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Operator’s ManualIngersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands in

Safety Precautions8Battery Installation and Cable RoutingWARNING: Improperly installed battery could result in a fire or explosion! A Thermo King appr

Glossary98dehydrator: A device used to remove moisture from refrigerant. Also called a drier.discharge air temperature: The temperature of air leaving

Glossary99Hertz: A unit of frequency equal to one cycle per second. Abbreviated “Hz.”HFC: A refrigerant consisting of hydrogen, fluorine and carbon.

Glossary100pre-heat: The heating of diesel engine glow plugs prior to start-up. Some engines use an intake manifold heater rather than glow plugs.pre-

Glossary101Vac (volts alternating current): An electric current that reverses direction at regularly recurring intervals.Vdc (volts direct current): A

102Serial Number and Refrigerant Label LocationsWrite the unit model and unit serial number in the spaces provided in the following Emergency Cold Lin

Serial Number and Refrigerant Label Locations103Figure 49: X214 Reciprocating Compressor Serial Number LocationFigure 50: X426 Reciprocating Compresso

Serial Number and Refrigerant Label Locations104Figure 52: Laminated Unit Serial Number PlateFigure 53: Refrigerant Type Label1. Unit Serial Plate2. R

105Recover RefrigerantAt Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can resul

106Emergency Cold LineIf you can’t get your rig rolling, and you have tried the Thermo King North American Service Directory (available from any Therm

107CALIFORNIAProposition 65 WarningDiesel exhaust is a chemical known to the State of California to cause cancer.

Safety Precautions9Electrical HazardRefrigerantAlthough fluorocarbon refrigerants are classified as safe, observe caution when working with refrigeran

Operator’s ManualIngersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands in

Safety Precautions10First AidFirst Aid–RefrigerantEyes: For contact with liquid, immediately flush eyes with large amounts of water. Get prompt medica

Safety Precautions11Safety Decals and LocationsFigure 1: Antifreeze Caution(Attached near radiator fill cap.)Figure 2: Belt Caution (Locations vary de

Safety Precautions12Figure 3: Automatic Start Caution (Locations vary depending on model. Decals are located near areas that contain moving parts whic

Safety Precautions13SmartPower Units (Electric Standby)Figure 5: Electrical Hazard (Locations vary depending on model. Typically located near power re

14Emission ControlIn compliance with the California ULG (Utility, Lawn and Garden) Rules, the following information is provided:1. Selection Of Fuel O

Emission Control15a. Emission control label: a new label, shown in Figure 7, contains important engine information.Figure 7: Emission Control Labelb.

Emission Control163-1 Emission Control Labels: Emission control labels are a requirement of the California ULG Rules. In the event the emission contro

Emission Control174. Emission Control Related Parts: The California ULG Rules require a manufacturing defect warranty on all emission control parts, i

Emission Control18(ULG) engine for the time listed below, provided there has been no abuse, neglect or improper maintenance of your utility equipment

Emission Control19Manufacturer Explanation Of Emission Control System Warranty CoverageA. Warranty Commencement DateThe California emission control sy

Emission Control20D. What is Not Covered1. Failures caused by abuse, neglect, or improper maintenance.2. Add-On or Modified Parts. The use of add-on o

Emission Control21EPA Emission Control System Warranty StatementThermo King warrants to the initial owner and each subsequent owner that the certified

Emission Control22This warranty covers the following emission-related parts and components:• Fuel Injection System• Intake Manifold• Exhaust Manifold•

Emission Control23LimitationsThermo King is not responsible for resultant damages to an emission-related part or component resulting from:• Any applic

24Unit DescriptionGeneral DescriptionThis manual covers the following Thermo King models:• T-680R, T-880R and T-1080R with reciprocating compressor.•

Unit Description25Design Features• Microprocessor Controller, SR-3 Truck• Alarm Code Display• Battery Voltage Display• Continuous System Monitoring• C

Unit Description26• Stainless Steel Condenser and Evaporator Hardware• TK374F Tier 4 Diesel Engine (T-680R, T-680S, T-880R and T-880S)• TK380F Tier 4

Unit Description27EngineEngine power for the T-680R, T-680S,T-880R and T-880S is provided by the TK374F, a three-cylinder, EPA Tier 4, special clean a

Copyright© 2013 Thermo King Corp., Minneapolis, MN, USAPrinted in USAT-680R / T-880R / T-1080RT-680S / T-880S / T-1080S Series with Standard SR-3 HMIT

Unit Description28NOTE: The use of 50/50% pre-mixed ELC is recommended to ensure that deionized water is being used. If 100% full strength concentrate

Unit Description29The CYCLE-SENTRY system automatically starts the unit on microprocessor demand and shuts down the unit when all demands are satisfie

Unit Description30DAS data can be downloaded through a serial port to an IBM® PC compatible computer. WinTrac™ 4.0 (or higher) software is used to vie

Unit Description31Standard Model 50 FeaturesThe following features are standard equipment on units equipped with Electric Standby.Automatic Diesel/Ele

Unit Description32Receiver Tank Sight Glass: The receiver tank sight glass is used to assist in checking the amount of refrigerant in the system.Compr

Unit Description33Figure 13: T-680S Front View (T-680R, T-880S and T-880R are similar)

Unit Description34Figure 14: T-1080S Front View (T-1080R is similar)

Unit Description35246357181. Engine Oil Dipstick (on side of engine) 5. Alternator2. Engine 6. Compressor (reciprocating shown)3. Coolant Expansion Ta

36Unit OperationSR-3 Truck HMI ControllerThe SR-3 Standard Truck HMI (Human/Machine Interface) Control Panel is supplied as standard equipment on SR-3

Unit Operation37• Selects and Indicates CYCLE-SENTRY or Continuous Mode Operation• Selects and Indicates High Speed Lock-Out Operation• Initiates and

2DisclaimerThis manual is published for informational purposes only. Thermo King Corporation makes norepresentations or warranties, express or implied

Unit Operation38Keys and LED IndicatorsThere are nine touch sensitive keys. Some of these keys have more than one function as shown in Figure 18.Figur

Unit Operation39There are amber indicator LED's located next to each of the four function keys below the display. The LED will glow amber when th

Unit Operation40POWER OFF KeyPressing the OFF Key will turn the unit off.UP ARROW KeyWhen the unit is turned on and the Standard Display is shown, pre

Unit Operation41ENTER KeyIf the setpoint has been changed using the UP ARROW Key and/or DOWN ARROW Key, pressing the ENTER Key enters the setpoint int

Unit Operation42HIGH SPEED LOCK-OUT KeyIf the unit is turned on, pressing the HIGH SPEED LOCK-OUT Key will activate High Speed Lock-Out. The unit will

Unit Operation43PRETRIP TEST KeyPressing and holding the PRETRIP TEST Key for 5 seconds will initiate either a Full Pretrip Test or Engine Running Pre

Unit Operation44Turning the Unit On and OffIMPORTANT: Verify the Base Controller On/Off Switch is turned on before turning on the HMI Control Panel. T

Unit Operation45Figure 20: Electric Motor Run Time Hours and Electric IconWhen the unit is ready to run the Standard Display of box temperature and se

Unit Operation46The Standard DisplayThe Standard Display is the default display that appears if no other display function is selected. The Standard Di

Unit Operation47• The setpoint display will flash for 10 additional seconds. If at the end of this time the ENTER Key still has not been pressed to co

3Table of ContentsIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Safety Precautions . . . . . . . . . . . . . . . .

Unit Operation48• If the ENTER Key is not pressed within 20seconds of making a change with the UP ARROW Key and/or DOWN ARROW Key, the setpoint is not

Unit Operation49CAUTION: The motor may start automatically any time the unit is turned on.When the motor is preparing to start, the SR-3 Standard Truc

Unit Operation50Switching from Electric to DieselIMPORTANT: Applies to units with the Electric Standby Option only. The operation of this feature can

Unit Operation51Figure 30: Press ON KeyPreferred Method for Manually Switching from Electric Mode to Diesel Mode 1. Press the Standard Truck HMI Contr

Unit Operation52To restart the unit in Diesel Mode, proceed as follows: • Press the Standard Truck HMI Control Panel ON Key. The Hourmeters display an

Unit Operation53CAUTION: If the unit is in CYCLE-SENTRY null and the mode is switched to Continuous Mode, the unit will start automatically.Selecting

Unit Operation54Initiating a Manual Defrost CycleDefrost cycles are usually initiated automatically based on time or demand. Manual defrost may also b

Unit Operation55AlarmsAlarm Code NotificationIf an alarm condition occurs, the Alarm Icon will appear on the display. If the alarm is a Check Alarm, t

Unit Operation56Figure 38: ENTER KeyThe display will return to the Standard Display about 30 seconds after all alarms have been cleared.Figure 39: Sta

Unit Operation572Check Evaporator Coil SensorManually monitor load temperature. Report alarm at end of the day.3Check (Control) Return Air SensorManua

Table of Contents4DAS - Data Acquisition System (Optional) . . . . . . . . . 29CargoLink (Optional) . . . . . . . . . . . . . . . . . . . . . . . .

Unit Operation5817Engine Failed to CrankIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.18High Engine Coolant Tempe

Unit Operation5929Defrost Damper Circuit CheckIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.30Defrost Damper Stuc

Unit Operation6040Check High Speed CircuitIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.41Check Engine Coolant Te

Unit Operation6161 Low Battery VoltageIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.62Ammeter Out of CalibrationI

Unit Operation6281High Compressor Tem pIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.82High Compressor Temp Shutd

Unit Operation6394Check Loader #1 CircuitIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.95Check Loader #2 CircuitI

Unit Operation64120Check Alternator Excite CircuitIf unit is shut down repair immediately. Otherwise, report alarm at end of the day.121Check Liquid I

Unit Operation65141Autoswitch Diesel to Electric DisabledReport alarm at end of the day.145Loss of Controller "On" Feedback SignalIf unit is

Unit Operation66Sending a ServiceWatch Data Logger Start of TripWhen the unit is turned on, press and hold the ENTER Key for 5 seconds to send a Start

Unit Operation67Full Pretrip TestFull Pretrip Tests include all of the tests shown below.• Amp Checks - Each electrical control component is energized

Table of Contents5Electric Standby Operation . . . . . . . . . . . . . . . . . . . 72Electric Power Receptacle . . . . . . . . . . . . . . . . . .

Unit Operation68• Whenever possible, run the Pretrip Test with an empty truck box.• If running a Pretrip Test on a truck loaded with dry cargo, insure

Unit Operation69• The Amps Check Test will be preformed and then the unit will start automatically. The balance of the tests will be completed.• The P

Unit Operation70Stopping a Pretrip Test: To stop a Pretrip Test at any time, press the POWER OFF Key to turn the unit off. This will generate Alarm Co

Unit Operation71Display BrightnessThe brightness of the SR-3 Standard Truck HMI Control Panel display can be adjusted to allow for changing ambient li

72Electric Standby OperationSmartPower (Model 50) units are equipped with Electric Standby. This feature allows the unit to operate on electric power

73Loading and Enroute InspectionsThermo King refrigeration units are designed to maintain the required temperature for the product being carried durin

Loading and Enroute Inspections74Inspecting the LoadNever assume that the product has been loaded properly. Watch for and perform the following tasks.

Loading and Enroute Inspections75Enroute InspectionsNOTE: Enroute inspections are recommended every four hours for the prevention of damage to the car

Loading and Enroute Inspections76f. The unit may have a low refrigerant charge. If liquid is not showing in the unit receiver tank sight glass, the re

77SpecificationsEngineModel: T-680R, T-680S, T-880R & T-880ST-1080R & T-1080STK374F (Tier 4)TK380F (Tier 4)Fuel Type No. 2 Diesel fuel under

6IntroductionThere is nothing complicated about operating and maintaining your Thermo King unit, but a few minutes studying this manual will be time w

Specifications78Engine rpm: Low Speed Operation 1625 ± 25 rpmHigh Speed Operation Reciprocating Compressor: 2200 ± 25 rpmScroll Compressor: 2200 ± 25

Specifications79Engine Coolant Type ELC (Extended Life Coolant), which is “RED” Use a 50/50 concentration of any of the following equivalents:Chevron

Specifications80Coolant System Capacity: T-680R, T-680S, T-880R, T-880ST-1080R, T-1080S4.5 quarts (4.3 liters) with coolant expansion tank6.5 quarts (

Specifications81Engine ClutchEngagement 600 ± 100 RPMDynamic Torque 66 ft-lb (89.5 N•m) minimum @ 1600 RPMRefrigeration SystemReciprocating Compressor

Specifications82Suction Pressure Regulator Valve Setting: T-680RT-880RT-1080R28 to 31 psig (193 to 214 kPa)35 to 37 psig (241 to 255 kPa)21 to 23 psig

Specifications83Compressor Oil Type Ester base P/N 203-516 required for Scroll compressor Discharge Pressure Regulator Valve Setting 350 ± 5 psig (24

Specifications84FusesFuse Size FunctionF2 15A Power to On/Off SwitchF3 40A Fuel Sol Pull-In/Starter CircuitF4None2ANo Fuse - All Bosch and Thermo King

Specifications85F25 7.5A HPCO Switch CircuitF26 5A Power to CAN Connector J98F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternat

Specifications86Condenser Inlet Solenoid (CIS) 1.8 6.9Hot Gas Solenoid (HGS) 1.1 11.3Purge Valve (PV) 1.1 11.3Liquid Injection Solenoid (LIS) (Scroll

Specifications87SmartPower Electrical Standby (Model 50 Units Only)T-680R, T-680S, T-880R, T-880S Electric Motor and Overload RelayVoltage/Phase/Frequ

7Safety PrecautionsThermo King recommends that all services be performed by a Thermo King dealer. However, there are several general safety practices

Specifications88Electric Heater Strips (Optional)Number 3Watts 750 watts (each)Resistance 71 ohms (each)SmartPower Standby Power RequirementsSupply Ci

89Maintenance Inspection ScheduleA closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The follow

Maintenance Inspection Schedule90• • Check condition of belts.• • Check engine oil pressure hot, on high speed. ••••Listen for unusual noises, vibrati

Maintenance Inspection Schedule91• Check condition of engine mounts.• Maintain year round antifreeze protection at –30 F (–34 C). • Test fuel injectio

Maintenance Inspection Schedule92Electrical• Check controller for alarms.• Run pretrip test• Check battery voltage.• Inspect battery terminals and ele

Maintenance Inspection Schedule93Refrigeration• • Check refrigerant level.• Check compressor oil level.• Check discharge and suction pressures.• Check

Maintenance Inspection Schedule94Structural• • Visually inspect unit for fluid leaks.• • Visually inspect unit for damaged, loose or broken parts (inc

95WarrantyTerms of the Thermo King Warranty are available on request. Please reference document TK 50047 for the Thermo King Self-Powered Truck Unit W

96GlossaryThis glossary is published for informational purposes only and the information being furnished herein should not be considered as all-inclus

Glossary97CFC: Chlorofluorocarbon. A chlorine-based refrigerant consisting of chlorine, fluorine and carbon. Example: R12. In many countries it is ill