Trane Technologies Thermo King Heat King HK450 HO User manual

Revision B
November 2019 TTKK 5566111177--66--OOPP--EENN
Heat King
HK450 HO and HK450 MAX
Operator’s Manual

2TK 56117-6-OP-EN
Introduction
This man al is p blished for informational p rposes only and the
information f rnished herein sho ld not be considered as all-incl sive or
meant to cover all contingencies. If more information is req ired, cons lt
yo r Thermo King Service Directory for the location and telephone n mber
of the local dealer.
TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqq iippmmeenntt wwhhiicchh hhaass
bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd oorr aalltteerreedd aass,, iinn tthhee
mmaann ffaacctt rreerr’’ss jj ddggmmeenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy
ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,,
oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss
mmaannuuaall oorr aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss
ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd oonnllyy bbee
uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee
pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr
ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
There is nothing complicated abo t operating and maintaining yo r Thermo
King nit, b t a few min tes st dying this man al will be time well spent.
Performing pre-trip checks and enro te inspections on a reg lar basis will
minimize operating problems. A reg lar maintenance program will also help
to keep yo r nit in top operating condition. If factory recommended
proced res are followed, yo will find that yo have p rchased the most
efficient and dependable temperat re control system available.
All service req irements, major and minor, sho ld be handled by a Thermo
King dealer for fo r very important reasons:
• They are eq ipped with the factory recommended tools to perform all
service f nctions
• They have factory trained and certified technicians
• They have gen ine Thermo King replacement parts
• The warranty on yo r new nit is valid only when the repair and
replacement of component parts is performed by an a thorized Thermo
King dealer

TK 56117-6-OP-EN 3
Customer Satisfaction Survey
Let yo r voice be heard!
Yo r feedback will help improve o r man als. The s rvey is accessible
thro gh any internet-connected device with a web browser.
Scan the Q ick Response (QR) code or click or type the web address https://
tranetechnologies.iad1.q altrics.com/jfe/form/SV_2octfSHoUJxsk6x?Q_
CHL=qr&Q_JFE=qdg to complete the s rvey.
IInnttrroodd ccttiioonn

4TK 56117-6-OP-EN
SSaaffeettyy PPrreeccaa ttiioonnss .................................................................................... 66
Danger, Warning, Ca tion, and Notice . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BlowerFan............................................ 6
A tomaticStart ........................................ 7
HotS rface............................................ 7
California Proposition 65 Warning Nameplate . . . . . . . . . . . . . . . 8
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UUnniitt DDeessccrriippttiioonn.......................................................................................... 99
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine.................................................... 11
HMI Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MMaann aall PPrreettrriipp IInnssppeeccttiioonn .. .. .. ........ ........ .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .. .. 1133
Before Starting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
OOppeerraattiinngg IInnssttrr ccttiioonnss.. .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .. .......... .. .. .. .. .. ........ .. 1177
HMI Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HMI Display Icons and Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 19
HMI Display Keys and Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 20
T rning the Unit OFF and OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Alarms.................................................... 25
Alarm Code Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Alarm Code Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of Contents

TK 56117-6-OP-EN 5
Displaying Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LLooaaddiinngg aanndd EEnnrroo ttee IInnssppeeccttiioonnss .. .. .......... .. .. .. .. .. .. ........ .. .. .. .. ........ 3300
Pre-Loading Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Enro te Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SSppeecciiffiiccaattiioonnss .. .. .. ........ .. .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .. .......... .. .. .. .. 3322
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unit Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrical F ses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SSeerriiaall NN mmbbeerr LLooccaattiioonnss .. .. .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .. ........ .. .. .. .. ...... 3355
MMaaiinntteennaannccee IInnssppeeccttiioonn SScchheedd llee .. .. .. .. .. ........ .. .. .. .. .. ........ .. .. .. .. .... 3377
WWaarrrraannttyy........ .. .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .... 3399
EPA and ARB S pplemental Emissions Warranty
Statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TTrroo bblleesshhoooottiinngg .. .. .. .. .. .. .......... .. .. .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. ........ .. .. .. .. .. .. 4400
EEmmeerrggeennccyy CCoolldd LLiinnee .. .. .. .. .. ........ .. .. .. .. .. ........ .. .. .. .. .......... .. .. .. .. .. ........ .. .. 4433
TTaabbllee ooff CCoonntteennttss

6TK 56117-6-OP-EN
Safety Precautions
anger, Warning, Caution, and Notice
Thermo King®recommends that all service be performed by a Thermo King
dealer and to be aware of several general safety practices.
Safety advisories appear thro gho t this man al as req ired (refer to
examples below). Yo r personal safety and the proper operation of this nit
depend pon the strict observance of these preca tions.
DDAANNGGEERR
EExxaammppllee!!
Indicates an imminently hazardo s sit ation which, if not avoided, will
res lt in death or serio s inj ry.
WWAARRNNIINNGG
EExxaammppllee!!
Indicates a potentially hazardo s sit ation which, if not avoided, co ld
res lt in death or serio s inj ry.
CCAAUUTTIIOONN
EExxaammppllee!!
Indicates a potentially hazardo s sit ation which, if not avoided, co ld
res lt in minor or moderate inj ry and nsafe practices.
NN TTIICCEE
EExxaammppllee!!
Indicates a sit ation that co ld res lt in eq ipment or property-damage
only accidents.
Safety ecals
Blower Fan
Be aware of the Fan ca tion decal near the blower fan.

TK 56117-6-OP-EN 7
Figure 1. Fan Warning
Automatic Start
Be aware of the A tomatic Start warning decal located inside the nit.
Figure 2. Automatic Start
Hot Surface
Be aware of the Hot S rface ca tion decal inside the nit.
SSaaffeettyy PPrreeccaa ttiioonnss

8TK 56117-6-OP-EN
Figure 3. Hot Surface
California Proposition 65 Warning Nameplate
Figure 4. P65 Warning Nameplate
General Safety Practices
DDAANNGGEERR
RRiisskk ooff IInnjj rryy!!
Keep hands and loose clothing clear of fans and belts at all times when the
nit is operating with the doors open.
WWAARRNNIINNGG
RRiisskk ooff IInnjj rryy!!
Do not apply heat to a closed cooling system. Before applying heat to a
cooling system, drain it. Then fl sh 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 eno gh to boil off the
water.
CCAAUUTTIIOONN
SShhaarrpp EEddggeess!!
Exposed coil fins can ca se lacerations. Service work on the evaporator or
condenser coils is best left to a certified Thermo King technician.
SSaaffeettyy PPrreeccaa ttiioonnss

TK 56117-6-OP-EN 9
Unit escription
Unit Overview
Heat King Cargo Heaters are one-piece diesel powered heating nits
designed for installation onto the front wall of trailers and intermodal
containers to provide freeze protection for temperat re sensitive cargo. A
remote mo nted HMI Controller operates the nit and displays nit
information. There are two Heat King models:
• HK450 HO (High O tp t 36,000 BTU)
• HK450 MAX (50,000 BTU)
HHKK445500 HHOO heat the cargo area by ro ting heated engine coolant thro gh the
radiator coil. A blower in front of the coil transfers the heated air into the
cargo box.
HHKK445500 MMAAXX provides additional heating capacity by incorporating an
exha st system heat exchanger. Engine coolant is ro ted thro gh the heat
exchanger and then into the radiator coil. A blower in front of the coil
transfers the heated air into the cargo box.
Figure 5. Front view HK450 MAX shown, HK450 HO similar

10 TK 56117-6-OP-EN
Figure 6. Engine Compartment Components
1. TG-VII Base Controller
2. Fuel Filter
3. Oil Fill Cap
4. Engine Thermostat
5. Exhaust Muffler / Heat Exchanger HK450 MAX units only.
Exhaust Muffler (not shown) HK450 HO units only.
6. Alternator
7. Battery Box and Hold Down Bracket
8. Maintenance On/Off Switch
9. Oil Drain Plug
10. Oil Filter
11. Oil Level Dipstick
12. Air Filter
UUnniitt DDeessccrriippttiioonn

TK 56117-6-OP-EN 11
Figure 7. Rear View (all models)
1. Air Inlet
2. Air Outlet
Engine
A Thermo King TK 270VF indirect injected two-cylinder, water cooled diesel
engine powers the nit. Refer to the Specifications section of this man al for
more information.
UUnniitt DDeessccrriippttiioonn

12 TK 56117-6-OP-EN
HMI Controller
The HMI Controller is located in a weather protected enclos re mo nted on
the o tside of the trailer or container. The controller is sed by the operator
to t rn the nit on and off, set desired cargo temperat re, and display nit
information.
Figure 8. HMI Controller shown mounted in weather protected enclosure
Protection evices
MMaaiinn FF ssee:: A 60 amp f se protects all nit electrical circ its.
EEnnggiinnee CCoooollaanntt TTeemmppeerraatt rree SSeennssoorr:: The engine coolant temperat re
sensor signals the TG-VII Base Controller to sh t down the nit if the engine
coolant temperat re exceeds the specified limit.
CCoooollaanntt LLeevveell SSwwiittcchh:: This switch monitors the coolant level. If coolant
level becomes low, an alarm code is displayed on the HMI Controller.
EEnnggiinnee LLooww OOiill PPrreessss rree SSwwiittcchh:: This switch signals the TG-VII Base
Controller to stop the engine if the oil press re drops below the specified
minim m.
EEmmeerrggeennccyy//MMaaiinntteennaannccee OOnn--OOffff SSwwiittcchh:: This switch c ts power to the
TG-VII Base Controller ca sing an immediate, total nit sh tdown when in
the off position.
UUnniitt DDeessccrriippttiioonn

TK 56117-6-OP-EN 13
Manual Pretrip Inspection
Before Starting the Unit
Pretrip inspections are an important part of a preventative maintenance
program designed to minimize operating problems and breakdowns.
Perform this pretrip inspection before every trip involving temperat re
controlled cargo.
NN TTEE:: PPrreettrriipp iinnssppeeccttiioonnss aarree nnoott iinntteennddeedd ttoo ttaakkee tthhee ppllaaccee ooff rreegguullaarr
mmaaiinntteennaannccee iinnssppeeccttiioonnss..
FF eell:: Make s re the f el s pply is adeq ate to g arantee engine operation
to the next check point.
EEnnggiinnee OOiill:: Check the engine oil level. It sho ld be at the F ll mark when the
dipstick is p shed all the way into the oil pan. Do not overfill.
CCAAUUTTIIOONN
SSeerrvviiccee PPrroocceedd rreess!!
T rn the nit off before attempting to check the engine oil.
CCoooollaanntt:: Remove the coolant filler cap and check the coolant level. Add
additional coolant to the expansion tank if necessary. Fill to level of ledge on
tank as shown in the ill stration.
All Heat King nits se Extended Life Coolant (ELC). The maintenance
interval for ELC is eight years or 15,000 ho rs. A nameplate near the coolant
expansion tank identifies nits with ELC. This coolant is Red instead of the
previo s Green or Bl e-Green coolants. For coolant description see the
Specifications section of this man al.
Figure 9. ELC (Extended Life Coolant) Nameplate
RCS1161

14 TK 56117-6-OP-EN
IImmppoorrttaanntt:: nly AT extended life coolants (Chevron Delo® XLC or
equivalent) should be added to Thermo King systems.
Conventional coolants should not be used (Typically identified
by green or blue-green color). If a conventional coolant is
combined with the Thermo King factory fill up to 25% by volume,
the coolant must be changed at the next service opportunity.
Above 25%, the coolant must be changed immediately.
Conventional coolants dilute/interact with the additive packages
of extended life coolant which significantly reduces the service
life of the coolant.
NNoottee:: The use of 55/45% 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.
Figure 10. Coolant Fill Level
1. Coolant Fill Level
CCAAUUTTIIOONN
HHaazzaarrddoo ss PPrreessss rreess!!
Do not remove expansion tank cap while coolant is hot.
MMaann aall PPrreettrriipp IInnssppeeccttiioonn

TK 56117-6-OP-EN 15
Figure 11. Coolant Expansion Tank and Filler Cap
RCS1162
1
2
1. Coolant Expansion Tank Pressure Cap
2. Coolant Filler Cap (check/add coolant here)
MMaann aall PPrreettrriipp IInnssppeeccttiioonn

16 TK 56117-6-OP-EN
Figure 12. Manual Pretrip Inspection Check Points
1. Coolant Expansion Tank 3. Engine Belt
2. Oil Level Dipstick 4. Battery Box and Hold Down Bracket
BBaatttteerryy:: Make s re the battery terminals are tight and free of corrosion.
BBeelltt:: Make s re the engine belt is in good condition and adj sted to the
proper tension.
CCaarrggoo BBooxx:: Check the interior and exterior of the box for damage. Any
damage to the walls or ins lation m st be repaired.
DDoooorrss:: Make s re that the doors and weather seals are in good condition.
The doors sho ld latch sec rely and the weather seals sho ld fit tightly.
EElleeccttrriiccaall:: Check all electrical connections to make certain they are sec rely
fastened. Wires and terminals sho ld be free of corrosion, cracks, and
moist re.
LLeeaakkss:: Inspect for f el leaks, engine oil leaks and coolant leaks.
RRaaddiiaattoorr ((HHeeaattiinngg)) CCooiill:: Make s re the coil is clean and free of debris.
SSttrr cctt rraall:: Vis ally inspect the nit for leaks, loose or broken parts, and
other damage.
MMaann aall PPrreettrriipp IInnssppeeccttiioonn

TK 56117-6-OP-EN 17
Operating Instructions
The HMI Controller consists of an On/Off Switch, an Ho rmeter and the
Display and Keypad.
• The ON/OFF Switch is sed to t rn the nit On and Off.
• The Ho rmeter displays Engine R n Time Ho rs. The right digit shows
tenths of an ho r.
The Display and Keypad are sed to:
• Display box temperat re (Ret rn Air Temperat re) in °F or °C.
• Display and change the setpoint.
• Display any existing alarm conditions and clear most alarm codes.
Figure 13. HMI Controller
1. Unit ON/OFF Switch
2. Hourmeter
3. Display and Keypad

18 TK 56117-6-OP-EN
HMI isplay Icons
The HMI Controller displays setpoint temperat re, box temperat re and
alarm information to the operator.
Figure 14. HMI isplay Icons
1. Return Air Temperature Icon
2. Setpoint Icon
3. Alarm Icon
4. Red “C” = Centigrade Display
5. Blue “F” = Fahrenheit Display
OOppeerraattiinngg IInnssttrr ccttiioonnss

TK 56117-6-OP-EN 19
HMI isplay Icons and escriptions
1. Return Air Temperature Icon
When the Return Air Temperature Icon is present, the display is showing the
actual box temperature inside the cargo box.
2. Setpoint Icon
When the Setpoint Icon is present the display is showing the current
setpoint. The setpoint can also be changed when the Setpoint Icon is
present.
3. Alarm Icon
When the Alarm Icon is present one or more alarm conditions have occurred.
• When the unit is first turned on, if the Alarm Icon is on steady yellow for
30 seconds and then turns off, one or more Log Alarms have occurred.
• If the Alarm Icon is on steady yellow and does not turn off one or more
Check Alarms have occurred.
• If the Alarm Icon is flashing red then one or more Shutdown Alarms
have occurred and the unit has been shut down. Immediate action must
be taken.
Consult the Alarm Codes table at the back of this section for suggested
corrective actions.
4. Red “C”
When the red “C” is turned on temperatures are being displayed in degrees
Celsius.
5. Blue “F”
When the blue “F” is turned on temperatures are being displayed in degrees
Fahrenheit.
Note: HMI Controller Display of C or F can be set by your Thermo King Dealer.
OOppeerraattiinngg IInnssttrr ccttiioonnss

20 TK 56117-6-OP-EN
HMI isplay Keys and escriptions
The HMI feat res three to ch sensitive keys. Some of these keys have more
than one f nction.
Figure 15. HMI isplay Keys and escription
1. SELECT Key
Scrolling: The SELECT Key is used to scroll between the three available
displays - Return Air Temperature, Setpoint Temperature and Alarms.
Setpoint: When the setpoint is shown on the display and a new setpoint has
been chosen using the Up and/or Down Arrow Keys, the SELECT Key must be
pressed within about 10 seconds to confirm and load the new setpoint.
Alarms: When an alarm code is shown on the display, pressing and holding
the SELECT Key will clear that alarm code. Each alarm code must be cleared
individually.
2. UP ARROW Key
Setpoint: When the setpoint is shown on the display, pressing the UP
ARROW Key will increase the setpoint.
Alarms: When an alarm code is shown on the display and more than one
alarm code exists, pressing the UP ARROW Key will scroll forward through
the existing alarm codes.
3. DOWN ARROW Key
Setpoint: When the setpoint is shown on the display, pressing the DOWN
ARROW Key will decrease the setpoint.
Alarms: When an alarm code is shown on the display and more than one
alarm code exists, pressing the DOWN ARROW Key will scroll backwards
through the existing alarm codes.
OOppeerraattiinngg IInnssttrr ccttiioonnss