acquisition System (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CargoLink™ (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electric Standby (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Standard Model 50 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional Model 50 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Compartment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Solenoids and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Sensors, Switches, and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Refrigeration System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cool Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Purge Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Table of Contents
6
Heat/Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Operating Instructions for Standard HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
SR-3 Truck HMI Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
SR-3 Truck HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Keys and LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Turning the Unit On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Selecting the High Speed Lock-Out Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Sending a Servicewatch Data Logger Start of Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Pretrip Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Conditions where Pretrip Tests are not allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Pretrip Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Pretrip Test Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Starting a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Pretrip Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Display Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Checking Truck HMI Control Panel Software Revision and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Operating Instructions for Premium HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
SR-3 Truck Premium HMI Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Premium HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Turning the Unit On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
If More Than One Language is Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Selecting High Speed Lockout Mode (If Enabled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Using the Gauges Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Using the Sensors Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Using The Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Main Menu Choices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Selecting CYCLE-SENTRY or Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Selecting Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Table of Contents
7
Diesel/Electric Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Adjust Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Alternator Charging System Diagnostic Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Interface Board Fuse F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Test Equipment for Checking Voltage and Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Alternator Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
General Diagnostic and Warranty Evaluation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Field Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Base Controller LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Smart FETs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SMART REEFER 3 (SR-3) Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Flywheel (RPM) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Unit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
AC Components (Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Electrical Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Evaporator Heaters (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Condenser Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Phase Select Module for Truck Unit Model 50 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Overload Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
EMI 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Engine Oil Pressure Switch/Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Engine Air Cleaner (EMI 2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Crankcase Breather System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Antifreeze Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Bleeding Air from the Cooling System for Units with Coolant Expansion Tank Only (Ending 10/16) . . . . . . 90
Bleeding Air from the Cooling System for Units with Coolant Expansion Tank and Overflow Bottle (Starting
10/16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Engine Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Coolant Level Switch for Units with Coolant Expansion Tank Only (Ending 10/16) . . . . . . . . . . . . . . . . . . . 98
Coolant Level Switch for Units with Coolant Expansion Tank and Overflow Bottle (Starting 10/16) . . . . . . 99
Engine Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Draining Water from Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Injection Pump Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fuel Limit Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fuel Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Speed Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Adjust Engine Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Restraining Mount (Snubber) Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Engine/Electric Motor (Jackshaft) Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Electric Motor (Jackshaft)/ Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Water Pump Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Refrigeration Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Evacuation, Dehydration, and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Set Up and Test of Evacuation Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Using Evacuation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Unit Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Refrigerant Gauge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Testing the Refrigerant Charge with an Empty Box (Controlled Check) . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Testing the Refrigerant Charge with a Loaded Box (Quick Check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Refrigeration System Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Low Side Pump Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
R404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Unit Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Compressors Shipped with POE Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Equipment Recommendations For Use With R404A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Refrigeration System Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Accumulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Compressor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Compressor Shaft Seal Change Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Compressor Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Compressor Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Compressor Temperature Sensor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Compressor Temperature Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Condenser Check Valve and Purge Check Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Condenser Inlet Solenoid (CIS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Condenser/Radiator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Dehydrator (Filter-Drier) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Discharge Pressure Regulator (DPR) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Discharge Pressure Regulator (DPR) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Discharge Pressure Transducer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Discharge Pressure Transducer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .143
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Discharge Strainer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Discharge Strainer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

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9
Electronic Throttling Valve (ETV) Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Electronic Throttling Valve (ETV) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Installation of Service Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Reassembly of Piston and Stepper Motor on Old Style ETV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Installation of Complete ETV Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Evaporator Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Expansion Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Heat Exchanger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
High Pressure Cutout Switch (HPCO) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
High Pressure Cutout Switch (HPCO) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
High Pressure Relief Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Hot Gas Solenoid (HGS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
In-Line Check Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Liquid Injection Solenoid (LIS) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Liquid Injection Solenoid (LIS) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Purge Valve (PV) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Receiver Tank Pressure Check Valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Receiver Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Solenoid Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Suction Pressure Transducer Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Suction Pressure Transducer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Centrifugal Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Clutch Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Check Condition of Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Check the Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Clutch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Disassembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Assembly Procedure (Using New Bearings and Seal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Structural Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Unit and Engine Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Unit Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Condenser, Evaporator and Radiator Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Micro-Channel Coil Cleaning Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Plastic Defrost Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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10
Fanshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Jackshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Electric Standby (Optional) Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Refrigeration Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Wiring and Schematic Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

11
Safety Precautions
Thermo King recommends that all service be
performed by a Thermo King dealer. However,
you should be aware of several general safety
practices:
The symbol appears next to a point that is
particularly important.
General Practices
DANGER: Denotes the possibility of
serious injury or death.
WARNING: Denotes the possibility of
serious equipment damage or serious
personal injury.
CAUTION: Denotes the possibility of
minor to severe equipment damage or
personal injury.
DANGER: Do not operate the compressor
with the discharge service valve closed.
Thisconditionincreasesinternal pressure,
which can cause an explosion.
DANGER: Never apply heat to a sealed
refrigeration system or container. Heat
increases internal pressure, which might
cause an explosion.
DANGER: Refrigerant in the presence of
an open flame, spark or electrical short
produces toxic gases that are severe
respiratory irritants.
DANGER: Keep your hands, clothing and
tools clear of fans when working on a unit
that is running. Loose clothing might
entangle moving pulleys or belts, causing
serious injury or possible death.
DANGER: Do not inhale refrigerant. Use
caution when working with refrigerant or
a refrigeration system in any confined
area with a limited air supply, such as a
cargo area or garage. Refrigerant
displaces air and can cause oxygen
depletion, resulting in suffocation and
possible death.
DANGER: Avoid engine operation in
confined spaces and areas or
circumstances where fumes from the
engine could become trapped and cause
serious injury or death.
WARNING: Make sure your gauge
manifold hoses are in good condition
before using them. Never let them come in
contact with moving belts, fans, pulleys or
hot surfaces. Defective gauge equipment
can damage components or cause serious
injury.
WARNING: Always wear goggles or safety
glasses when working on a unit.
Refrigerant liquid, oil and battery acid can
permanently damage your eyes. See “First
Aid” on page 15.
WARNING: Use extreme caution when
drilling holes in a unit. Holes might
weaken structural components. Holes
drilled into electrical wiring can cause a
fire or explosion.
WARNING: Exposed coil fins can cause
lacerations. Service work on the
evaporator or condenser coils is best left to
a certified Thermo King technician.
WARNING: Do not apply heat to a closed
cooling system. Before applying heat to a
cooling system, drain it. Then flush it with
water and drain the water. Antifreeze
contains water and ethylene glycol. The
ethylene glycol is flammable and can
ignite if the antifreeze is heated enough to
boil off the water.
WARNING: Be careful when using
ladders or scaffolding to install or service
a unit. Observe the manufacture’s safety
labels and warnings.
CAUTION: Make sure all mounting bolts
are tight and are the correct length for
their applications. Improper torque and
incorrect bolt lengths can damage
equipment.

Safety Precautions
12
NOTE: In the USA, EPA Section 608
Certification is required to work on refrigeration
systems.
Auto Start/Stop
Battery Installation and Cable
Routing Battery Removal
This order is important because the frame is
grounded to the negative battery terminal. If the
negative terminal is still connected, a complete
circuit exists from the positive terminal of the
battery to the frame. Metal objects contacting the
positive side and the frame simultaneously will
cause sparks or arcing. If there are sufficient
hydrogen gases emitted from the battery, an
explosion might occur, causing equipment
damage, serious injury, even death.
Refrigerant Hazards
CAUTION: The unit may start
automatically and at any time when the
unit On/Off switch is in the On position.
Units with the CYCLE-SENTRYTM start
automatically in both CYCLE-SENTRY
mode and Continuous mode. Be sure to
turn the On/Off switch Off before opening
doors or inspecting or working on any part
of the unit.
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!
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.
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.
DANGER: Disconnect the negative
battery terminal (-) first when removing a
battery. Connect the positive terminal (+)
first when installing a battery.
DANGER: Do not use a Halide torch.
When a flame comes in contact with
refrigerant, toxic gases are produced.
These gases can cause suffocation, even
death.
DANGER: Store refrigerant in proper
containers, out of direct sunlight and away
from intense heat. Heat increases pressure
inside storage containers,which can cause
them to burst.

Safety Precautions
13
Refrigerant Oil Hazards
Electrical Hazards
High Voltage
DANGER: Do not use oxygen (O2) or
compressed air for leak testing. Oxygen
mixed with refrigerant is combustible.
WARNING: Wear butyl lined gloves when
handling refrigerant to help prevent
frostbite.
CAUTION: Refrigerant in a liquid state
evaporates rapidly when exposed to the
atmosphere, freezing anything it contacts.
Be careful when handling refrigerant to
protect your skin from frostbite.
CAUTION: When being transferred,
refrigerant must be in liquid state to avoid
possible equipment damage.
CAUTION: When transferring
refrigerant, use a process that prevents or
greatly restricts refrigerant from escaping
into the atmosphere. Refrigerant damages
the earth’s upper ozone layer.
WARNING: Protect your eyes from
contact with refrigerant oil. The oil can
cause serious eye injuries. Avoid
prolonged or repeated contact with
refrigerant oil. To prevent irritation, wash
your hands and clothing thoroughly after
handling the oil.
CAUTION: Use the correct oil in Thermo
King systems to avoid damaging
equipment and invalidating its warranty.
CAUTION: Do not mix refrigerant oils
because that can cause system damage.
CAUTION: Use dedicated equipment to
prevent contaminating systems with the
wrong type of oil.
CAUTION: Store refrigerant oil in an
approved sealed container to avoid
moisture contamination.
CAUTION: Do not expose the refrigerant
oil to the air any longer than necessary.
The oil will absorb moisture, which results
in much longer evacuation times and
possible system contamination.
CAUTION: Wipe up spills immediately.
Refrigerant oil can damage paints and
rubber materials.
DANGER: When servicing or repairing a
temperature control unit, the possibility of
serious or even fatal injury from electrical
shock exists. Extreme care must be used
when working with a refrigeration unit
that is connected to a source of operating
power, even if the unit is not operating.
Lethal voltage potentials can exist at the
unit power cord, inside the control box, at
the motors and within the wiring
harnesses.
WARNING: Make sure the unit On/Off
switch is turned Off before connecting or
disconnecting the standby power plug.
Never attempt to stop the unit by
disconnecting the power plug.
WARNING: Make sure the unit power
plug is clean and dry before connecting it
to a power source.
WARNING: Do not make rapid moves
when working on high voltage circuits in
refrigeration units. Do not grab for falling
tools because youmight accidentallytouch
a high voltage source.
WARNING: Use tools with well insulated
handles. Never hold uninsulated metal
tools near exposed, energized conductors.
WARNING: Treat all wires and
connections as if they were high voltage
until a meter and wiring diagram indicate
otherwise.

Safety Precautions
14
Low Voltage
Microprocessor Service
Precautions
Take precautions to prevent electrostatic
discharge when servicing the microprocessor and
its related components. Even tiny amounts of
current can severely damage or destroy electronic
components.
Observe the following precautions when servicing
a microprocessor control system to avoid
damaging electronic components. Refer to the
appropriate microprocessor diagnostic manual for
more information.
• If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
• Disconnect power to the unit.
• Avoid wearing clothing that generates static
electricity (wool, nylon, polyester, etc.).
• Wear a wrist strap (P/N 204-622 or its
equivalent) with the lead end connected to the
microprocessor’s ground terminal. These
straps are available from most electronic
equipment distributors. DO NOT wear these
straps with power applied to the unit.
• Avoid unnecessary contact with the electronic
components.
• Store and ship electronic components in
antistatic bags and protective packaging.
• Leave electronic components in their antistatic
packing materials until you’re ready to use
them.
• After servicing any electronic components,
check the wiring for possible errors before
restoring power to the unit.
• Never use a battery and a light bulb to test
circuits on any microprocessor-based
equipment.
Welding Precautions
Take precautions before electrically welding any
portion of the unit or the vehicle to which it is
attached. Ensure that welding currents are not
allowed to flow through the unit’s electronic
circuits.
Observe the following precautions when welding
to avoid damaging electronic components.
• If the microprocessor has a power switch, turn
it OFF before connecting or disconnecting the
battery.
• Disconnect power to the unit.
• Disconnect all wire harnesses from the
microprocessor.
• If there are any electrical circuit breakers in
the control box, switch them OFF.
• Close the control box.
WARNING: Never work alone on high
voltage circuits in the refrigeration unit.
Another person should be nearby to shut
off the unit and provide aid in the event of
an accident.
WARNING: Safety glasses, rubber-
insulated gloves and cable cutters should
be near your work area, in the event of an
electrical accident.
WARNING: Use caution when working
with electrical circuits that contain
capacitors. Some capacitors hold a
significant charge that might cause burns
or shocks if accidentally discharged. Make
sure capacitors are discharged before
working on electrical circuits.
WARNING: Control circuits used in
refrigeration units are low voltage (12 to
24 volts dc). This voltage is not dangerous,
but the large amount of amperage
available from the alternator can cause
severe burns if accidentally shorted to
ground with metal objects, such as tools.
WARNING: Do not wear jewelry, watches
or rings because they increase the risk of
shorting out electrical circuits and
damaging equipment or causing severe
burns.

Safety Precautions
15
• Components that could be damaged by
welding sparks should be removed from the
unit.
• Use normal welding procedures, but keep the
ground return electrode as close to the area
being welded as practical. This will reduce the
likelihood of stray welding currents passing
through any electronic circuits.
First Aid
First Aid, Refrigerant
In the event of frostbite, protect the frozen area
from further injury, warm the area rapidly and
maintain respiration.
EYES : For contact with liquid, immediately flush
eyes with large amounts of water. CALL A
PHYSICIAN.
SKIN: Flush area with large amounts of warm
water. Do not apply heat. Remove contaminated
clothing and shoes. Wrap burns with dry, sterile,
bulky dressing to protect from infection. CALL A
PHYSICIAN. Wash contaminated clothing before
reuse.
INHALATION: Move victim to fresh air and use
CPR (cardio pulmonary resuscitation) or
mouth-to-mouth resuscitation to restore breathing,
if necessary. Stay with victim until emergency
personnel arrive.
First Aid, Refrigerant Oil
EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.
First Aid, Engine Coolant
EYES : Immediately flush with water for at least
15 minutes. CALL A PHYSICIAN. Wash skin
with soap and water.
INGESTION: Do not induce vomiting.
Immediately contact local poison control center or
physician.
First Aid, Electrical Shock
Take IMMEDIATE action after a person has
received an electrical shock. Get quick medical
assistance, if possible.
The source of the shock must be quickly stopped,
by either shutting off the power or removing the
victim. If the power cannot be shut off, the wire
should be cut with an non-conductive tool, such as
a wood-handle axe or thickly insulated cable
cutters. Rescuers should wear insulated gloves
and safety glasses, and avoid looking at wires
being cut. The ensuing flash can cause burns and
blindness.
If the victim must be removed from a live circuit,
pull the victim away with a non-conductive
material. Use wood, rope, a belt or coat to pull or
push the victim away from the current. DO NOT
TOUCH the victim. You will receive a shock from
current flowing through the victim’s body. After
separating the victim from power source,
immediately check for signs of a pulse and
respiration. If no pulse is present, start CPR
(cardio pulmonary resuscitation). If a pulse is
present, respiration might be restored by using
mouth-to-mouth resuscitation. Call for emergency
medical assistance.

16
Specifications
Engine
Model: T-680S and T-880S
T-1080S TK374F (Tier 4) 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
T-680S and T-880S w/Bypass Oil Filter 9.0 quarts (8.5 liters) 10.0 quarts (9.5 liters) Fill to full mark on dipstick
T-1080S Crankcase & Oil Filter
T-1080S w/Bypass Oil Filter 12.0 quarts (11.4 liters) 13.0 quarts (12.3 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
5 to 104 F (-15 to 40 C): SAE 10W-30 (Synthetic or
Synthetic Blend)
-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 1625 ± 25 rpm 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. (0.15 to 0.25 mm)
Exhaust Valve Clearance 0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature 70 F (21 C)
Fuel Injection Timing 16 ± 1 degrees BTDC
Injection Nozzle Pressure 1784 to 1929 psig (12,300 to 13,300 kPa)
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
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.

Specifications
17
Units Built Prior to October 2016
Coolant System Capacity: T-680S and T-880S
T-1080S
Units with coolant expansion tank only
6.0 quarts (5.7 liters)
6.5 quarts (6.2 liters)
Coolant Expansion Tank Cap Pressure 15 psig (103 kPa)
7 psig (48 kPa) after November 2015
Units Built After October 2016
Coolant System Capacity: T-680S and T-880S
T-1080S
Units with coolant expansion tank and overflow bottle
7.64 quarts (7.23 liters)
8.36 quarts (7.91 liters)
Coolant Expansion Tank Cap Pressure 10 psig (69 kPa)
Belt Tension
Belt Tension No. on TK Gauge
P/N 204-427 Frequency Gauge P/N 204-1903 Setting Where Applicable
New Belt Field Reset New Belt Field Reset
Water Pump Belt 40 40
Engine/Electric Motor (Jackshaft) 81 77 62 Hz 55 Hz
Electric Motor (Jackshaft)/Compressor 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: T-680S and T-880S
T-1080S TK04 Scroll 4 HP TK06 Scroll 6 HP
Refrigerant Charge: T-680S and T-880S
T-1080S 7.0 lb (3.2 kg) R-404A 7.5 lb (3.4 kg) R-404A
*Compressor Oil Charge 2.0 quarts (1.9 liters)
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
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.
Electrical Control System
Control System Voltage 12.5 Vdc
Battery Charging System 12 volt, 37 amp, brush type, Thermo King alternator
Voltage Regulator Setting 13.8 to 14.4 volts @ 77 F (25 C)
NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King
Alternator.
Engine (Continued)

Specifications
18
Fuses
Fuse Size Function
F2 15A Power to On/Off Switch
F3 40A Fuel Sol Pull-In/Starter Circuit
F4 None
2A No Fuse - All Bosch and Thermo King Alternators 2A Fuse - All Prestolite Alternators
F5 40A Preheat Circuit
F6 15A Damper and High Speed Circuits
F7 2A 8XP Circuit - Controller On Feedback to HMI
F8 5A 2A Power to CAN Connector J12
F9 5A 2A Power to CAN Connector J14
F10 10A 8X Power (Install fuse in right position)
F12 5A 2A Power to CAN Connector J13
F13 2A 8FC Circuit (Remote Status Light/Optional Power)
F20 2A Alternator Sense
F21 60A Main Fuse (2 Circuit)
F25 7.5A HPCO Switch Circuit
F26 5A 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.
Electrical Components
Component Current Draw (Amps)
at 12.5 Vdc Resistance (Ohms)
Glow Plugs (3) Each 4.3 2.3 ± 0.2
Fuel Solenoid: Pull In Coil
Hold In Coil 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
Hot Gas Solenoid (HGS) 1.1 11.3
Purge Valve (PV) 1.1 11.3
Liquid Injection Solenoid (LIS) 1.1 11.3
Electronic Throttling Valve (ETV):
Coil A (Red [EVA] and Blue [EVB] Wires)
Coil B (Black [EVC] and White [EVD] Wires) — —20 to 35 20 to 35
Starter Motor (No Load Bench Test) 90

Specifications
19
Electrical Standby (Model 50 Units Only)
T-680S and T-880S Electric Motor and Overload Relay
Voltage/Phase/Frequency Horsepower Kilowatts rpm Full Load
(amps) Overload Relay Setting (amps)
230/3/50 6.0 4.5 1460 17.0 19
230/3/60 7.2 5.4 1765 19.4 22
400/3/50 6.0 4.5 1460 9.8 11
460/3/60 7.2 5.4 1765 9.7 11
T-1080S Electric Motor and Overload Relay
Voltage/Phase/Frequency Horsepower Kilowatts rpm Full Load
(amps) Overload Relay Setting (amps)
230/3/50 10.0 7.5 1460 22.5 25
208-230/3/60 12.0 8.9 1765 28.8 32
400/3/50 10.0 7.5 1460 17.0 16
460/3/60 12.0 8.9 1765 14.4 16
Electric Heater Strips (Optional)
Number 3
Watts 750 watts (each)
Resistance 71 ohms (each)
Standby Power Requirements
Supply Circuit Breaker:
T-680S and T-880S 230/3/50-60
T-1080S 208-230/3/50-60
All 380-460/3/50-60
30 amps
50 amps
20 amps
Extension Cord Size: Up to 50 ft—10 gauge
75 ft—8 gauge