Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
Heat King 430 &
Heat King 430 HO
TK 55203-6-OP (Rev. 0, 10/2011)
©2011 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2011 Ingersoll-Rand Company
Printed in U.S.A.
Heat King 430 &
Heat King 430 HO
TK 55203-6-OP (Rev. 0, 10/2011)
Heat King 430 &
Heat King 430 HO
TK 55203-6-OP (Rev. 0, 10/2011)
Copyright© 2011 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
Heat King 430 &
Heat King 430 HO
TK 55203-6-OP (Rev. 0, 10/2011)
Copyright© 2011 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no
representations or warranties, express or implied, with respect to the information, recommendations
and descriptions contained in this manual and such information, recommendations and descriptions
should not be regarded as all-inclusive or covering all contingencies. In the event you have any
questions or require further information, please contact your local Thermo King dealer.
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to
implement these procedures correctly may cause damage to the Thermo King unit or other property or
personal injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or
any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or
resulting from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo
King unit.
2
Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no
representations or warranties, express or implied, with respect to the information, recommendations
and descriptions contained in this manual and such information, recommendations and descriptions
should not be regarded as all-inclusive or covering all contingencies. In the event you have any
questions or require further information, please contact your local Thermo King dealer.
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to
implement these procedures correctly may cause damage to the Thermo King unit or other property or
personal injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or
any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or
resulting from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo
King unit.
2
Introduction
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a
regular basis will minimize on-the-road operating problems. A
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
IMPORTANT: This manual is published for informational
purposes only and the information furnished herein should
not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Thermo King Service Directory for the location and
telephone number of the local dealer.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
•
They are equipped with the factory recommended tools to
perform all service functions
•
They have factory trained and certified technicians
•
They have genuine Thermo King replacement parts
•
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
3
Introduction
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a
regular basis will minimize on-the-road operating problems. A
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
IMPORTANT: This manual is published for informational
purposes only and the information furnished herein should
not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Thermo King Service Directory for the location and
telephone number of the local dealer.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
•
They are equipped with the factory recommended tools to
perform all service functions
•
They have factory trained and certified technicians
•
They have genuine Thermo King replacement parts
•
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
3
Introduction
4
Introduction
4
Table of Contents
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
California Emission Control System Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Your Warranty Rights And Obligations . . . . . . . . . 15
Manufacturer’s Warranty Coverage . . . . . . . . . . . 16
Owner’s Warranty Responsibilities . . . . . . . . . . . . 16
Manufacturer Explanation Of Emission Control System
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EPA Emission Control System Warranty Statement . . 19
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Thermo King Corporation Responsibilities . . . . . . . . . 20
Owner Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . 20
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . .24
TG-VII HMI Control Panel . . . . . . . . . . . . . . . . . . .26
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .26
Manual Pretrip Inspection
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . .27
ThermoGuard VII HMI Operating Instructions . . . . .31
ThermoGuard VII HMI Display . . . . . . . . . . . . . . .32
Display Icon Descriptions . . . . . . . . . . . . . . . . . . .33
Display Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Turning the Unit ON and OFF . . . . . . . . . . . . . . . .37
The Standard Display . . . . . . . . . . . . . . . . . . . . . .37
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . .38
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . .40
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Alarm Code Types . . . . . . . . . . . . . . . . . . . . . . . . .40
5
Table of Contents
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
California Emission Control System Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Your Warranty Rights And Obligations . . . . . . . . . 15
Manufacturer’s Warranty Coverage . . . . . . . . . . . 16
Owner’s Warranty Responsibilities . . . . . . . . . . . . 16
Manufacturer Explanation Of Emission Control System
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EPA Emission Control System Warranty Statement . . 19
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Thermo King Corporation Responsibilities . . . . . . . . . 20
Owner Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . 20
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . .24
TG-VII HMI Control Panel . . . . . . . . . . . . . . . . . . .26
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .26
Manual Pretrip Inspection
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . .27
ThermoGuard VII HMI Operating Instructions . . . . .31
ThermoGuard VII HMI Display . . . . . . . . . . . . . . .32
Display Icon Descriptions . . . . . . . . . . . . . . . . . . .33
Display Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Turning the Unit ON and OFF . . . . . . . . . . . . . . . .37
The Standard Display . . . . . . . . . . . . . . . . . . . . . .37
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . .38
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . .40
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Alarm Code Types . . . . . . . . . . . . . . . . . . . . . . . . .40
5
Table of Contents
Alarm Code Notification . . . . . . . . . . . . . . . . . . . . 41
Displaying Alarm Codes . . . . . . . . . . . . . . . . . . . . 41
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . 42
Important Alarm Notes . . . . . . . . . . . . . . . . . . . . . 43
ThermoGuard VII HMI Alarm Codes . . . . . . . . . . . . . . 43
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 71
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CALIFORNIA Proposition 65 Warning . . . . . . . . . . 77
Loading and Enroute Inspections . . . . . . . . . . . . . . 47
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . . 47
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 49
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Unit Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Serial Number Label Locations . . . . . . . . . . . . . . . . 55
Maintenance Inspection Schedule . . . . . . . . . . . . . . 57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6
Table of Contents
Alarm Code Notification . . . . . . . . . . . . . . . . . . . . 41
Displaying Alarm Codes . . . . . . . . . . . . . . . . . . . . 41
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . 42
Important Alarm Notes . . . . . . . . . . . . . . . . . . . . . 43
ThermoGuard VII HMI Alarm Codes . . . . . . . . . . . . . . 43
Loading and Enroute Inspections . . . . . . . . . . . . . . 47
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . . 47
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 49
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Unit Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . 52
Electrical Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Serial Number Label Locations . . . . . . . . . . . . . . . . 55
Maintenance Inspection Schedule . . . . . . . . . . . . . . 57
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . . 71
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CALIFORNIA Proposition 65 Warning . . . . . . . . . . 77
Safety Precautions
Thermo King recommends all services be performed by a
Thermo King dealer. However, there are several general safety
practices you should be aware of:
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring could cause
a fire. Never drill into structural components.
WARNING: Turn all unit On/Off switches to the Off
position before opening doors or inspecting any part
of the unit.
WARNING: Always wear goggles or safety glasses
when working with or around the engine cooling
system or battery. Hot engine coolant or battery acid
can cause permanent damage if they come in contact
with your eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating.
7
Safety Precautions
Thermo King recommends all services be performed by a
Thermo King dealer. However, there are several general safety
practices you should be aware of:
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring could cause
a fire. Never drill into structural components.
WARNING: Turn all unit On/Off switches to the Off
position before opening doors or inspecting any part
of the unit.
WARNING: Always wear goggles or safety glasses
when working with or around the engine cooling
system or battery. Hot engine coolant or battery acid
can cause permanent damage if they come in contact
with your eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating.
7
Safety Precautions
Safety Decals
AMA662
Figure 2: Caution: Fan Warning
AMA661
Figure 1: Coolant Type and Warning
AMA663
Figure 3: Automatic Start Warning
8
Safety Precautions
Safety Decals
AMA662
Figure 2: Caution: Fan Warning
AMA661
Figure 1: Coolant Type and Warning
AMA663
Figure 3: Automatic Start Warning
8
Safety Precautions
AMA665
Figure 4: Hot Surface Warning
9
Safety Precautions
AMA665
Figure 4: Hot Surface Warning
9
Safety Precautions
10
Safety Precautions
10
Emission Control
In compliance with the California ULG (Utility, Lawn and
Garden) Rules, the following information is provided:
1. Selection Of Fuel Oil: Use diesel fuel only.
2-1. Modification To Any Engine Component:
Modifications to any engine component which many cause
engine exhaust emission output changes are not allowed.
Any engine modification not in compliance with regulation
will be the responsibility of the engine manufacturer, dealer or
customer who made the modification.
2-4. Fuel Oil System: Fuel oil system must remain intact
and receive regular prescribed maintenance. Example: Fuel
filter replacement at required operation hour interval.
3. Engine Identification: Engines must be identified in a
manner that will determine when they were built and what
regulations they comply with. The engine must be labeled with
an emission control label and the engine family name, both
described below.
2-2. Air Induction System: Air induction system must
remain intact and receive regular prescribed maintenance.
Example: Air cleaner element replacement at required
operation hour interval.
2-3. Exhaust System: Exhaust system must remain intact
and cannot be modified in any manner that will further restrict
exhaust flow.
11
Emission Control
In compliance with the California ULG (Utility, Lawn and
Garden) Rules, the following information is provided:
1. Selection Of Fuel Oil: Use diesel fuel only.
2-1. Modification To Any Engine Component:
Modifications to any engine component which many cause
engine exhaust emission output changes are not allowed.
Any engine modification not in compliance with regulation
will be the responsibility of the engine manufacturer, dealer or
customer who made the modification.
2-4. Fuel Oil System: Fuel oil system must remain intact
and receive regular prescribed maintenance. Example: Fuel
filter replacement at required operation hour interval.
3. Engine Identification: Engines must be identified in a
manner that will determine when they were built and what
regulations they comply with. The engine must be labeled with
an emission control label and the engine family name, both
described below.
2-2. Air Induction System: Air induction system must
remain intact and receive regular prescribed maintenance.
Example: Air cleaner element replacement at required
operation hour interval.
2-3. Exhaust System: Exhaust system must remain intact
and cannot be modified in any manner that will further restrict
exhaust flow.
11
Emission Control
a.
Emission control label: a new label, shown in
Figure 5, contains important engine information.
b.
AMA04
Engine Family Name, as assigned by the California
Air Resources Board, identifies engine family group,
by largest displacement, within an engine family, and
is shown in Figure 6.
AMA06
Figure 6: Engine Family Name
Figure 5: Emission Control Label
12
Emission Control
a.
Emission control label: a new label, shown in
Figure 5, contains important engine information.
AMA04
Engine Family Name, as assigned by the California
Air Resources Board, identifies engine family group,
by largest displacement, within an engine family, and
is shown in Figure 6.
AMA06
Figure 5: Emission Control Label
12
b.
Figure 6: Engine Family Name
Emission Control
3-1 Emission Control Labels: Emission control labels are
a requirement of the California ULG Rules. In the event the
emission control label provided on the engine is inaccessible,
there will be a supplemental label containing the same
information, provided by the equipment manufacturer, located
in a readily accessible location, shown in Figure 7:
All engine labels and supplementary labels will contain the
following information:
•
Engine Family Name
•
Displacement
•
Manufacturer
The above information, along with the engine serial number,
will be required to obtain proper service information and
correct service repair parts. An example list which identifies
the exhaust control system is shown in Figure 8.
AMA05
Figure 7: Emission Control Label Location
13
Emission Control
3-1 Emission Control Labels: Emission control labels are
a requirement of the California ULG Rules. In the event the
emission control label provided on the engine is inaccessible,
there will be a supplemental label containing the same
information, provided by the equipment manufacturer, located
in a readily accessible location, shown in Figure 7:
All engine labels and supplementary labels will contain the
following information:
•
Engine Family Name
•
Displacement
•
Manufacturer
The above information, along with the engine serial number,
will be required to obtain proper service information and
correct service repair parts. An example list which identifies
the exhaust control system is shown in Figure 8.
AMA05
Figure 7: Emission Control Label Location
13
Emission Control
1.
Engine Model
Engine Family Name
TK270
6YDXL0.57W2N
Note: Design parameters to bring engine family into compliance were
utilized; no after treatment measures incorporated.
Figure 8: Exhaust Control Systems
14
Emission Control
1.
Engine Model
Engine Family Name
TK270
6YDXL0.57W2N
Note: Design parameters to bring engine family into compliance were
utilized; no after treatment measures incorporated.
Figure 8: Exhaust Control Systems
14
Emission Control
4. Emission Control Related Parts: The California ULG
Rules require a manufacturing defect warranty on all emission
control parts, including:
5. Maintenance Schedule: To maintain optimum engine
performance and compliance with the California ULG Rules,
the maintenance schedule must be adhered to.
•
Fuel Injection Pump
•
Fuel Injection Nozzle
•
High Pressure Oil Line
Regular scheduled maintenance is the major key to engine
service life and emission regulation compliance. Scheduled
maintenance requirements must be performed regularly. See
the Maintenance Schedule provided in this Operator’s Manual.
•
Air Cleaner Element1
•
Fuel Filter Element1
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold) Gasket
•
Muffler Gasket
The warranty period is two years and complete details are
included in the section of this manual titled “California
Emission Control System Warranty Statement, Your Warranty
Rights And Obligations.”
1
Any warranted part which is scheduled for replacement as
required maintenance shall be warranted for the period of time
up to the first scheduled replacement point for that part.
California Emission Control
System Warranty Statement
Your Warranty Rights And
Obligations
The California Air Resources Board and Thermo King are
pleased to explain the California emission control system
warranty on your 1996 and later utility equipment (ULG)
engine. In California, new utility equipment (ULG) engines
must be designed, built, and equipped to meet the state’s
stringent anti-smog standards. Thermo King must warrant the
California emission control system on your utility equipment
15
Emission Control
4. Emission Control Related Parts: The California ULG
Rules require a manufacturing defect warranty on all emission
control parts, including:
5. Maintenance Schedule: To maintain optimum engine
performance and compliance with the California ULG Rules,
the maintenance schedule must be adhered to.
•
Fuel Injection Pump
•
Fuel Injection Nozzle
•
High Pressure Oil Line
Regular scheduled maintenance is the major key to engine
service life and emission regulation compliance. Scheduled
maintenance requirements must be performed regularly. See
the Maintenance Schedule provided in this Operator’s Manual.
•
Air Cleaner Element1
•
Fuel Filter Element1
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold) Gasket
•
Muffler Gasket
The warranty period is two years and complete details are
included in the section of this manual titled “California
Emission Control System Warranty Statement, Your Warranty
Rights And Obligations.”
1
Any warranted part which is scheduled for replacement as
required maintenance shall be warranted for the period of time
up to the first scheduled replacement point for that part.
California Emission Control
System Warranty Statement
Your Warranty Rights And
Obligations
The California Air Resources Board and Thermo King are
pleased to explain the California emission control system
warranty on your 1996 and later utility equipment (ULG)
engine. In California, new utility equipment (ULG) engines
must be designed, built, and equipped to meet the state’s
stringent anti-smog standards. Thermo King must warrant the
California emission control system on your utility equipment
15
Emission Control
(ULG) engine for the time listed below, provided there has
been no abuse, neglect or improper maintenance of your utility
equipment (ULG) engine.
Your California emission control system includes parts such as
the fuel injection pump, the fuel injection nozzle, and the
high-pressure fuel line. Also included are the air filter element
and the fuel filter element which are covered under this
California emission control system warranty only up to the first
scheduled maintenance replacement.
Where a warrantable condition exists, Thermo King will repair
your utility equipment (ULG) engine with California emission
control system parts or components at no cost to you, including
diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
1996 and later utility equipment (ULG) engines: California
emission control system parts and components are warranted
for the period of two years (24 months). If any California
emission control system part or component on your utility
equipment (ULG) engine is defective, the part or component
will be repaired or replaced by Thermo King.
Owner’s Warranty Responsibilities
As the utility equipment (ULG) engine owner, you are
responsible for the performance of the required maintenance
listed in this Operator’s Manual. Thermo King recommends
that you retain all receipts covering maintenance on your utility
equipment (ULG) engine, but Thermo King cannot deny
warranty solely for the lack of receipts or your failure to ensure
the performance of all scheduled maintenance.
As the utility equipment (ULG) engine owner, you should be
aware that Thermo King may deny you warranty coverage if
your utility equipment (ULG) engine, or a part or component,
has failed due to abuse, neglect, improper maintenance, or
unapproved modifications.
You are responsible for presenting your utility equipment
(ULG) engine to an authorized Thermo King dealer as soon as
a problem exists. The emission control system parts or
component repairs should be completed in a reasonable
amount of time not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, contact a Thermo King service representative
at 952-887-2337.
16
Emission Control
(ULG) engine for the time listed below, provided there has
been no abuse, neglect or improper maintenance of your utility
equipment (ULG) engine.
Your California emission control system includes parts such as
the fuel injection pump, the fuel injection nozzle, and the
high-pressure fuel line. Also included are the air filter element
and the fuel filter element which are covered under this
California emission control system warranty only up to the first
scheduled maintenance replacement.
Where a warrantable condition exists, Thermo King will repair
your utility equipment (ULG) engine with California emission
control system parts or components at no cost to you, including
diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
1996 and later utility equipment (ULG) engines: California
emission control system parts and components are warranted
for the period of two years (24 months). If any California
emission control system part or component on your utility
equipment (ULG) engine is defective, the part or component
will be repaired or replaced by Thermo King.
16
Owner’s Warranty Responsibilities
As the utility equipment (ULG) engine owner, you are
responsible for the performance of the required maintenance
listed in this Operator’s Manual. Thermo King recommends
that you retain all receipts covering maintenance on your utility
equipment (ULG) engine, but Thermo King cannot deny
warranty solely for the lack of receipts or your failure to ensure
the performance of all scheduled maintenance.
As the utility equipment (ULG) engine owner, you should be
aware that Thermo King may deny you warranty coverage if
your utility equipment (ULG) engine, or a part or component,
has failed due to abuse, neglect, improper maintenance, or
unapproved modifications.
You are responsible for presenting your utility equipment
(ULG) engine to an authorized Thermo King dealer as soon as
a problem exists. The emission control system parts or
component repairs should be completed in a reasonable
amount of time not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, contact a Thermo King service representative
at 952-887-2337.
Emission Control
Manufacturer Explanation Of
Emission Control System
Warranty Coverage
at a Thermo King authorized service dealer. To obtain the
phone number of your nearest Thermo King authorized
service dealer, call the Cold Line at: 952-887-2202.
2.
Warranty Period: Any warranted California emission
control system part or component that is not scheduled for
replacement as required maintenance, or that is scheduled
only for regular inspection to the effect of repair or
replacement as necessary, shall be warranted for the
warranty period. Any warranted part that is scheduled for
replacement as required maintenance shall be warranted
for the period of time up to the first scheduled replacement
point for that part or component.
3.
Diagnosis: The owner shall not be charged for diagnostic
labor which leads to the determination that a California
emission control system warranted part or component is
defective, if the diagnostic work is performed at a Thermo
King authorized service dealer.
4.
Consequential Damages: Thermo King is liable for
damages to other engine parts or components caused by
the failure of an emission control system part or
component within the above stated California emission
control system warranty period.
A. Warranty Commencement Date
The California emission control system warranty period begins
on the date the engine or equipment is delivered to the original
retail purchaser.
B. Length Of Coverage
Thermo King warrants to the original purchaser, and each
subsequent purchaser, that the engine emission control system
is free from defects in material and workmanship that cause the
failure of the warranted California emission control system
part or component for a period of two years (24 months)
beginning on the day the utility equipment (ULG) engine is
delivered to the original purchaser.
C. What Is Covered
1.
Repair or Replacement of Parts: Repair or replacement
of any California emission control system warranted part
or component will be performed at no charge to the owner
17
Emission Control
Manufacturer Explanation Of
Emission Control System
Warranty Coverage
at a Thermo King authorized service dealer. To obtain the
phone number of your nearest Thermo King authorized
service dealer, call the Cold Line at: 952-887-2202.
2.
Warranty Period: Any warranted California emission
control system part or component that is not scheduled for
replacement as required maintenance, or that is scheduled
only for regular inspection to the effect of repair or
replacement as necessary, shall be warranted for the
warranty period. Any warranted part that is scheduled for
replacement as required maintenance shall be warranted
for the period of time up to the first scheduled replacement
point for that part or component.
3.
Diagnosis: The owner shall not be charged for diagnostic
labor which leads to the determination that a California
emission control system warranted part or component is
defective, if the diagnostic work is performed at a Thermo
King authorized service dealer.
4.
Consequential Damages: Thermo King is liable for
damages to other engine parts or components caused by
the failure of an emission control system part or
component within the above stated California emission
control system warranty period.
A. Warranty Commencement Date
The California emission control system warranty period begins
on the date the engine or equipment is delivered to the original
retail purchaser.
B. Length Of Coverage
Thermo King warrants to the original purchaser, and each
subsequent purchaser, that the engine emission control system
is free from defects in material and workmanship that cause the
failure of the warranted California emission control system
part or component for a period of two years (24 months)
beginning on the day the utility equipment (ULG) engine is
delivered to the original purchaser.
C. What Is Covered
1.
Repair or Replacement of Parts: Repair or replacement
of any California emission control system warranted part
or component will be performed at no charge to the owner
17
Emission Control
D. What is Not Covered
1.
Failures caused by abuse, neglect, or improper
maintenance.
2.
Add-On or Modified Parts. The use of add-on or modified
parts can be grounds for disallowing a warranty claim.
Thermo King is not liable for failures of emission control
system parts or components caused by the use of add-on or
modified parts.
3.
Use of fuel other than the California Title 13, CCR Section
2282 (g)(3), low sulfur, low aromatic, with a cetane
number of 48 minimum, will nullify this warranty.
call the customer service representative at 888-887-2202 for
the location of the nearest Thermo King authorized service
dealer.
G. Maintenance, Replacement and Repair of Emission
Control System Related Parts
Any Thermo King approved replacement part can be used in
the performance of any warranty maintenance or repairs on
emission control system parts or components, and must be
provided without charge to the owner if the part is still under
the California emission control system warranty.
H. Emission Control System Warranty Parts List
E. How to File a Claim
•
Part Name
Warranty claims for California emission control system parts
or components are to be filed by the Thermo King authorized
servicing dealer on behalf of the engine owner.
•
Fuel Injection Pump
•
Fuel injection Nozzle
•
High Pressure Fuel Oil Line
•
Air Cleaner Element
•
Fuel Filter Element
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold)
F.
Where to Get Warranty Service
Warranty service or repairs shall be provided at all Thermo
King authorized service dealers. You can generally find dealers
in the Yellow Pages of your regional telephone directory, or
18
Emission Control
D. What is Not Covered
1.
Failures caused by abuse, neglect, or improper
maintenance.
2.
Add-On or Modified Parts. The use of add-on or modified
parts can be grounds for disallowing a warranty claim.
Thermo King is not liable for failures of emission control
system parts or components caused by the use of add-on or
modified parts.
3.
Use of fuel other than the California Title 13, CCR Section
2282 (g)(3), low sulfur, low aromatic, with a cetane
number of 48 minimum, will nullify this warranty.
call the customer service representative at 888-887-2202 for
the location of the nearest Thermo King authorized service
dealer.
G. Maintenance, Replacement and Repair of Emission
Control System Related Parts
Any Thermo King approved replacement part can be used in
the performance of any warranty maintenance or repairs on
emission control system parts or components, and must be
provided without charge to the owner if the part is still under
the California emission control system warranty.
H. Emission Control System Warranty Parts List
E. How to File a Claim
•
Part Name
Warranty claims for California emission control system parts
or components are to be filed by the Thermo King authorized
servicing dealer on behalf of the engine owner.
•
Fuel Injection Pump
•
Fuel injection Nozzle
•
High Pressure Fuel Oil Line
•
Air Cleaner Element
•
Fuel Filter Element
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold)
F.
Where to Get Warranty Service
Warranty service or repairs shall be provided at all Thermo
King authorized service dealers. You can generally find dealers
in the Yellow Pages of your regional telephone directory, or
18
Emission Control
•
Gasket Muffler
I.
Maintenance Statements
The owner is responsible for the performance of the required
maintenance as defined by Thermo King within this Operator’s
Manual.
EPA Emission Control System
Warranty Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific, emission-related parts for a period of five years
or 3,000 hours of operation, whichever comes first, after
date of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In an emergency, repairs can be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges, for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts which are not genuine
Thermo King parts.
19
Emission Control
•
Gasket Muffler
I.
Maintenance Statements
The owner is responsible for the performance of the required
maintenance as defined by Thermo King within this Operator’s
Manual.
EPA Emission Control System
Warranty Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific, emission-related parts for a period of five years
or 3,000 hours of operation, whichever comes first, after
date of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In an emergency, repairs can be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges, for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts which are not genuine
Thermo King parts.
19
Emission Control
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
Responsibilities
As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
King authorized service dealer or other establishment
authorized by Thermo King.
Thermo King Corporation Responsibilities
This warranty covers the following emission-related parts and
components:
•
Fuel Injection System
•
Intake Manifold
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
This warranty is subject to the following:
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
•
New, remanufactured, or repaired parts or components
required to correct the defect.
NOTE: Items replaced under this warranty become the
property of Thermo King.
•
Labor, during normal working hours, required to make the
warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
Owner Responsibilities
During the emission warranty period, the owner is responsible
for:
20
Emission Control
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
Responsibilities
As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
King authorized service dealer or other establishment
authorized by Thermo King.
Thermo King Corporation Responsibilities
This warranty covers the following emission-related parts and
components:
•
Fuel Injection System
•
Intake Manifold
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
This warranty is subject to the following:
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
•
New, remanufactured, or repaired parts or components
required to correct the defect.
NOTE: Items replaced under this warranty become the
property of Thermo King.
•
Labor, during normal working hours, required to make the
warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
Owner Responsibilities
During the emission warranty period, the owner is responsible
for:
20
Emission Control
•
The performance of all required maintenance. A warranty
claim will not be denied because the scheduled
maintenance was not performed. However, if the lack of
required maintenance was the reason for the repair, then
the claim will be denied.
•
Premium of overtime cost.
•
Cost to investigate complaints that are not caused by
defect in Thermo King material or workmanship.
•
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of
material and services as specified herein. Thermo King is not
responsible for incidental or consequential damages such as
downtime or loss of engine-powered equipment.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided with the unit.
•
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair, or abuse.
21
Emission Control
•
The performance of all required maintenance. A warranty
claim will not be denied because the scheduled
maintenance was not performed. However, if the lack of
required maintenance was the reason for the repair, then
the claim will be denied.
•
Premium of overtime cost.
•
Cost to investigate complaints that are not caused by
defect in Thermo King material or workmanship.
•
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of
material and services as specified herein. Thermo King is not
responsible for incidental or consequential damages such as
downtime or loss of engine-powered equipment.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided with the unit.
•
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair, or abuse.
21
Emission Control
22
Emission Control
22
Unit Description
General Description
The Thermo King Heat King 430 and Heat King 430 HO
Cargo Heaters are one-piece diesel powered heating units
designed for installation in trailers and intermodal containers.
The unit is operated by use of a TG-VII HMI Control Panel.
The unit mounts on the front of the trailer or container. There
are two basic models.
•
Heat King 430
•
Heat King 430 High Output (HO)
The Heat King 430 and Heat King 430 HO heat the cargo area
by routing heated engine coolant through a radiator coil located
in the cargo area.
The Heat King High Output model produces additional heating
capacity through the use of an exhaust system heat exchanger
which transfers heat from the exhaust into the engine cooling
system.
AMA680
Figure 9: Front View
23
Unit Description
General Description
The Thermo King Heat King 430 and Heat King 430 HO
Cargo Heaters are one-piece diesel powered heating units
designed for installation in trailers and intermodal containers.
The unit is operated by use of a TG-VII HMI Control Panel.
The unit mounts on the front of the trailer or container. There
are two basic models.
•
Heat King 430
•
Heat King 430 High Output (HO)
The Heat King 430 and Heat King 430 HO heat the cargo area
by routing heated engine coolant through a radiator coil located
in the cargo area.
The Heat King High Output model produces additional heating
capacity through the use of an exhaust system heat exchanger
which transfers heat from the exhaust into the engine cooling
system.
AMA680
Figure 9: Front View
23
Unit Description
Engine
Heat and power are provided by a indirect injected TK 270
two-cylinder, water cooled diesel engine rated at 9.2
continuous horsepower at 2,550 rpm.
ELC (Extended Life Coolant)
The maintenance interval for ELC (Extended Life Coolant) is
five years or 12,000 hours. A nameplate on the coolant
expansion tank identifies units with ELC (see “Safety Decals
and Locations”). The engine coolant, Texaco Extended Life
Coolant, is Red instead of the previous Green or Blue-Green
conventional coolants.
CAUTION: Do not add Red Extended Life Coolants
to cooling systems using Green or Blue-Green
coolants. Do not add Green or Blue-Green coolants
to cooling systems using Red Extended Life Coolants.
CAUTION: Do not remove expansion tank cap while
the coolant is hot.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to ensure that deionized water is being used. If 100% full
strength concentrate is used, deionized or distilled water is
recommended instead of tap water to ensure the integrity of
the cooling system is maintained.
24
Unit Description
Engine
Heat and power are provided by a indirect injected TK 270
two-cylinder, water cooled diesel engine rated at 9.2
continuous horsepower at 2,550 rpm.
ELC (Extended Life Coolant)
The maintenance interval for ELC (Extended Life Coolant) is
five years or 12,000 hours. A nameplate on the coolant
expansion tank identifies units with ELC (see “Safety Decals
and Locations”). The engine coolant, Texaco Extended Life
Coolant, is Red instead of the previous Green or Blue-Green
conventional coolants.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to ensure that deionized water is being used. If 100% full
strength concentrate is used, deionized or distilled water is
recommended instead of tap water to ensure the integrity of
the cooling system is maintained.
24
CAUTION: Do not add Red Extended Life Coolants
to cooling systems using Green or Blue-Green
coolants. Do not add Green or Blue-Green coolants
to cooling systems using Red Extended Life Coolants.
CAUTION: Do not remove expansion tank cap while
the coolant is hot.
Unit Description
1
10
12
3
4
1.
Engine Thermostat
7.
Oil Sump
2.
Air Cleaner
8.
Oil Drain Tube
3.
Muffler - Standard
Model
Heat Exchanger HO Model
9.
Oil Filter
4.
Alternator
10. Engine Fuel Filter
5.
Battery Box
11.
6.
Maintenance
ON/OFF Switch
12. TG-VII Base Controller
Engine Oil Dipstick
Engine Compartment Components
2 11
9
8
7
6
5
AMA1398
Figure 10: Engine Compartment Components
25
Unit Description
1
10
12
3
4
1.
Engine Thermostat
7.
Oil Sump
2.
Air Cleaner
8.
Oil Drain Tube
3.
Muffler - Standard
Model
Heat Exchanger HO Model
9.
Oil Filter
4.
Alternator
10. Engine Fuel Filter
5.
Battery Box
11.
6.
Maintenance
ON/OFF Switch
12. TG-VII Base Controller
Engine Oil Dipstick
Engine Compartment Components
2 11
9
8
7
6
5
AMA1398
Figure 10: Engine Compartment Components
25
Unit Description
TG-VII HMI Control Panel
Protection Devices
Main Fuse: A 60 amp fuse protects all unit electical circuits.
1
3
Engine Coolant Temperature Sensor: The engine
coolant temperature sensor signals the TG-VII controller to
shut down the unit if the engine coolant temperature exceeds
the specified limit.
Coolant Level Switch: This switch monitors the coolant
level. If coolant level becomes low, an alarm code 37 is
displayed on the TG-VII HMI Control Panel.
Engine Low Oil Pressure Switch: This switch signals
the TG-VII controller to stop the engine if the oil pressure
drops below the specified minimum.
2
1.
Unit ON/OFF Switch
2.
Hourmeter
3.
HMI Display and Keypad
Emergency/Maintenance On-Off Switch: This switch
cuts power to the TG-VII controller causing an immediate,
total unit shutdown when in the off position.
Figure 11: TG-VII HMI Control Panel
The Control Panel shown in Figure 11 is used to turn the unit
on and off, operate the unit and display unit information.
26
Unit Description
TG-VII HMI Control Panel
Protection Devices
Main Fuse: A 60 amp fuse protects all unit electical circuits.
1
3
Engine Coolant Temperature Sensor: The engine
coolant temperature sensor signals the TG-VII controller to
shut down the unit if the engine coolant temperature exceeds
the specified limit.
Coolant Level Switch: This switch monitors the coolant
level. If coolant level becomes low, an alarm code 37 is
displayed on the TG-VII HMI Control Panel.
2
1.
Unit ON/OFF Switch
2.
Hourmeter
3.
HMI Display and Keypad
Figure 11: TG-VII HMI Control Panel
The Control Panel shown in Figure 11 is used to turn the unit
on and off, operate the unit and display unit information.
26
Engine Low Oil Pressure Switch: This switch signals
the TG-VII controller to stop the engine if the oil pressure
drops below the specified minimum.
Emergency/Maintenance On-Off Switch: This switch
cuts power to the TG-VII controller causing an immediate,
total unit shutdown when in the off position.
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 temperature controlled cargo.
Coolant: 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 (refer to Figure 12 and
Figure 13).
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
1
Fuel: Make sure the fuel supply is adequate to guarantee
engine operation to the next check point.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is pushed all the way into the oil
pan. Do not overfill.
1.
CAUTION: Turn the engine off before checking the
engine oil level.
Coolant Fill Level
Figure 12: Coolant Fill Level
The coolant should be a 50:50 mixture of antifreeze and water,
and should provide protection to –30 F (–34 C). The HK uses
“RED” Extended Life Coolant (ELC).For coolant description
27
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 temperature controlled cargo.
Coolant: 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 (refer to Figure 12 and
Figure 13).
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
1
Fuel: Make sure the fuel supply is adequate to guarantee
engine operation to the next check point.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is pushed all the way into the oil
pan. Do not overfill.
CAUTION: Turn the engine off before checking the
engine oil level.
1.
Coolant Fill Level
Figure 12: Coolant Fill Level
The coolant should be a 50:50 mixture of antifreeze and water,
and should provide protection to –30 F (–34 C). The HK uses
“RED” Extended Life Coolant (ELC).For coolant description
27
Manual Pretrip Inspection (Before Starting the Unit)
see the Specifications section of this manual. See the unit
Maintenance Manual for coolant system maintenance
procedures.
WARNING: Do not remove the Expansion Tank
Pressure Cap while the coolant is hot.
CAUTION: Do not add “RED” Extended Life
Coolants to cooling systems using “GREEN” or
“BLUE-GREEN” coolants. Do not add “GREEN” or
“BLUE-GREEN” coolants to cooling systems using
“RED” Extended Life Coolants. See “Engine
Coolant Types” in “Specifications” for more
information.
1
2
Figure 13: Coolant Expansion Tank and Filler Cap
1. Coolant Expansion Tank Pressure Cap
(WARNING: Do not open when engine is hot.)
2. Coolant Filler Cap (check/add coolant here.
28
Manual Pretrip Inspection (Before Starting the Unit)
see the Specifications section of this manual. See the unit
Maintenance Manual for coolant system maintenance
procedures.
WARNING: Do not remove the Expansion Tank
Pressure Cap while the coolant is hot.
CAUTION: Do not add “RED” Extended Life
Coolants to cooling systems using “GREEN” or
“BLUE-GREEN” coolants. Do not add “GREEN” or
“BLUE-GREEN” coolants to cooling systems using
“RED” Extended Life Coolants. See “Engine
Coolant Types” in “Specifications” for more
information.
1
2
Figure 13: Coolant Expansion Tank and Filler Cap
1. Coolant Expansion Tank Pressure Cap
(WARNING: Do not open when engine is hot.)
2. Coolant Filler Cap (check/add coolant here.
28
Manual Pretrip Inspection (Before Starting the Unit)
1
2
1. Coolant Expansion Tank
2. Engine Oil Dipstick
3. Battery Box
4. Belt
Battery: Make sure the battery terminals are tight and free of
corrosion.
Belt: Make sure the engine belt is in good condition and
adjusted to the proper tension.
Cargo Box: Check the interior and exterior of the box for
damage. Any damage to the walls or insulation must be
repaired.
3
4
AMA1398
Doors: Make sure that the doors and weather seals are in good
condition. The doors should latch securely and the weather
seals should fit tightly.
Electrical: Check all electrical connections to make certain
they are securely fastened. Wires and terminals should be free
of corrosion, cracks, and moisture.
Figure 14: Manual Pretrip Inspection
29
Manual Pretrip Inspection (Before Starting the Unit)
1
2
1. Coolant Expansion Tank
2. Engine Oil Dipstick
3. Battery Box
4. Belt
Battery: Make sure the battery terminals are tight and free of
corrosion.
Belt: Make sure the engine belt is in good condition and
adjusted to the proper tension.
Cargo Box: Check the interior and exterior of the box for
damage. Any damage to the walls or insulation must be
repaired.
4
3
Figure 14: Manual Pretrip Inspection
AMA1398
Doors: Make sure that the doors and weather seals are in good
condition. The doors should latch securely and the weather
seals should fit tightly.
Electrical: Check all electrical connections to make certain
they are securely fastened. Wires and terminals should be free
of corrosion, cracks, and moisture.
29
Manual Pretrip Inspection (Before Starting the Unit)
Leaks: Inspect for fuel leaks, engine oil leaks and coolant
leaks.
Radiator (Heating) Coil: Make sure the coil is clean and
free of debris.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
30
Manual Pretrip Inspection (Before Starting the Unit)
Leaks: Inspect for fuel leaks, engine oil leaks and coolant
leaks.
Radiator (Heating) Coil: Make sure the coil is clean and
free of debris.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
30
ThermoGuard VII HMI Operating Instructions
The ThermoGuard VII HMI Control Panel turns the unit On
and Off and displays unit information.
•
The ON/OFF Switch is used to turn the Heat King unit On
and Off.
•
The Hourmeter displays Engine Run Time Hours. The
right digit shows tenths of an hour.
1
3
The ThermoGuard VII HMI Control Panel is used to:
•
Display box temperature (Return Air Temperature) in °F
or °C. See Maintenance Manual for procedure to change
temperature units.
•
Display and change the setpoint
•
Display any existing alarm conditions and clear most
alarm codes.
2
1.
Unit ON/OFF Switch
2.
Hourmeter
3.
HMI Display and Keypad
Figure 15: ThermoGuard VII HMI Control Panel
31
ThermoGuard VII HMI Operating Instructions
The ThermoGuard VII HMI Control Panel turns the unit On
and Off and displays unit information.
•
The ON/OFF Switch is used to turn the Heat King unit On
and Off.
•
The Hourmeter displays Engine Run Time Hours. The
right digit shows tenths of an hour.
1
3
The ThermoGuard VII HMI Control Panel is used to:
•
Display box temperature (Return Air Temperature) in °F
or °C. See Maintenance Manual for procedure to change
temperature units.
•
Display and change the setpoint
•
Display any existing alarm conditions and clear most
alarm codes.
2
1.
Unit ON/OFF Switch
2.
Hourmeter
3.
HMI Display and Keypad
Figure 15: ThermoGuard VII HMI Control Panel
31
ThermoGuard VII HMI Operating Instructions
The ThermoGuard VII HMI Control Panel communicates with
the Base Controller via the CAN (Controller Area Network)
bus. It is connected to the Base Controller via CAN Connector
J35 on the Base Controller. The ThermoGuard VII HMI
Control Panel is located in a weather protected enclosure
mounted on the outside of the trailer or container.
4
5
2
1
The ThermoGuard VII HMI Control Panel consists of a
display, three touch-sensitive keys and five icons.
ThermoGuard VII HMI Display
The ThermoGuard VII HMI Display presents setpoint
temperature, box temperature and alarm information to the
operator. All display segments and icons are shown lighted in
Figure 16.
3
Figure 16: ThermoGuard VII HMI Display Icons
(See page 33, Display Icon Descriptions)
32
ThermoGuard VII HMI Operating Instructions
The ThermoGuard VII HMI Control Panel communicates with
the Base Controller via the CAN (Controller Area Network)
bus. It is connected to the Base Controller via CAN Connector
J35 on the Base Controller. The ThermoGuard VII HMI
Control Panel is located in a weather protected enclosure
mounted on the outside of the trailer or container.
4
2
1
The ThermoGuard VII HMI Control Panel consists of a
display, three touch-sensitive keys and five icons.
ThermoGuard VII HMI Display
The ThermoGuard VII HMI Display presents setpoint
temperature, box temperature and alarm information to the
operator. All display segments and icons are shown lighted in
Figure 16.
32
5
3
Figure 16: ThermoGuard VII HMI Display Icons
(See page 33, Display Icon Descriptions)
ThermoGuard VII HMI Operating Instructions
Display Icon Descriptions
3. Alarm Icon
1. Return Air Temperature Icon
When the Alarm Icon is present one or
more alarm conditions have occurred.
When the Return Air Temperature Icon
is present, the display is showing the
actual box temperature inside the cargo
box.
• 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.
2. Setpoint Icon
• If the Alarm Icon is on steady yellow
and does not turn off one or more
Check Alarms have occurred.
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.
• 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 ThermoGuard VII Alarm
Codes table at the back of this section
for suggested corrective actions.
33
ThermoGuard VII HMI Operating Instructions
Display Icon Descriptions
3. Alarm Icon
1. Return Air Temperature Icon
When the Alarm Icon is present one or
more alarm conditions have occurred.
When the Return Air Temperature Icon
is present, the display is showing the
actual box temperature inside the cargo
box.
• 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.
2. Setpoint Icon
• If the Alarm Icon is on steady yellow
and does not turn off one or more
Check Alarms have occurred.
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.
• 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 ThermoGuard VII Alarm
Codes table at the back of this section
for suggested corrective actions.
33
ThermoGuard VII HMI Operating Instructions
C
4. Red “C”
When the red “C” is turned on
temperatures are being displayed in
degrees Celsius.
F
5. Blue “F”
When the blue “F” is turned on
temperatures are being displayed in
degrees Fahrenheit.
Note: Display of C or F can be set with PC Monitor. See unit
Diagnostic Manual.
34
ThermoGuard VII HMI Operating Instructions
C
4. Red “C”
When the red “C” is turned on
temperatures are being displayed in
degrees Celsius.
F
5. Blue “F”
When the blue “F” is turned on
temperatures are being displayed in
degrees Fahrenheit.
Note: Display of C or F can be set with PC Monitor. See unit
Diagnostic Manual.
34
ThermoGuard VII HMI Operating Instructions
Display Keys
The ThermoGuard VII HMI Control Panel features three touch
sensitive keys. Some of these keys have more than one
function.
3
1
2
Figure 17: ThermoGuard VII HMI Display Keys
(See page 35, Display Key Descriptions)
35
ThermoGuard VII HMI Operating Instructions
Display Keys
The ThermoGuard VII HMI Control Panel features three touch
sensitive keys. Some of these keys have more than one
function.
3
1
2
Figure 17: ThermoGuard VII HMI Display Keys
(See page 35, Display Key Descriptions)
35
ThermoGuard VII HMI Operating Instructions
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.
Figure 18: Display Key Descriptions
36
ThermoGuard VII HMI Operating Instructions
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.
Figure 18: Display Key Descriptions
36
ThermoGuard VII HMI Operating Instructions
Turning the Unit ON and OFF
The Standard Display
The unit is turned on and off using the ON/OFF Switch. When
the unit is turned on the display briefly shows [888] and all five
icons are lighted as the ThermoGuard VII HMI Control Panel
initializes.
When the unit is ready to run the Standard Display is shown.
This is the default display that appears if no other display
function is selected. The Standard Display shows the box
temperature as indicated by the Return Air Temperature Icon
located above the Select Key. The box temperature shown here
is 33°F (1°C).
1
1.
ON/OFF Switch
Figure 19: ON/OFF Switch
Figure 20: Standard Display
The Hourmeter shows that the unit’s diesel engine has run for a
total of 18.6 hours.
37
ThermoGuard VII HMI Operating Instructions
Turning the Unit ON and OFF
The Standard Display
The unit is turned on and off using the ON/OFF Switch. When
the unit is turned on the display briefly shows [888] and all five
icons are lighted as the ThermoGuard VII HMI Control Panel
initializes.
When the unit is ready to run the Standard Display is shown.
This is the default display that appears if no other display
function is selected. The Standard Display shows the box
temperature as indicated by the Return Air Temperature Icon
located above the Select Key. The box temperature shown here
is 33°F (1°C).
1
1.
ON/OFF Switch
Figure 19: ON/OFF Switch
Figure 20: Standard Display
The Hourmeter shows that the unit’s diesel engine has run for a
total of 18.6 hours.
37
ThermoGuard VII HMI Operating Instructions
Changing the Setpoint
To change the setpoint, the setpoint must first be shown on the
display. From the Standard Display of Box Temperature, press
the SELECT Key until the Setpoint Icon appears.
2
1
When the Setpoint Icon appears the current setpoint will be
shown on the display. The current setpoint shown in Figure is
35°F (2°C).
IMPORTANT: Close the control box cover and latch securely
after using the ThermoGuard VII HMI Control Panel. Make
certain the cover seal is not damaged.
1.
SELECT Key
2.
SETPOINT Icon
Figure 22: Changing the Setpoint
When the current setpoint is shown on the display, press the UP
ARROW Key and/or DOWN ARROW Key as necessary to
chose the new setpoint. Here the setpoint has been increased to
40°F (4°C) using the UP ARROW Key.
Figure 21: ThermoGuard VII HMI
Control Panel Cover
The factory-established minimum setpoint temperature is -20 F
(-29 C) and the maximum is 80 F (27 C).
38
ThermoGuard VII HMI Operating Instructions
Changing the Setpoint
To change the setpoint, the setpoint must first be shown on the
display. From the Standard Display of Box Temperature, press
the SELECT Key until the Setpoint Icon appears.
2
1
When the Setpoint Icon appears the current setpoint will be
shown on the display. The current setpoint shown in Figure is
35°F (2°C).
IMPORTANT: Close the control box cover and latch securely
after using the ThermoGuard VII HMI Control Panel. Make
certain the cover seal is not damaged.
1.
SELECT Key
2.
SETPOINT Icon
Figure 22: Changing the Setpoint
When the current setpoint is shown on the display, press the UP
ARROW Key and/or DOWN ARROW Key as necessary to
chose the new setpoint. Here the setpoint has been increased to
40°F (4°C) using the UP ARROW Key.
Figure 21: ThermoGuard VII HMI
Control Panel Cover
38
The factory-established minimum setpoint temperature is -20 F
(-29 C) and the maximum is 80 F (27 C).
ThermoGuard VII HMI Operating Instructions
2
1
After the new setpoint has been confirmed by pressing the
SELECT Key, the display will return to the Standard Display.
The Return Air Temperature Icon located above the Select Key
will appear and the box temperature will be shown in the
display.
1
1.
UP ARROW Key
2.
SELECT Key
Figure 23: UP ARROW Key
1.
When the desired setpoint has been selected using the UP
ARROW Key and DOWN ARROW Key, the SELECT Key
must be pressed within about 10 seconds to confirm and load
the new setpoint.
IMPORTANT: Failure to confirm the new setpoint by
pressing the SELECT Key within 10 seconds of changing the
setpoint will result in no setpoint change. The setpoint will
return to the original setpoint.
Return Air Temperature Icon
Figure 24: Return Air Temperature Icon
IMPORTANT: Always check to be sure the desired setpoint
has been set.
NOTE: If the ThermoGuard VII HMI fails, the unit will
continue to operate using the current temperature setpoint.
39
ThermoGuard VII HMI Operating Instructions
2
1
After the new setpoint has been confirmed by pressing the
SELECT Key, the display will return to the Standard Display.
The Return Air Temperature Icon located above the Select Key
will appear and the box temperature will be shown in the
display.
1
1.
UP ARROW Key
2.
SELECT Key
Figure 23: UP ARROW Key
1.
When the desired setpoint has been selected using the UP
ARROW Key and DOWN ARROW Key, the SELECT Key
must be pressed within about 10 seconds to confirm and load
the new setpoint.
IMPORTANT: Failure to confirm the new setpoint by
pressing the SELECT Key within 10 seconds of changing the
setpoint will result in no setpoint change. The setpoint will
return to the original setpoint.
Return Air Temperature Icon
Figure 24: Return Air Temperature Icon
IMPORTANT: Always check to be sure the desired setpoint
has been set.
NOTE: If the ThermoGuard VII HMI fails, the unit will
continue to operate using the current temperature setpoint.
39
ThermoGuard VII HMI Operating Instructions
Starting the Diesel Engine
Turn the unit ON using the ON/OFF Switch. Diesel engine
preheats and starts are completely automatic. The engine will
preheat and start as required when the unit is turned on. The
engine pre-heat and start sequence will be delayed if there is no
current need for the engine to run.
CAUTION: The engine may start automatically any time the
unit is turned on.
WARNING: Never use starting fluid.
When the engine is preparing to start, the ThermoGuard VII
Control Panel will continue to show the Standard Display as
shown in Figure 25. The preheat buzzer (located on the unit
Base Controller) will sound during the engine pre-heat and
crank sequence.
Alarms
Alarm Code Types
Log Alarms: This level of alarm serves as a notice to take
corrective action before the condition impacts unit
performance. Log Alarms are indicated for 30 seconds each
time the unit is turned on. Maintenance items such as Check
Engine RPM Sensor are Log Alarms.
If Log Alarm(s) are present, the Alarm Icon will appear in
yellow on the display for 30 seconds when the unit is first
turned on. The Alarm Icon will go off after 30 seconds.
Figure 25: Standard Display
Check Alarms: This level of alarm serves as a notice to take
corrective action before a problem becomes severe. The unit
will run with Check Alarms but some features and functions
may be inhibited.
40
ThermoGuard VII HMI Operating Instructions
Starting the Diesel Engine
Turn the unit ON using the ON/OFF Switch. Diesel engine
preheats and starts are completely automatic. The engine will
preheat and start as required when the unit is turned on. The
engine pre-heat and start sequence will be delayed if there is no
current need for the engine to run.
CAUTION: The engine may start automatically any time the
unit is turned on.
WARNING: Never use starting fluid.
When the engine is preparing to start, the ThermoGuard VII
Control Panel will continue to show the Standard Display as
shown in Figure 25. The preheat buzzer (located on the unit
Base Controller) will sound during the engine pre-heat and
crank sequence.
Alarms
Alarm Code Types
Log Alarms: This level of alarm serves as a notice to take
corrective action before the condition impacts unit
performance. Log Alarms are indicated for 30 seconds each
time the unit is turned on. Maintenance items such as Check
Engine RPM Sensor are Log Alarms.
If Log Alarm(s) are present, the Alarm Icon will appear in
yellow on the display for 30 seconds when the unit is first
turned on. The Alarm Icon will go off after 30 seconds.
Figure 25: Standard Display
40
Check Alarms: This level of alarm serves as a notice to take
corrective action before a problem becomes severe. The unit
will run with Check Alarms but some features and functions
may be inhibited.
ThermoGuard VII HMI Operating Instructions
If Check Alarm(s) are present, the Alarm Icon will appear in
yellow on the display and will remain on until the alarm
condition is corrected and cleared.
Shutdown Alarms: This level of alarm serves as a notice
that continued operation could cause damage to the unit or the
load. The unit will be shut down to protect the unit and load.
1
If Shutdown Alarm(s) are present, the Alarm Icon will flash in
red on the display and will remain on until the alarm condition
is corrected and cleared. The unit will be shut down. The unit
will remain shut down until the Shutdown Alarm is manually
cleared.
1.
Alarm Icon
Figure 26: Alarm Icon
Alarm Code Notification
If an alarm condition occurs, the Alarm Icon will appear on the
Standard Display. If the alarm is a Log Alarm, the yellow
Alarm Icon will be displayed for 30 seconds on unit startup. If
the alarm is a Check Alarm, the yellow Alarm Icon will turn on
and remain on but the unit will continue to run. If the alarm is
a Shutdown Alarm, the red Alarm Icon will flash on and off
and the unit will shut down. In Figure 26, a steady yellow
Alarm Icon indicates a Check Alarm has been set.
Displaying Alarm Codes
From the Standard Display of Box Temperature, press the
SELECT Key until only the Alarm Icon is shown. When only
the Alarm Icon is present the most recent alarm code will be
shown on the display. Alarm Code 37 Check Engine Coolant
Level is shown in Figure 27.
41
ThermoGuard VII HMI Operating Instructions
If Check Alarm(s) are present, the Alarm Icon will appear in
yellow on the display and will remain on until the alarm
condition is corrected and cleared.
Shutdown Alarms: This level of alarm serves as a notice
that continued operation could cause damage to the unit or the
load. The unit will be shut down to protect the unit and load.
If Shutdown Alarm(s) are present, the Alarm Icon will flash in
red on the display and will remain on until the alarm condition
is corrected and cleared. The unit will be shut down. The unit
will remain shut down until the Shutdown Alarm is manually
cleared.
1
1.
Alarm Icon
Figure 26: Alarm Icon
Alarm Code Notification
If an alarm condition occurs, the Alarm Icon will appear on the
Standard Display. If the alarm is a Log Alarm, the yellow
Alarm Icon will be displayed for 30 seconds on unit startup. If
the alarm is a Check Alarm, the yellow Alarm Icon will turn on
and remain on but the unit will continue to run. If the alarm is
a Shutdown Alarm, the red Alarm Icon will flash on and off
and the unit will shut down. In Figure 26, a steady yellow
Alarm Icon indicates a Check Alarm has been set.
Displaying Alarm Codes
From the Standard Display of Box Temperature, press the
SELECT Key until only the Alarm Icon is shown. When only
the Alarm Icon is present the most recent alarm code will be
shown on the display. Alarm Code 37 Check Engine Coolant
Level is shown in Figure 27.
41
ThermoGuard VII HMI Operating Instructions
1
2
2
1
1.
Alarm Icon
2.
1.
SELECT Key
UP ARROW
2.
DOWN ARROW
Figure 28: UP/DOWN Arrows
Figure 27: Display Alarm Codes
If more than one alarm code has been set, they are displayed
with the most recent alarm shown first. Use the UP ARROW
Key and/or DOWN ARROW Key to scroll through the alarms.
Clearing Alarm Codes
After the alarm situation is resolved, display the Alarm Code
as shown in Figure 28. Then press and hold the SELECT Key
to clear the alarm code currently being displayed. Continue to
press and hold the SELECT Key as necessary to clear any
remaining alarms. When all alarms have been cleared the
display will show all dashes to indicate that no alarm codes
exist. The Standard Display will reappear in about 10 seconds.
42
ThermoGuard VII HMI Operating Instructions
1
2
2
1
1.
Alarm Icon
2.
SELECT Key
Figure 27: Display Alarm Codes
If more than one alarm code has been set, they are displayed
with the most recent alarm shown first. Use the UP ARROW
Key and/or DOWN ARROW Key to scroll through the alarms.
42
1.
UP ARROW
2.
DOWN ARROW
Figure 28: UP/DOWN Arrows
Clearing Alarm Codes
After the alarm situation is resolved, display the Alarm Code
as shown in Figure 28. Then press and hold the SELECT Key
to clear the alarm code currently being displayed. Continue to
press and hold the SELECT Key as necessary to clear any
remaining alarms. When all alarms have been cleared the
display will show all dashes to indicate that no alarm codes
exist. The Standard Display will reappear in about 10 seconds.
ThermoGuard VII HMI Operating Instructions
Important Alarm Notes
1.
SELECT Key
2.
2
•
If an alarm will not clear, it may still exist. If the alarm is
not corrected, it will not clear or may be immediately set
again.
1
•
Some alarms cannot be cleared using the ThermoGuard
VII HMI Control Panel. These alarms must be cleared by
maintenance personnel using PC Monitor.
All Dashes
Figure 29: Clearing Alarm Codes
ThermoGuard VII HMI Alarm Codes
NOTE: Not all alarm codes may be used with all applications
---
No Alarms Exist
03
Check (Control) Return Air
Sensor
Manually monitor load temperature. Report alarm at end of the day.
04
Check (Control) Discharge Air
Sensor
Manually monitor load temperature. Report alarm at end of the day.
43
ThermoGuard VII HMI Operating Instructions
Important Alarm Notes
1.
SELECT Key
2.
2
•
If an alarm will not clear, it may still exist. If the alarm is
not corrected, it will not clear or may be immediately set
again.
1
•
Some alarms cannot be cleared using the ThermoGuard
VII HMI Control Panel. These alarms must be cleared by
maintenance personnel using PC Monitor.
All Dashes
Figure 29: Clearing Alarm Codes
ThermoGuard VII HMI Alarm Codes
NOTE: Not all alarm codes may be used with all applications
---
No Alarms Exist
03
Check (Control) Return Air
Sensor
Manually monitor load temperature. Report alarm at end of the day.
04
Check (Control) Discharge Air
Sensor
Manually monitor load temperature. Report alarm at end of the day.
43
ThermoGuard VII HMI Operating Instructions
ThermoGuard VII HMI Alarm Codes
06
Check Coolant Temp Sensor
Report alarm at end of the day.
07
Check Engine RPM Sensor
Report alarm at end of the day.
11
Unit Controlling on Alternate
Sensor
Manually monitor load temperature. Report alarm at end of the day.
12
Sensor Shutdown
Both Return Air Temperature and Discharge Air Temperature sensors have
failed and unit is shut down. Repair immediately.
13
Sensor Check
Manually monitor load temperature. Report alarm at end of the day.
17
Engine Failed to Crank
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day
18
High Engine Coolant
Temperature
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
19
Low Engine Oil Pressure
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
20
Engine Failed to Start
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
25
Alternator Check
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
44
ThermoGuard VII HMI Operating Instructions
ThermoGuard VII HMI Alarm Codes
06
Check Coolant Temp Sensor
Report alarm at end of the day.
07
Check Engine RPM Sensor
Report alarm at end of the day.
11
Unit Controlling on Alternate
Sensor
Manually monitor load temperature. Report alarm at end of the day.
12
Sensor Shutdown
Both Return Air Temperature and Discharge Air Temperature sensors have
failed and unit is shut down. Repair immediately.
13
Sensor Check
Manually monitor load temperature. Report alarm at end of the day.
17
Engine Failed to Crank
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day
18
High Engine Coolant
Temperature
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
19
Low Engine Oil Pressure
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
20
Engine Failed to Start
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
25
Alternator Check
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
44
ThermoGuard VII HMI Operating Instructions
ThermoGuard VII HMI Alarm Codes
31
Check Oil Pressure Switch
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
33
Check Engine RPM
Report alarm at end of the day.
35
Check Run Relay Circuit
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
42
Unit Forced to Low Speed
Report alarm at end of the day.
61
Low Battery Voltage
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
63
Engine Stopped
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
68
Internal Controller Fault Code
Report alarm at end of the day.
70
Hourmeter Failure
Report alarm at end of the day.
74
Controller Reset to Defaults
Report alarm at end of the day.
84
Restart Null
Report alarm at end of the day.
45
ThermoGuard VII HMI Operating Instructions
ThermoGuard VII HMI Alarm Codes
31
Check Oil Pressure Switch
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
33
Check Engine RPM
Report alarm at end of the day.
35
Check Run Relay Circuit
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
42
Unit Forced to Low Speed
Report alarm at end of the day.
61
Low Battery Voltage
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
63
Engine Stopped
If unit is shut down repair immediately. Otherwise, report alarm at end of the
day.
68
Internal Controller Fault Code
Report alarm at end of the day.
70
Hourmeter Failure
Report alarm at end of the day.
74
Controller Reset to Defaults
Report alarm at end of the day.
84
Restart Null
Report alarm at end of the day.
45
ThermoGuard VII HMI Operating Instructions
46
ThermoGuard VII HMI Operating Instructions
46
Loading and Enroute Inspections
Thermo King temperature control units are designed to
maintain the required temperature for the product being carried
during its time in transit. Because of the unit’s unique design,
special care is required during loading to prevent cargo
spoilage.
WARNING: The unit may START automatically AT
ANY TIME while it is turned ON. Make sure to turn
the unit ON/OFF and maintenance switches off
before opening unit doors or inspecting any part of
the unit.
Pre-Loading Inspection
1
4
2
3
1.
Gasket equaly
compressed
2. Unit inspection
5
6
4. Good air circulation
5. Tight doors and gaskets
3. Interior and exterior 6. Proper cargo temperature
Figure 30: Pre-Loading Inspection
47
Loading and Enroute Inspections
Thermo King temperature control units are designed to
maintain the required temperature for the product being carried
during its time in transit. Because of the unit’s unique design,
special care is required during loading to prevent cargo
spoilage.
WARNING: The unit may START automatically AT
ANY TIME while it is turned ON. Make sure to turn
the unit ON/OFF and maintenance switches off
before opening unit doors or inspecting any part of
the unit.
Pre-Loading Inspection
1
4
2
3
1.
Gasket equaly
compressed
2. Unit inspection
6
5
4. Good air circulation
5. Tight doors and gaskets
3. Interior and exterior 6. Proper cargo temperature
Figure 30: Pre-Loading Inspection
47
Loading and Enroute Inspections
1.
Inspect all door seals, including vent doors, for condition
and a tight seal with no air leakage.
2.
Inspect the cargo compartment inside and out for damaged
or loose skin and insulation.
3.
Inspect the inside of the cargo compartment for damaged
walls, air ducts, floor channels or “T” flooring, and
clogged or damaged floor channels which could block the
air return, creating isolated areas in the load that are
difficult to maintain at the desired temperature.
4.
Make sure products are at the proper temperature before
loading. Any variance should be noted on the manifest.
5.
Supervise product loading to make sure that there is
sufficient air space around and through the load so air flow
is not restricted.
Enroute Inspections
NOTE: Enroute inspections are recommended every four
hours for the prevention of damage to the cargo.
1.
Note the setpoint to make certain no one has altered the
setting since picking up the load.
2.
Check for improper air circulation within the cargo
compartment. Inspect the cargo compartment (if possible)
to determine if air is circulating properly. Poor air
circulation can be due to improper loading of the cargo or
shifting of the load.
48
Loading and Enroute Inspections
1.
Inspect all door seals, including vent doors, for condition
and a tight seal with no air leakage.
2.
Inspect the cargo compartment inside and out for damaged
or loose skin and insulation.
3.
Inspect the inside of the cargo compartment for damaged
walls, air ducts, floor channels or “T” flooring, and
clogged or damaged floor channels which could block the
air return, creating isolated areas in the load that are
difficult to maintain at the desired temperature.
4.
Make sure products are at the proper temperature before
loading. Any variance should be noted on the manifest.
5.
Supervise product loading to make sure that there is
sufficient air space around and through the load so air flow
is not restricted.
48
Enroute Inspections
NOTE: Enroute inspections are recommended every four
hours for the prevention of damage to the cargo.
1.
Note the setpoint to make certain no one has altered the
setting since picking up the load.
2.
Check for improper air circulation within the cargo
compartment. Inspect the cargo compartment (if possible)
to determine if air is circulating properly. Poor air
circulation can be due to improper loading of the cargo or
shifting of the load.
Specifications
Engine Specifications
Engine
Thermo King TK 270
Fuel Type
Use Diesel Fuel only.
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
* Refer to Service Bulletin SB537 for acceptable bio-diesel fuel blends.
Oil Capacity
Crankcase and filter: 3.1 quarts (2.9 liters)
Fill to full mark on dipstick
Oil Type: Mineral Oil
Synthetic Oil** (After First 500 Hours)
API Classification CG-4 (or better)
API Classification CG-4 (or better)
** Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an
emergency requires addition of petroleum oil. Mixing is not recommended, however, since it will dilute the superior
performance properties of the synthetic oil.
49
Specifications
Engine Specifications
Engine
Thermo King TK 270
Fuel Type
Use Diesel Fuel only.
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
* Refer to Service Bulletin SB537 for acceptable bio-diesel fuel blends.
Oil Capacity
Crankcase and filter: 3.1 quarts (2.9 liters)
Fill to full mark on dipstick
Oil Type: Mineral Oil
Synthetic Oil** (After First 500 Hours)
API Classification CG-4 (or better)
API Classification CG-4 (or better)
** Thermo King synthetic oil is compatible with petroleum lubricants so there is no danger if accidental mixing occurs or if an
emergency requires addition of petroleum oil. Mixing is not recommended, however, since it will dilute the superior
performance properties of the synthetic oil.
49
Specifications
Engine Specifications (Continued)
Oil Viscosity
5 to 122 F (–15 to 50 C): SAE 15W-40
–13 to 104 F (–25 to 40 C): SAE 10W-40
–13 to 86 F (–25 to 30 C): SAE 10W-30
–22 to 32 F (–30 to 0 C): SAE 5W-30
Engine RPM STD: Low Speed Operation
High Speed Operation
1550 ± 25 RPM
2550 ± 25 RPM
Engine RPM HO:
1550 ± 25 RPM
2950 ± 25 RPM
Low Speed Operation
High Speed Operation
Cooling System Capacity
HK-430: 4.7 quarts (4.4 liters)
HK-430 HO: 9.0 quarts (8.5 liters)
Engine Coolant Type: Conventional
Conventional coolant (antifreeze) is green or blue-green. Units
equipped with conventional coolant do not have an ELC nameplate
on the expansion tank.
CAUTION: Make sure you know what type of coolant is in your unit. Do
not mix conventional coolant and ELC.
50
Specifications
Engine Specifications (Continued)
Oil Viscosity
5 to 122 F (–15 to 50 C): SAE 15W-40
–13 to 104 F (–25 to 40 C): SAE 10W-40
–13 to 86 F (–25 to 30 C): SAE 10W-30
–22 to 32 F (–30 to 0 C): SAE 5W-30
Engine RPM STD: Low Speed Operation
High Speed Operation
1550 ± 25 RPM
2550 ± 25 RPM
Engine RPM HO:
1550 ± 25 RPM
2950 ± 25 RPM
Low Speed Operation
High Speed Operation
Cooling System Capacity
HK-430: 4.7 quarts (4.4 liters)
HK-430 HO: 9.0 quarts (8.5 liters)
Engine Coolant Type: Conventional
Conventional coolant (antifreeze) is green or blue-green. Units
equipped with conventional coolant do not have an ELC nameplate
on the expansion tank.
CAUTION: Make sure you know what type of coolant is in your unit. Do
not mix conventional coolant and ELC.
50
Specifications
Engine Specifications (Continued)
Engine Coolant Type (continued):
ELC (Extended Life Coolant)
ELC is red. Units equipped with ELC have an ELC nameplate on the
expansion tank (see “Safety Decals and Locations”).
Use a 50/50 concentration of any of the following equivalents:
Texaco ELC (16445, 16447)
Havoline Dex-Cool® (7994, 7995, 7997, 7998)
Havoline XLC for Europe (30379, 33013)
Shell Dexcool® (94040)
Shell Rotella (94041)
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
Engine Thermostat
160 F (71 C)
Radiator Cap Pressure
15 psig (103 kPa)
51
Specifications
Engine Specifications (Continued)
Engine Coolant Type (continued):
ELC (Extended Life Coolant)
ELC is red. Units equipped with ELC have an ELC nameplate on the
expansion tank (see “Safety Decals and Locations”).
Use a 50/50 concentration of any of the following equivalents:
Texaco ELC (16445, 16447)
Havoline Dex-Cool® (7994, 7995, 7997, 7998)
Havoline XLC for Europe (30379, 33013)
Shell Dexcool® (94040)
Shell Rotella (94041)
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
Engine Thermostat
160 F (71 C)
Radiator Cap Pressure
15 psig (103 kPa)
51
Specifications
Belt Tension
NOTE: Use belt tension gauge (see Tool Catalog) whenever possible to check belt tension. New belts should be tensioned cold,
and then tensioned cold again after 10 hours of unit operation.
Engine/Alternator/Water Pump
Value of 45 using tension gauge TK No. 204-427
Unit Controller
Type
ThermoGuard TG-VII HMI
ThermoGuard TG-VII Base Controller
Electrical Control System
Voltage
12.5 Vdc (nominal)
Battery (Recommended)
Group C31, 12 volt
Battery Charging System
12 V 37 amp alternator
Voltage Regulator Setting
14 V @ 75 F (24 C)
52
Specifications
Belt Tension
NOTE: Use belt tension gauge (see Tool Catalog) whenever possible to check belt tension. New belts should be tensioned cold,
and then tensioned cold again after 10 hours of unit operation.
Engine/Alternator/Water Pump
Value of 45 using tension gauge TK No. 204-427
Unit Controller
Type
ThermoGuard TG-VII HMI
ThermoGuard TG-VII Base Controller
Electrical Control System
Voltage
12.5 Vdc (nominal)
Battery (Recommended)
Group C31, 12 volt
Battery Charging System
12 V 37 amp alternator
Voltage Regulator Setting
14 V @ 75 F (24 C)
52
Specifications
Electrical Fuses
Fuse ID
Rating
Purpose
F1
60A
Main Fuse, all circuits
F2
2A
Display
F3
2A
Remote Light
F4
15A
Maintenance Switch
F5
7.5A
Run Relay
F6
30A
Preheat
F7
40A
Starter/Fuel Solenoid
F8
15A
Fuel Heater
F9
2A
Hourmeter
F11
10A
Power from On Relay
F13
15A
High Speed Solenoid
F14
2A
Alternator
See Maintenance Manual for fuse locations.
53
Specifications
Electrical Fuses
Fuse ID
Rating
Purpose
F1
60A
Main Fuse, all circuits
F2
2A
Display
F3
2A
Remote Light
F4
15A
Maintenance Switch
F5
7.5A
Run Relay
F6
30A
Preheat
F7
40A
Starter/Fuel Solenoid
F8
15A
Fuel Heater
F9
2A
Hourmeter
F11
10A
Power from On Relay
F13
15A
High Speed Solenoid
F14
2A
Alternator
See Maintenance Manual for fuse locations.
53
Specifications
54
Specifications
54
Serial Number Label Locations
Write the unit model and unit serial number in the spaces
provided in the following Emergency Cold Line chapter. This
information is needed to service the unit.
1
2
3
1
4
2
Figure 32: Laminated Unit Serial Number Plate
AMA676
Figure 31: Serial Number Locations
1.
Unit Serial Number Plate
2.
Engine Serial Number Plate
1.
Unit Serial Number
2.
Bill of Material Number
3.
Unit Model
4.
Unit ID
55
Serial Number Label Locations
Write the unit model and unit serial number in the spaces
provided in the following Emergency Cold Line chapter. This
information is needed to service the unit.
1
2
3
1
4
2
AMA676
Figure 31: Serial Number Locations
1.
Unit Serial Number Plate
2.
Engine Serial Number Plate
Figure 32: Laminated Unit Serial Number Plate
1.
Unit Serial Number
2.
Bill of Material Number
3.
Unit Model
4.
Unit ID
55
Serial Number Label Locations
56
Serial Number Label Locations
56
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
After first week of operation:
The schedule covers units with conventional coolant and units
with ELC. See “ELC (Extended Life Coolant)” on page 31 for
more information about coolants.
•
Check belt tension.
•
Tighten unit mounting bolts.
•
Check coolant level.
For more specific detail, see the maintenance manual for your
unit and to the PreTrip Inspection chapter in this manual.
57
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
After first week of operation:
The schedule covers units with conventional coolant and units
with ELC. See “ELC (Extended Life Coolant)” on page 31 for
more information about coolants.
•
Check belt tension.
•
Tighten unit mounting bolts.
•
Check coolant level.
For more specific detail, see the maintenance manual for your
unit and to the PreTrip Inspection chapter in this manual.
57
Maintenance Inspection Schedule
Monthly
Pre-Trip
•
•
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
ThermoGuard VII HMI
Check seal and operation of protective cover after each use of the
ThermoGuard VII HMI Control Panel. Inspect for damage to the enclosure.
Engine
These service intervals require the use of either CG-4 mineral oil or
synthetic oil.
•
Check fuel supply.
•
•
•
Check engine oil level.
•
•
•
Inspect belts for condition and proper tension.
•
•
•
Check engine oil pressure; hot, high speed. Minimum 40 psig (276 kPa,
2.8 bar).
•
•
•
•
Listen for unusual noises, vibrations, etc.
58
Maintenance Inspection Schedule
Monthly
Pre-Trip
•
•
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
ThermoGuard VII HMI
Check seal and operation of protective cover after each use of the
ThermoGuard VII HMI Control Panel. Inspect for damage to the enclosure.
Engine
These service intervals require the use of either CG-4 mineral oil or
synthetic oil.
•
Check fuel supply.
•
•
•
Check engine oil level.
•
•
•
Inspect belts for condition and proper tension.
•
•
•
Check engine oil pressure; hot, high speed. Minimum 40 psig (276 kPa,
2.8 bar).
•
•
•
58
•
Listen for unusual noises, vibrations, etc.
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Engine (continued)
•
•
Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year
(whichever occurs first).
•
•
Clean and service crankcase breather and check air cleaner hose for
damage.
•
•
Inspect and clean fuel prefilter and electric fuel pump filter.
•
•
Drain water from fuel tank and check vent.
•
•
Check and adjust engine speeds (high and low speed).
59
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Engine (continued)
•
•
Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year
(whichever occurs first).
•
•
Clean and service crankcase breather and check air cleaner hose for
damage.
•
•
Inspect and clean fuel prefilter and electric fuel pump filter.
•
•
Drain water from fuel tank and check vent.
•
•
Check and adjust engine speeds (high and low speed).
59
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Engine (continued)
•
Check condition of engine mounts.
•
Maintain year around antifreeze protection at –30 F (–34 C).
—
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank (see
“Safety Decals and Locations”).
•
Oil change interval with API classification CG-4 (or better) mineral oil or
synthetic oil.
NOTE: Seasonal oil change is recommended. Refer to Maintenance Manual for
long-term storage procedures.
60
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Engine (continued)
•
•
Check condition of engine mounts.
•
Maintain year around antifreeze protection at –30 F (–34 C).
—
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank (see
“Safety Decals and Locations”).
Oil change interval with API classification CG-4 (or better) mineral oil or
synthetic oil.
NOTE: Seasonal oil change is recommended. Refer to Maintenance Manual for
long-term storage procedures.
60
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Electrical
•
•
•
•
Check for charge and discharge (glow plug) operation.
•
•
Inspect battery terminals and electrolyte level.
•
•
Check operation of protection shutdown circuits.
•
•
Inspect wire harness for damaged wires or connections. Check for tight
terminal connections.
•
Inspect DC (battery charging) alternator bearings and brushes.
61
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Electrical
•
•
•
•
Check for charge and discharge (glow plug) operation.
•
•
Inspect battery terminals and electrolyte level.
•
•
Check operation of protection shutdown circuits.
•
•
Inspect wire harness for damaged wires or connections. Check for tight
terminal connections.
•
Inspect DC (battery charging) alternator bearings and brushes.
61
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air ducts
and bulkheads).
•
•
Inspect lubricant leakage and bearing wear (noise).
•
•
Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
62
Maintenance Inspection Schedule
Monthly
Pre-Trip
Every
1,200
Hours
Annual Inspect/Service These Items
3,000
Hours
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air ducts
and bulkheads).
•
•
Inspect lubricant leakage and bearing wear (noise).
•
•
Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
62
Troubleshooting
The following information is provided to assist you in locating and correcting minor problems. If these procedures do not correct
the problem, contact your nearest Thermo King dealer or authorized service center
Condition
Unit switch ON - nothing happens
Possible Cause
Remedy
Dead battery
Recharge or replace battery.
Blown fuse
Turn unit off and correct cause.
Replace fuse.
Battery connections
Clean and tighten.
Shutdown alarm
See ThermoGuard VII HMI Alarm
Codes section of this manual.
Unit maintenance switch is
switched OFF
Turn switch to ON position.
Unit switch ON - indicator lights come
on but engine does not crank
Corroded battery connections
Clean and tighten.
Engine cranks but fails to start
No fuel or wrong fuel in tank
Fill fuel tank. After filling a completely
empty tank, bleed fuel system.
63
Troubleshooting
The following information is provided to assist you in locating and correcting minor problems. If these procedures do not correct
the problem, contact your nearest Thermo King dealer or authorized service center
Condition
Unit switch ON - nothing happens
Possible Cause
Remedy
Dead battery
Recharge or replace battery.
Blown fuse
Turn unit off and correct cause.
Replace fuse.
Battery connections
Clean and tighten.
Shutdown alarm
See ThermoGuard VII HMI Alarm
Codes section of this manual.
Unit maintenance switch is
switched OFF
Turn switch to ON position.
Unit switch ON - indicator lights come
on but engine does not crank
Corroded battery connections
Clean and tighten.
Engine cranks but fails to start
No fuel or wrong fuel in tank
Fill fuel tank. After filling a completely
empty tank, bleed fuel system.
63
Troubleshooting
Condition
Engine stops after starting
Possible Cause
Remedy
Engine too cold
Preheat unit for correct amount of
time; see Starting Instructions.
Glow plugs defective
Replace glow plugs.
Air in fuel system
Bleed fuel system. Also check if fuel
lines are tight and filters are clean.
Air in injection pump
Bleed fuel system.
Defective electric fuel pump
Replace fuel pump.
Plugged electric fuel pump
Remove restriction.
Fuel filter obstructed
Replace filter element.
Low oil pressure
Add oil. Check for leaks.
Vent of fuel tank obstructed
Remove obstruction.
Shutdown alarm
See ThermoGuard VII HMI Alarm
Codes section of this manual.
64
Troubleshooting
Condition
Engine stops after starting
64
Possible Cause
Remedy
Engine too cold
Preheat unit for correct amount of
time; see Starting Instructions.
Glow plugs defective
Replace glow plugs.
Air in fuel system
Bleed fuel system. Also check if fuel
lines are tight and filters are clean.
Air in injection pump
Bleed fuel system.
Defective electric fuel pump
Replace fuel pump.
Plugged electric fuel pump
Remove restriction.
Fuel filter obstructed
Replace filter element.
Low oil pressure
Add oil. Check for leaks.
Vent of fuel tank obstructed
Remove obstruction.
Shutdown alarm
See ThermoGuard VII HMI Alarm
Codes section of this manual.
Troubleshooting
Condition
Engine does not reach full power
Engine is sooting heavily, emits black
clouds of smoke (excessive fuel to air
ratio)
Possible Cause
Remedy
Dirt or air in fuel system
Bleed or clean fuel system.
Fuel line leaks
Tighten connections of fuel lines. If
necessary, replace damaged lines.
Fuel filter blocked
Install new filter.
Electric fuel pump filter dirty
Clean and replace diesel filter.
Air filter clogged
Clear air filter.
Fuel tank vent clogged
Unclog vent.
Air is drawn into feed pump
Check all fuel lines and fittings.
Wrong fuel
Drain and refill with correct fuel grade.
Clogged intake filter
Clear air filter.
Restricted exhaust system
Clean.
Oil being drawn in
Check oil level in oil bath air filter.
Insufficient air
Clear air filter.
65
Troubleshooting
Condition
Engine does not reach full power
Engine is sooting heavily, emits black
clouds of smoke (excessive fuel to air
ratio)
Possible Cause
Remedy
Dirt or air in fuel system
Bleed or clean fuel system.
Fuel line leaks
Tighten connections of fuel lines. If
necessary, replace damaged lines.
Fuel filter blocked
Install new filter.
Electric fuel pump filter dirty
Clean and replace diesel filter.
Air filter clogged
Clear air filter.
Fuel tank vent clogged
Unclog vent.
Air is drawn into feed pump
Check all fuel lines and fittings.
Wrong fuel
Drain and refill with correct fuel grade.
Clogged intake filter
Clear air filter.
Restricted exhaust system
Clean.
Oil being drawn in
Check oil level in oil bath air filter.
Insufficient air
Clear air filter.
65
Troubleshooting
Condition
Engine knocks
Engine runs hot
Oil pressure too low or drops suddenly
Possible Cause
Remedy
Insufficient air
Clean air filter.
Air in fuel system
Bleed fuel system.
Engine is cold
Warm up engine.
Fuel return line plugged
Remove restriction.
Dirty radiator
Clean radiator.
Engine coolant is low
Add coolant slowly while engine is in
operation.
Dirty or plugged radiator
Clean radiator.
Cooling system heavily scaled
Clean cooling system.
Worn or loose belt
Replace belt or adjust.
Insufficient oil in pan
Refill oil pan after correcting cause of
loss.
Leak in oil line
Tighten oil line fittings.
66
Troubleshooting
Condition
Engine knocks
Engine runs hot
Oil pressure too low or drops suddenly
66
Possible Cause
Remedy
Insufficient air
Clean air filter.
Air in fuel system
Bleed fuel system.
Engine is cold
Warm up engine.
Fuel return line plugged
Remove restriction.
Dirty radiator
Clean radiator.
Engine coolant is low
Add coolant slowly while engine is in
operation.
Dirty or plugged radiator
Clean radiator.
Cooling system heavily scaled
Clean cooling system.
Worn or loose belt
Replace belt or adjust.
Insufficient oil in pan
Refill oil pan after correcting cause of
loss.
Leak in oil line
Tighten oil line fittings.
Troubleshooting
Condition
High oil consumption
Possible Cause
Remedy
Oil leaks
Check and eliminate possible causes.
Clogged air cleaner
Clean air cleaner.
Crankcase breather blocked
Clean crankcase breather.
Blue smoke (oil consumption)
Excessive oil consumption
Refer to high oil consumption (above).
Repair as necessary.
White smoke (fuel is not burning)
Cold engine
Allow engine to warm up.
Air or water in fuel
Bleed system. Replace filters, clean
fuel system, drain and clean tank and
check supply tank for water. Use
known good fuel.
Insufficient preheat
Check glow plugs.
Loose alternator belt
Tighten belt.
Loose connections in the electrical
system
Check all electrical connections and
charging system.
Battery defective
Replace.
Alternator defective
Replace.
Battery not charging
67
Troubleshooting
Condition
High oil consumption
Possible Cause
Remedy
Oil leaks
Check and eliminate possible causes.
Clogged air cleaner
Clean air cleaner.
Crankcase breather blocked
Clean crankcase breather.
Blue smoke (oil consumption)
Excessive oil consumption
Refer to high oil consumption (above).
Repair as necessary.
White smoke (fuel is not burning)
Cold engine
Allow engine to warm up.
Air or water in fuel
Bleed system. Replace filters, clean
fuel system, drain and clean tank and
check supply tank for water. Use
known good fuel.
Insufficient preheat
Check glow plugs.
Loose alternator belt
Tighten belt.
Loose connections in the electrical
system
Check all electrical connections and
charging system.
Battery defective
Replace.
Alternator defective
Replace.
Battery not charging
67
Troubleshooting
68
Troubleshooting
68
Warranty
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50046 for the Thermo King
Trailer Unit Warranty.
69
Warranty
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50046 for the Thermo King
Trailer Unit Warranty.
69
Warranty
70
Warranty
70
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AKB12
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
71
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AKB12
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
71
72
72
Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Battery Sentry: Part of the CYCLE-SENTRY™ system. The
Battery Sentry module monitors alternator charge rate and will
keep the unit running until the battery is adequately charged.
box temperature: The temperature within a
temperature-controlled compartment.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
bulkhead: 1) return air bulkhead. A metal or plastic “wall”
placed at the front of the box to prevent loading of product
tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
divider. A thick, insulated “wall” used to separate
compartments of a multi-temperature truck or trailer.
calorie: The amount of heat required to raise temperature of
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
cycles per second: See Hertz.
F: See Fahrenheit.
73
Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Battery Sentry: Part of the CYCLE-SENTRY™ system. The
Battery Sentry module monitors alternator charge rate and will
keep the unit running until the battery is adequately charged.
box temperature: The temperature within a
temperature-controlled compartment.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
bulkhead: 1) return air bulkhead. A metal or plastic “wall”
placed at the front of the box to prevent loading of product
tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
divider. A thick, insulated “wall” used to separate
compartments of a multi-temperature truck or trailer.
calorie: The amount of heat required to raise temperature of
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
cycles per second: See Hertz.
F: See Fahrenheit.
73
Glossary
Fahrenheit: A unit of temperature measurement used in the
United States. Abbreviated “F.”
fuse: An electrical safety device (typically a cartridge)
inserted into an electrical circuit. It contains material that will
melt or break when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HMI: Human Machine Interface.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit.
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
74
Glossary
Fahrenheit: A unit of temperature measurement used in the
United States. Abbreviated “F.”
fuse: An electrical safety device (typically a cartridge)
inserted into an electrical circuit. It contains material that will
melt or break when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HMI: Human Machine Interface.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
74
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit.
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
Glossary
return air bulkhead: A structure (metal or plastic) mounted
in the front of a trailer and designed to prevent restriction of
return air flow to the Thermo King unit due to improper
loading. See bulkhead.
rpm: Revolutions per minute.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
75
Glossary
return air bulkhead: A structure (metal or plastic) mounted
in the front of a trailer and designed to prevent restriction of
return air flow to the Thermo King unit due to improper
loading. See bulkhead.
rpm: Revolutions per minute.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
75
Glossary
76
Glossary
76
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
77
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
77
78
78
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
Heat King 430 &
Heat King 430 HO
TK 55203-6-OP (Rev. 0, 10/2011)
©2011 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions
for customers globally. Its world class brands include Hussmann, a manufacturer of
refrigeration and food merchandising solutions, Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2011 Ingersoll-Rand Company
Printed in U.S.A.
Heat King 430 &
Heat King 430 HO
TK 55203-6-OP (Rev. 0, 10/2011)