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Thermo King has a policy of coninuous product and data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.
Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com
©2020 Trane Technologies TK55681-11-IM Jan 2020
Installation Manual
Trailer EditionPrecedent™C-600*, C-600M, S-600, S-700, S-600M and S-610M/DEBattery Charger Kits and SupplementalPower Package Retrofit Kits*C-600 CANNOT HAVE SUPPLEMENTAL POWER PACKAGE INSTALLED
January 2020
Revision 9
TK-55681-11-IM
Installation Manual
Trailer EdPrecedenC-600*, C 0, S-600M and S-610M/DE
Battery C pplemental Power Package Retrofit KTK 55681-11-IM (R
*C-600 CANNOT H AGE INSTALLED
ht© 2013 T U.S.A. in U.S.A.
CopyrigPrinted
ition t™ -600M, S-600, S-70
harger Kits and Suits
ev. 9, 01/20)
AVE SUPPLEMENTAL POWER PACK
hermo King Corp., Minneapolis, MN,
2
or to supplemental power package.
16, 18, 30 and 32; changed text from Excite Harness to
Connector for clarity.
connected device with a web browser.
.com/SE/?SID=SV_2octfSHoUJxsk6x to
Release HistoryReleased (06/13) Rev. 0
Rev. 1 (08/13) Cover, pages,3, 18,32, 34; Changed text from stand alone alternat
Rev. 2 (12/13) Cover, deleted text, “equipped with Yanmar diesel engines”, pagesSense Harness.
Rev. 3 (08/14) Added S-700 and S-600M to manual.
Rev. 4 (10/16 Corrected wiring errors on pages 28,42,43, and 54.
Rev. 5 (01/17) Updated manual to include S-610M/DE units.
Rev. 6 (04/17) Corrected Error
Rev. 7 (05/18) Added new 45 and 60 ft. battery cable kits on page 5.
Rev. 8 (01/19) Renamed the 3-pin battery harness connector from BCE-02 to Alt.
Rev. 9 (01/20) Updated text on pages 14, 28, 42, 54 and 55.
Customer Satisfaction SurveyLet your voice be heard!
Your feedback will help improve our manuals. The survey is accessible through any internet-
Scan the Quick Response (QR) code or click or type the web address http://irco.az1.qualtricscomplete the survey.
3
d Supplemental Power Package Retrofit Kits onto ponents (not supplied) are required to complete iring Requirements” on page 75.
s warranties express or implied, with respect to ld not be regarded as all-inclusive or covering t should be consulted.
aintained, repaired or altered as, in the
ty damage or any other direct, indirect, y information, recommendations or
Introduction
This installation manual was written to assist with the installation of the Thermo King Battery Charger anPrecedent C-600*, C-600M, S-600, S-700, S-600M and S-610/DE units. Additional kits or individual comliftgate charger applications. Contact your Thermo King dealer for available kits. See “Liftgate Charger W
*NOTE: C-600 UNIT CANNOT HAVE SUPLEMENTAL POWER PACKAGE INSTALLED.
Due to its complexity, you should not attempt this installation unless you:
• Are an experienced mechanic
• Can safely lift 34 kilos (75 lbs.)
• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems
• Have a basic understanding of electricity and electrical wiring
• Have the necessary tools and equipment to complete the installation.
This manual is published for informational purposes only. Thermo King makes no representationthe information recommendations and descriptions contained herein. Information provided shouall contingencies. If further information is required, Thermo King Corporation Service Departmen
Thermo King’s warranty shall not apply to any equipment which has been “so installed, mmanufacturer’s judgment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, properspecial, or consequential damages whatsoever, arising out of the use of this manual or andescriptions contained herein.
4
are doing with the table of
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ower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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Table Of Contents
NOTE: Match up the part number and conversion that youcontents page for that conversion.
Available Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-600 / S-600 / S-700 Model 30 - Charger 401215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-600 / S-700 Model 30 - Charger 401208 + Alternator 452591 . . . . . . . . . . . . . . . . . . . . . . . .
S-600 / S-610M/DE / S-700 Model 30 - Alternator 401209 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger 401210 . . . . . . . . . . . . . . . . . . . .
S-600 / S-700 Model 50 (230 Volt Only) - Charger 40-1210 + Alternator 452591 . . . . . . . . . .
S-600 / S-610M/DE / S-700 Model 50 (230 and 460 Volt) - Alternator 401347 . . . . . . . . . . . . .
S-600M Model 30 - Charger 401261 Optional Supplemental Power . . . . . . . . . . . . . . . . . . . .
S-600M Model 30 - Alternator 401262 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger 401263 Optional Supplemental P
S-610M Model 30 - Charger 401348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-600M Model 30 - Alternator 401341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-600M Model 50 (230 and 460 Volt) - Alternator 401342 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S-600M Model 50 - (230 and 460 Volt) Alternator 40-1264 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconfiguring the SR4 Controller / Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liftgate Charger Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
arness + Battery Cable Kit
rness Battery Cable Kit
rness Battery Cable Kit
rness Battery Cable Kit
rness Battery Cable Kit
l power
able Kit +Other
able Kit
able Kit *
able Kit *
able Kit 781863 & 773085*
able Kit
able Kit
able Kit 781869 & 773103
able Kit
able Kit
able Kit 781866 & 773085
nesses Battery Cable Kits
22188 45 ft. 401223
22189 60 ft. 401224
or auxiliary items cannot be wired to t of TRU system when battery ou must install the supplemental age and wire liftgates and auxiliary
Available Conversion Kits
* Customer selects correct belt from kit.
Convert Alternator Unit to Battery Charger:
Model Battery Charger Kit
C-600, S-600, S-700 model 30 30A 401215*
C-600, S-600, S-700 model 50 230V 30A 401210
S-600M model 30 120A 401261
S-610M model 30 120A 401348
S-600M, S-610M/DE model 50 230V 120A 401263
C-600M 120A Std. w/battery charger
Any model 50 460V Not available
Convert Alternator Unit to Battery Charger and add Supplemental Power Alternator:
Model BC and Supp Alt Kit + Alternator + Excite H
C-600 Not Available
S-600, S-700 model 30 30A, 120A 401208 452591 & 422341 Excite Ha
S-600, S-700 model 50 230V 30A, 120A 401210 452591 & 422341 Excite Ha
S-600M, S-610M/DE model 30 120A, 120A 401261 Reuse 120A from unit Excite Ha
S-600M, S-610M/DE model 50 230V 120A, 120A 401263 Reuse 120A from unit Excite Ha
C-600M 120A, 65A below Std. w/battery charger. See chart below to add supplementa
Any model 50 460V Not Available
Add Supplemental Power Alternator to a Battery Charger Unit:
Model Suppl Alt Kit + Excite Harness + Battery C
C-600 Not Available Excite Harness Battery C
S-600, S-700, S-610M/DE model 30 120A 401209 Excite Harness Battery C
S-600, S-700, S-610M/DE model 50 230V or 460V 12 hp 120A 401347 Excite Harness Battery C
S-600, S-700, S-610M/DE model 50 460V 19hp 120A 401347 Excite Harness Battery C
S-600 model 30 120A 401262 Excite Harness Battery C
S-600M model 50 230V or 460V 12 hp 120A 401264 Excite Harness Battery C
S-600M model 50 460V 19hp 120A 401264 Excite Harness Battery C
C-600M model 30 (65A only) 65A 401341 Excite Harness Battery C
C-600M model 50 230V 460V 12hp (65A only) 65A 401342 Excite Harness Battery C
C-600M model 50 460V 19hp 65A 401342 Excite Harness Battery C
Excite Har
9 ft. 4
60 ft. 4
IMPORTANT: Liftgatesunit battery or any parcharger is installed. Ypower alternator packitems to it.
6
ger 401215
hen battery charger is installed. You must y wish to also install an EON power pack
ey and Belt Installationnter of tensioner.
y off tensioner and discard.
lley onto tensioner.
o tensioner.
just to proper tension.
remove the Positive (+) battery cable from rom unit (if applicable).
C-600 / S-600 / S-700 Model 30 - Char
IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system winstall the supplemental power alternator package and wire liftgates and auxiliary items to it. You mawired to the supplemental alternator.
Alternator and Belt Removal1. Open front curbside and roadside door panels.
2. Disconnect following alternator harness connections:
• 1-pin connector (WRPM-02)• 2-pin connector (WRPM-02)• 2-pin connector (SENSE, EXC)• Terminal ring (CHA-01)• Terminal ring (2A-01)
3. Loosen adjusting bolt for pulley tensioner.
4. Remove and discard belt.
5. Remove alternator bolts and alternator.
NOTE: Alternator will no longer be used.
New Tensioner Pull6. Remove c-clip from ce
• Slide smooth pulle
7. Install new grooved pu
• Reinstall c-clip ont
8. Install new belt and ad
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and the unit’s battery. Disconnect the remote power supply at its source and remove power cable f
781875 - Belt S-600
781856 - Belt S-700
781858 - Belt C-600
7
rger 401215
C-600 / S-600 / S-700 Model 30 - Cha8
01215 (continued)
oval (if exists) Control Box door and disconnect rrent sensor.
nector and sensor will no longer be needed.
C-600 / S-600 / S-700 Model 30 - Charger 4
Alternator Harness Removal 9. Open Control Box door and disconnect following alternator harness
wires:
• Power wire (2A-01) from the 2A stud on the SR-4 controller board.
• Alternator ground wire (CHA-01) from the ground stud on frame.
• 3-pin connector (2Y-02, EXC-02) from main harness.
• Carefully remove complete alternator harness from unit and discard.
Current Sensor Rem10. Open Blower and Fans
2-pin connector from cu
• Remove sensor.
NOTE: The empty con
9
r 401215 (continued)
C-600 / S-600 / S-700 Model 30 - Charge10
01215 (continued)
C-600 / S-600 / S-700 Model 30 - Charger 4Access to Battery Charger Mounting Studs11. Remove roadside door panel.
12. Remove 5 bolts securing door hinge bracket.
13. Remove 3 bolts holding battery charger box cover.
14. Remove cover to expose four studs on panel.
11
01215 (continued)
C-600 / S-600 / S-700 Model 30 - Charger 412
401215 (continued)
Installationnto battery charger box cover.
er onto each stud.
er onto studs.
sher and M6 locking nut onto each stud and tighten
onnector (BAT-LOAD-01, BAT-GND-01) to CU/ALT) from battery cable to ECU unit.
nd wires to the unit ground plate located behind the nect as follows:
BAT-01) to ground plate 6 GND PLT
BC-01) to ground plate 6 GND PLT-01
sensor on frame member with a clamp.
C-600 / S-600 / S-700 Model 30 - Charger
Low Voltage Harness Installation15. Inside the Control Box, connect the battery charger harness:
• 4-pin connector (JCANH-01, JCANL-01, JSH-02, JCH-01) to J33 on SR-4 controller board.
• Single power wire (2L-01) to 2A stud on SR-4 controller board.
• 3-pin (ALT. CONNECTOR) to mating connector (2Y-02, ECX-02) from the main harness.
16. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on Battery Charger.
17. Remove the two screws from the charger cover, loosen connectors and install the following wires:
• Single wire (CHBAT-01) along with ECU Power Harness (supplied loose in kit) wire (BAT-GND-01) to connection A.
• ECU Power Harness single wire (BAT-LOAD-01) to connection B.
• Single wire (2BC-02) to connection C.
• Reinstall cover, tighten screws and connectors.
Battery Charger 18. Attach nameplate o
19. Install a nylon wash
20. Install battery charg
21. Install a M6 flat wanuts securely.
22. Connect the 2-pin cmating connector (E
23. Route the two groucontrol box and con
• Single wire (CH
• Single wire (CH
24. Secure temperature
13
01215 (continued)
C-600 / S-600 / S-700 Model 30 - Charger 414
01215 (continued)
H2
2
2
2
2
3
3
3
4 ControllerSR4 Controller / Trouble Shooting” on page 74 ion.
C-600 / S-600 / S-700 Model 30 - Charger 4
igh Voltage Battery Charger Harness Installation5. Route high voltage harness attached to battery charger to the
Blower and Fans Control Box.
6. Open cover and remove the blind grommet inside box. Install harness conduit fitting and nut securely.
7. Route and attach wires to the Evaporator Fan High Speed contactor high voltage terminals on the bus bar:
• Attach one wire to L1, L2 and L3.
NOTE: The wires can be put in any order onto the contactor since the battery charger rectifies the 3 phase, however the ground wire must only be attached to the ground stud.
8. Attach ground wire (GND) to ground stud inside box.
9. Close and secure the Control box and Blower and Fans Control box covers.
0. Reinstall door hinge brackets.
1. Reinstall roadside door panel.
2. Close and secure roadside and curbside doors.
Programming the SRSee “Reconfiguring the to complete the installat
15
401215 (continued)
Ground Stud
C-600 / S-600 / S-700 Model 30 - Charger
16
lternator 452591
t be ordered separately.
wire them to the supplemental alternator.
llation(SENSE, EXC) onto alternator.
re into control box:
irmly into pin C of 3-pin (ALT. CONNECTOR) ry charger harness installed earlier.
CONNECTOR) to the mating connector cated inside the control box.
wire to accessory positive (+) battery power. DO it’s battery.
NSE wire to the closest accessory battery if
individual components (not supplied) are ate charger applications. Contact your vailable kits. See “Liftgate Charger Wiring 5.
move the Positive (+) battery cable from m unit (if applicable).
NOTE: ocedures on pages 8-15 ete this installation.
S-600 / S-700 Model 30 - Charger 401208 + A
IMPORTANT: Sense Harness (422188 and 422189) is required and mus
IMPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and reFailure to rewire will result in battery charger fault.
37 or 65 Amp Alternator Removal1. Open front curbside and roadside door panels.
2. Disconnect following alternator harness connections:
• 1-pin connector (WRPM-02)
• 2-pin connector (WRPM-02)
• 2-pin connector (SENSE, EXC)
• Terminal ring (CHA-01)
• Terminal ring (2A-01)
3. Loosen adjusting bolt for pulley tensioner.
4. Remove alternator bolts and alternator.
120 Amp Alternator Installation5. Remove pulley from existing alternator and reinstall onto 120 amp
alternator.
• Tighten M16 nut to 61 N•m (45 ft-lb).
6. Install 120 amp alternator using the same mounting hardware.
• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).
• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).
• Reinstall belt and adjust to proper tension.
Sense Harness Insta7. Attach 2-pin connector
8. Route single (EXC) wi
• Insert (EXC) wire flocated on the batte
• Attach 3-pin (ALT. (2Y-02, EXC-02) lo
9. Route single (SENSE) NOT connect this to un
IMPORTANT: Connect SEusing multiple batteries.
NOTE: Additional kits or required to complete liftgThermo King dealer for aRequirements” on page 7
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and rethe unit’s battery. Disconnect the remote power supply at its source and remove power cable fro
Follow the prto compl
17
Alternator 452591
S-600 / S-700 Model 30 - Charger 40-1208 +18
nator 401209
he supplemental power package.
e them to the supplemental alternator.
allation connector (SENSE, EXC) onto alternator.
nto control box:
ly into pin C of 3-pin (ALT. CONNECTOR) harger harness installed earlier.
NNECTOR) to the mating connector ed inside the control box.
e to accessory positive (+) battery power. nit’s battery.
E wire to the closest accessory battery if
ividual components (not supplied) are charger applications. Contact your lable kits. See “Liftgate Charger Wiring
d wraps.
Controllerontroller / Trouble Shooting” on page 74 to
ve the Positive (+) battery cable from the (if applicable).
S-600 / S-610M/DE / S-700 Model 30 - Alter
IMPORTANT: Your unit must already be equipped with a Battery Charger to install tSense Harness (422188 and 422189) is required and must be ordered separately.
IMPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewirFailure to rewire will result in battery charger fault.
120 Amp Alternator Installation1. Open front curbside and roadside door panels.
2. Loosen adjusting bolt for pulley tensioner.
3. Remove and discard belt.
4. Remove c-clip from center of tensioner.
• Slide grooved pulley off tensioner and discard.
5. Install new smooth pulley onto tensioner.
• Reinstall c-clip onto tensioner.
6. Installed supplied pulley from kit onto alternator.
• Tighten M16 nut to 61 N•m (45 ft-lb).
7. Install alternator onto bracket with supplied hardware.
• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).
• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).
8. Install new belt and adjust to proper tension.
Sense Harness Inst9. Attach sense harness 2-pin
10. Route single (EXC) wire i
• Insert (EXC) wire firmlocated on the battery c
• Attach 3-pin (ALT. CO(2Y-02, EXC-02) locat
11. Route single (SENSE) wirDO NOT connect this to u
IMPORTANT: Connect SENSusing multiple batteries.
NOTE: Additional kits or indrequired to complete liftgateThermo King dealer for avaiRequirements” on page 75.
12. Secure all wiring with ban
13. Close and secure all doors.
Programming the SR4See “Reconfiguring the SR4 Ccomplete the installation.
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remounit’s battery. Disconnect the remote power supply at its source and remove power cable from unit
781876 - Belt S-600 / S-610M/DE
781857 - Belt S-700
19
ternator 401209
S-600 / S-610M/DE / S-700 Model 30 - Al20
ly) - Charger 401210
when battery charger is installed. You must may wish to also install an EON power pack
nd remove the Positive (+) battery cable from le from unit (if applicable).
C-600 / S-600 / S-700 Model 50 (230 Volt On
IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU systeminstall the supplemental power alternator package and wire liftgates and auxiliary items to it. Youwired to the supplemental alternator.
Alternator and Belt Removal1. Open front curbside and roadside door panels.
2. Disconnect following alternator harness connections:
• 1-pin connector (WRPM-02)• 2-pin connector (WRPM-02)• 2-pin connector (SENSE, EXC)• Terminal ring (CHA-01)• Terminal ring (2A-01)
3. Remove alternator belt.
4. Remove alternator bolts and alternator.
NOTE: Alternator will no longer be used.
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position athe unit’s battery. Disconnect the remote power supply at its source and remove power cab
21
ly) - Charger 401210
C-600 / S-600 / S-700 Model 50 (230 Volt On22
rger 401210 (continued)
emoval (if exists)ans Control Box door and disconnect
m current sensor.
connector and sensor will no longer be needed.
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Cha
Alternator Harness Removal 5. Open Control Box door and disconnect following alternator harness
wires:
• Power wire (2A-01) from the 2A stud on the SR-4 controller board.
• Alternator ground wire (CHA-01) from the ground stud on frame.
• 3-pin connector (2Y-02, EXC-02) from main harness.
• Carefully remove complete alternator harness from unit and discard.
Current Sensor R6. Open Blower and F
2-pin connector fro
• Remove sensor.
NOTE: The empty
23
ger 401210 (continued)
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Char24
rger 401210 (continued)
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - ChaAccess to Battery Charger Mounting Studs7. Remove roadside door panel.
8. Remove 5 bolts securing door hinge bracket.
9. Remove 3 bolts holding battery charger box cover.
10. Remove cover to expose four studs on panel.
25
ger 401210 (continued)
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Char26
rger 401210 (continued)
Installationnto battery charger box cover.
er onto each stud.
er onto studs.
sher and M6 locking nut onto each stud and tighten
onnector (BAT-LOAD-01, BAT-GND-01) to CU/ALT) from battery cable to ECU unit.
nd wires to the unit ground plate located behind the nect as follows:
BAT-01) to ground plate 6 GND PLT
BC-01) to ground plate 6 GND PLT-01
sensor on frame member with a clamp.
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Cha
Low Voltage Harness Installation11. Inside the Control Box, connect the battery charger harness:
• 4-pin connector (JCANH-01, JCANL-01, JSH-02, JCH-01) to J33 on SR-4 controller board.
• Single power wire (2L-01) to 2A stud on controller board.
• 3-pin (ALT. CONNECTOR) to mating connector (2Y-02, ECX-02) from the main harness.
12. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on Battery Charger.
13. Remove the two screws from the charger cover, loosen connectors and install the following wires:
• Single wire (CHBAT-01) along with ECU Power Harness (supplied loose in kit) wire (BAT-GND-01) to connection A.
• ECU Power Harness single wire (BAT-LOAD-01) to connection B.
• Single wire (2BC-02) to connection C.
• Reinstall cover, tighten screws and connectors.
Battery Charger 14. Attach nameplate o
15. Install a nylon wash
16. Install battery charg
17. Install a M6 flat wanuts securely.
18. Connect the 2-pin cmating connector (E
19. Route the two groucontrol box and con
• Single wire (CH
• Single wire (CH
20. Secure temperature
27
rger 401210 (continued
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Cha28
rger 40-1210 (continued
SR4 Controller. SR4 Controller / Trouble Shooting” on page 74 to n.
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Cha
High Voltage Battery Charger Harness Installation21. Route high voltage harness attached to battery charger into the
Blower and Fans Control Box.
22. Open cover and remove the blind grommet inside box and install harness conduit fitting and nut securely.
23. Route and attach wires to the Evaporator Fan High Speed contactor high voltage terminals on the bus bar:
• Attach one wire to L1, L2 and L3.
NOTE: The wires can be put in any order onto the contactor since the battery charger rectifies the 3 phase, however the ground wire must only be attached to the ground stud.
24. Attach ground wire (GND) to ground stud inside box.
25. Early Production Units Only - Check fuse size and change if needed.
• Replace the 10 amp fuses with the 15 Amp fuses supplied.
26. Close and secure the Control box and Blower and Fans Control box covers.
27. Reinstall door hinge bracket.
28. Reinstall roadside door panel.
29. Close and secure roadside and curbside doors.
Programming theSee “Reconfiguring thecomplete the installatio
29
rger 401210 (continued
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Cha30
0 + Alternator 452591
llationSENSE, EXC) onto alternator.
into control box:
mly into pin C of 3-pin (ALT. CONNECTOR) charger harness installed earlier.
ONNECTOR) to the mating connector ated inside the control box.
ire to accessory positive (+) battery power. unit’s battery.
SE wire to the closest accessory battery if
dividual components (not supplied) are te charger applications. Contact your ailable kits. See “Liftgate Charger Wiring .
NOTE: cedures on pages 22-29
ete this installation.
S-600 / S-700 Model 50 (230 Volt Only) - Charger 40-121
IMPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewire them to the supplemental alternator. Failure to rewire will result in battery charger fault.
37 or 65 Amp Alternator Removal1. Open front curbside and roadside door panels.
2. Disconnect following alternator harness connections:
• 1-pin connector (WRPM-02)
• 2-pin connector (WRPM-02)
• 2-pin connector (SENSE, EXC)
• Terminal ring (CHA-01)
• Terminal ring (2A-01)
3. Remove alternator bolts and alternator.
120 Amp Alternator Installation4. Remove pulley from existing alternator and reinstall onto 120 amp
alternator.
• Tighten M16 nut to 61 N•m (45 ft-lb)
5. Install 120 amp alternator using the same mounting hardware.
• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).
• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).
• Reinstall belt, adjust tension and tighten alternator bolts.
Sense Harness Insta6. Attach 2-pin connector (
7. Route single (EXC) wire
• Insert (EXC) wire firlocated on the battery
• Attach 3-pin (ALT. C(2Y-02, EXC-02) loc
8. Route single (SENSE) wDO NOT connect this to
IMPORTANT: Connect SENusing multiple batteries.
NOTE: Additional kits or inrequired to complete liftgaThermo King dealer for avRequirements” on page 75
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remove the Positive (+) battery cable from the unit’s battery. Disconnect the remote power supply at its source and remove power cable from unit (if applicable).
Follow the proto compl
31
210 + Alternator 452591
S-600 / S-700 Model 50 (230 Volt Only) - Charger 40-132
lt) - Alternator 401347l the supplemental power package. tely.
ire them to the supplemental alternator.
stallationin connector (SENSE, EXC) to alternator.
e into control box:
rmly into pin C of 3-pin (ALT. CONNECTOR) y charger harness installed earlier.
ONNECTOR) to the mating connector cated inside the control box.
ire to accessory positive (+) battery power. unit’s battery.
SE wire to the closest accessory battery if
ndividual components (not supplied) are te charger applications. Contact your ailable kits. See “Liftgate Charger Wiring
5.
and wraps.
rs.
4 Controller. Controller / Trouble Shooting” on page 74 to
ove the Positive (+) battery cable from unit (if applicable).
S-600 / S-610M/DE / S-700 Model 50 (230 and 460 VoIMPORTANT: Your unit must already be equipped with a Battery Charger to instalSense Harness (422188 and 422189) is also required and must be ordered separa
IMPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewFailure to rewire will result in battery charger fault.
Alternator InstallationNOTE: Different belts are required for 12 hp units, while a different alternator pulley and belt are required for 19 hp units. Be sure you have the correct ones for your particular unit.
1. Open front curbside and roadside door panels.
2. Install pulley onto alternator. See note above.
• Tighten M16 nut to 61 N•m (45 ft-lb)
3. Install belt. See note above.
4. Install alternator with supplied hardware and adjust belt to proper tension.
• Tighten M10 alternator hardware to 23 N•m (17 ft-lb).
• Tighten M8 alternator hardware to 30 N•m (22 ft-lb).
Sense Harness In5. Attach sense harness 2-p
6. Route single (EXC) wir
• Insert (EXC) wire filocated on the batter
• Attach 3-pin (ALT. C(2Y-02, EXC-02) lo
7. Route single (SENSE) wDO NOT connect this to
IMPORTANT: Connect SENusing multiple batteries.
NOTE: Additional kits or irequired to complete liftgaThermo King dealer for avRequirements” on page 7
8. Secure all wiring with b
9. Close and secure all doo
Programming the SRSee “Reconfiguring the SR4complete the installation.
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remthe unit’s battery. Disconnect the remote power supply at its source and remove power cable from
781833 - Belt, 12 hp S-600
781878 - Belt, 12 hp S-610M / DE
781864 - Belt, 12 hp S-700
781863 - Belt, 19 hp773085 - Pulley, 19 hp(Pulley and belt must be purchased separately)
33
Volt) - Alternator 401347
S-600 / S-610M/DE / S-700 Model 50 (230 and 46034
pplemental Power
battery charger is installed. You must install lso install an EON power pack wired to the
er 0 amp alternator)ny liftgate or auxiliary items from the unit and rewire them to the supplemental will result in battery charger fault.
on
in connector (SENSE, EXC) to alternator.
into control box:
mly into pin C of 3-pin (ALT. CONNECTOR) charger harness installed earlier.
ONNECTOR) to the mating connector ated inside the control box.
ire to accessory positive (+) battery power. unit’s battery.
SE wire to the closest accessory battery if
dividual components (not supplied) are te charger applications. Contact your ailable kits. See “Liftgate Charger Wiring .
ove the Positive (+) battery cable from unit (if applicable).
S-600M Model 30 - Charger 401261 Optional Su
IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when the supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish to asupplemental alternator.
If you want supplemental power, skip steps 1-5 below.
Charger Only
Alternator and Belt Removal1. Open front curbside and roadside door panels.
2. Disconnect following alternator harness connections:
• 2-pin connector (2Y-02, EXC-02)• 2-pin connector (WRPM-02)• 1-pin connector (WRPM-02)• Terminal ring (CHA-01)• Terminal ring (2A-02)
3. Cut alternator belt.
4. Remove and discard alternator belt.
5. Remove alternator bolts and alternator.
NOTE: Alternator will no longer be used.
Supplemental Pow(Using existing 12IMPORTANT: Disconnect abattery or charging systemalternator. Failure to rewire
Sense Harness Installati
6. Attach sense harness 2-p
7. Route single (EXC) wire
• Insert (EXC) wire firlocated on the battery
• Attach 3-pin (ALT. C(2Y-02, EXC-02) loc
8. Route single (SENSE) wDO NOT connect this to
IMPORTANT: Connect SENusing multiple batteries.
NOTE: Additional kits or inrequired to complete liftgaThermo King dealer for avRequirements” on page 75
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remthe unit’s battery. Disconnect the remote power supply at its source and remove power cable from
35
upplemental Power
S-600M Model 30 - Charger 401261 Optional S36
(continued)
S-600M Model 30 - Charger 401261Access to Battery Charger Mounting Studs9. Remove roadside door panel.
10. Remove 5 bolts securing door hinge bracket.
11. Remove 3 bolts holding battery charger box cover.
12. Remove cover to expose four studs on panel.
37
(continued)
S-600M Model 30 - Charger 40126138
(continued)
emoval (if exists)ans Control Box door and disconnect 2-pin
rent sensor.
connector and sensor will no longer be needed.
S-600M Model 30 - Charger 401261
Removing WiresInside the Control Box disconnect and remove the following wires:
13. Power wire (2A-01) from 2A stud on SR4 controller board and 2A stud on expansion module.
14. Power wire (2A-03) from 2 stud on relay board and 2A stud on expansion module.
15. Alternator harness power wire (2A-02) from the 2A stud on the expansion module board.
16. Alternator 3-pin connector (2Y-02, EXC-02) from main harness.
17. Remove alternator ground wire (CHA-01) from the ground stud on frame.
• Carefully remove complete alternator harness from unit and discard.
Current Sensor R18. Open Blower and F
connector from cur
• Remove sensor.
NOTE: The empty
39
(continued)
S-600M Model 30 - Charger 40126140
(continued)
ng wires onto the battery charger:rews from the charger cover, loosen connectors and wires from the battery charger power harness:
connection A.
) to connection B.
) to connection C.
tighten screws and connectors.
arness out of control box and connect the 8-pin connector on Battery Charger.
Installationnto battery charger box cover.
er onto each stud.
er onto studs.
sher and M6 locking nut onto each stud and tighten
nd wires to the unit ground plate located behind the nect as follows:
BC-01) to ground plate 6 GND PLT
BC-02) to ground plate 6 GND PLT-01
sensor on frame member with a clamp.
S-600M Model 30 - Charger 401261
Install the following harnesses inside the control box: 19. Diode Harness:
• wire (2ASR4-02) to 2A on SR-4 controller board.
• wire (2AEXP-02) to 2A on expansion module.
20. Battery Charger Harness:
• 4-pin connector (JCANH-01, JCANL-01, JSH-02, JCH-01) to J33 on SR-4 controller board.
• 3-pin (ALT. CONNECTOR) to mating connector (2Y-02, ECX-02) from the main harness.
• Route 8-pin connector, temperature sensor and ground wire out of control box. These will be connected in a later step.
21. Battery Charger Power Harness:
• wire (2AEXP-01) to 2A on expansion module.
• wire (2ASR4-01) to 2A on SR-4 controller board.
• Route remaining wires out of the control box.
22. Jumper Wire Installation:
• wire (2-03) from 2A on control board to 2 on relay board.
Install the followi23. Remove the two sc
install the following
• (CHBC-02) to
• wire (LOAD-01
• wire (BATT-01
• Reinstall cover,
24. Route low voltage hconnector to mating
Battery Charger 25. Attach nameplate o
26. Install a nylon wash
27. Install battery charg
28. Install a M6 flat wanuts securely.
29. Route the two groucontrol box and con
• Single wire (CH
• Single wire (CH
30. Secure temperature
41
(continued)
S-600M Model 30 - Charger 40126142
(continued)
SR4 Controller
SR4 Controller / Trouble Shooting” on page 74 to n.
S-600M Model 30 - Charger 401261
High Voltage Battery Charger Harness Installation31. Route high voltage harness attached to battery charger to the
Blower and Fans Control Box.
32. Open cover and remove the blind grommet inside box. Install harness conduit fitting and nut securely.
33. Route and attach wires to the Evaporator Fan High Speed contactor high voltage terminals on the bus bar:
• Attach one wire to L1, L2 and L3.
NOTE: The wires can be put in any order onto the contactor since the battery charger rectifies the 3 phase, however the ground wire must only be attached to the ground stud.
34. Attach ground wire (GND) to ground stud inside box.
35. Close and secure the Control box and Blower and Fans Control box covers.
36. Reinstall door hinge brackets.
37. Reinstall roadside door panel.
38. Close and secure roadside and curbside doors.
Programming the
See “Reconfiguring thecomplete the installatio
43
(continued)
Ground Stud
S-600M Model 30 - Charger 401261
44
262
I he supplemental power package. S
I them to the supplemental alternator. Failure t
11
2
3
4
5
tallationn connector (SENSE, EXC) onto alternator.
ox:
ly into pin C of 3-pin (ALT. CONNECTOR) charger harness installed earlier.
ONNECTOR) to the mating connector ted inside the control box.
re to accessory positive (+) battery power. unit’s battery.
E wire to the closest accessory battery if
ividual components (not supplied) are e charger applications. Contact your Thermo s. See “Liftgate Charger Wiring
d wraps.
.
Controllerontroller / Trouble Shooting” on page 74 to
ve the Positive (+) battery cable from nit (if applicable).
S-600M Model 30 - Alternator 401
MPORTANT: Your unit must already be equipped with a Battery Charger to install tense Harness (42-975 or 42-976) is required and must be ordered separately.
MPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewireo rewire will result in battery charger fault.
20 Amp Alternator Installation. Open front curbside and roadside door panels.
. Install the shim and pulley onto the generator pulley with the supplied M8 screws and flatwashers.
• Tighten bolts to 21 N•m (16 ft-lb).
. Installed supplied pulley onto alternator.
• Tighten M16 nut to 61 N•m (45 ft-lb).
. Install alternator onto bracket with supplied hardware.
• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).
• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).
. Install new belt and adjust to proper tension.
Sense Harness Ins6. Attach sense harness 2-pi
7. Route wires into control b
• Insert (EXC) wire firmlocated on the battery
• Attach 3-pin (ALT. C(2Y-02, EXC-02) loca
8. Route single (SENSE) wiDO NOT connect this to
IMPORTANT: Connect SENSusing multiple batteries.
NOTE: Additional kits or indrequired to complete liftgatKing dealer for available kitRequirements” on page 75.
9. Secure all wiring with ban
10. Close and secure all doors
Programming the SR4See “Reconfiguring the SR4 Cfinish the installation.
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remothe unit’s battery. Disconnect the remote power supply at its source and remove power cable from u
45
401262
S-600M Model 30 - Alternator46
harger 401263
I n battery charger is installed. You must install t also install an EON power pack wired to the s
I
A1
2
3
4
N
wer 20 amp alternator) any liftgate or auxiliary items from the unit m and rewire them to the supplemental
ire will result in battery charger fault.
tion
-pin connector (SENSE, EXC) to alternator.
re into control box:
irmly into pin C of 3-pin (ALT. CONNECTOR) ry charger harness installed earlier.
CONNECTOR) to the mating connector ocated inside the control box.
wire to accessory positive (+) battery power. to unit’s battery.
NSE wire to the closest accessory battery if
individual components (not supplied) are ate charger applications. Contact your vailable kits. See “Liftgate Charger Wiring
75.
move the Positive (+) battery cable from m unit (if applicable).
S-600M / S-610M / DE / Model 50 - (230 Volt Only) COptional Supplemental Power
MPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system whehe supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish toupplemental alternator.
f you want supplemental power, skip steps 1-4 below.
lternator and Belt Removal. Open front curbside and roadside door panels.
. Disconnect following alternator harness connections:
• 1-pin connector (WRPM-02)• 2-pin connector (WRPM-02)• 2-pin connector (SENSE, EXC)• Terminal ring (CHA-01)• Terminal ring (2A-01)
. Remove alternator belt.
. Remove alternator bolts and alternator.
OTE: Alternator will no longer be used.
Supplemental Po(Using existing 1IMPORTANT: Disconnectbattery or charging systealternator. Failure to rew
Sense Harness Installa
5. Attach sense harness 2
6. Route single (EXC) wi
• Insert (EXC) wire flocated on the batte
• Attach 3-pin (ALT.(2Y-02, EXC-02) l
7. Route single (SENSE)DO NOT connect this
IMPORTANT: Connect SEusing multiple batteries.
NOTE: Additional kits orrequired to complete liftgThermo King dealer for aRequirements” on page
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and rethe unit’s battery. Disconnect the remote power supply at its source and remove power cable fro
47
harger 401263
S-600M / S-610M / DE / Model 50 - (230 Volt Only) COptional Supplemental Power48
) Charger 401263 nued)
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti
Access to Battery Charger Mounting Studs8. Remove roadside door panel.
9. Remove 5 bolts securing door hinge bracket.
10. Remove 3 bolts holding battery charger box cover.
11. Remove cover to expose four studs on panel.
49
) Charger 401263 nued)
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti
50
) Charger 401263 nued)
emoval (if exists)ans Control Box door and disconnect
m current sensor.
connector and sensor will no longer be needed.
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti
Removing WiresInside the Control Box disconnect and remove the following wires:
12. Power wire (2A-01) from 2A stud on SR4 controller board and 2A stud on expansion module.
13. Power wire (2A-03) from 2 stud on relay board and 2A stud on expansion module.
14. Alternator harness power wire (2A-02) from the 2A stud on the expansion module board.
15. Alternator 3-pin connector (2Y-02, EXC-02) from main harness.
16. Remove alternator ground wire (CHA-01) from the ground stud on frame.
• Carefully remove complete alternator harness from unit and discard.
Current Sensor R17. Open Blower and F
2-pin connector fro
• Remove sensor.
NOTE: The empty
51
) Charger 401263 nued)
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti
52
) Charger 401263 nued)
ng wires onto the battery charger:rews from the charger cover, loosen connectors and wires from the battery charger power harness:
) to connection A.
) to connection B.
) to connection C.
tighten screws and connectors.
arness out of control box and connect the 8-pin connector on Battery Charger.
Installationnto battery charger box cover.
er onto each stud.
er onto studs.
sher and M6 locking nut onto each stud and tighten
nd wires to the unit ground plate located behind the nect as follows:
BC-01) to ground plate 6 GND PLT
BC-02) to ground plate 6 GND PLT-01
sensor on frame member with a clamp.
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti
Install the following harnesses inside the control box: 18. Diode Harness:
• wire (2ASR4-02) to 2A on SR-4 controller board.
• wire (2AEXP-02) to 2A on expansion module.
19. Battery Charger Harness:
• 4-pin connector (JCANH-01, JCANL-01, JSH-02, JCH-01) to J33 on SR-4 controller board.
• 3-pin (ALT. CONNECTOR) to mating connector (2Y-02, ECX-02) from the main harness.
• Route 8-pin connector, temperature sensor and ground wire out of control box. These will be connected in a later step.
20. Battery Charger Power Harness:
• wire (2AEXP-01) to 2A on expansion module.
• wire (2ASR4-01) to 2A on SR-4 controller board.
• Route remaining wires out of the control box.
21. Jumper Wire Installation:
• wire (2-03) from 2A on SR-4 controller board to 2 on relay board
Install the followi22. Remove the two sc
install the following
• wire (CHBC-02
• wire (LOAD-01
• wire (BATT-01
• Reinstall cover,
23. Route low voltage hconnector to mating
Battery Charger 24. Attach nameplate o
25. Install a nylon wash
26. Install battery charg
27. Install a M6 flat wanuts securely.
28. Route the two groucontrol box and con
• Single wire (CH
• Single wire (CH
29. Secure temperature
53
) Charger 401263 nued)
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti
54
) Charger 401263 ued))
SR4 Controller. SR4 Controller / Trouble Shooting” on page 74 to n.
S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (contin
High Voltage Battery Charger Harness Installation30. Route high voltage harness attached to battery charger into the
Blower and Fans Control Box.
31. Open cover and remove the blind grommet inside box and install harness conduit fitting and nut securely.
32. Route and attach wires to the Evaporator Fan High Speed contactor high voltage terminals on the bus bar:
• Attach one wire to L1, L2 and L3.
NOTE: The wires can be put in any order onto the contactor since the battery charger rectifies the 3 phase, however the ground wire must only be attached to the ground stud.
33. Attach ground wire (GND) to ground stud inside box.
34. Close and secure the Control box and Blower and Fans Control box covers.
35. Reinstall door hinge bracket.
36. Reinstall roadside door panel.
37. Close and secure roadside and curbside doors.
Programming theSee “Reconfiguring thecomplete the installatio
55
Charger 401263
ued)
S-600M / S-610M / DE / Model 50 - (230 Volt Only)Optional Supplemental Power (contin
56
01348
when battery charger is installed. You must may wish to also install an EON power pack
ulley and Belt Installation center of tensioner.
ulley off tensioner and discard.
pulley onto tensioner.
onto tensioner.
adjust to proper tension.
nd remove the Positive (+) battery cable from le from unit (if applicable).
S-610M Model 30 - Charger 4
IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU systeminstall the supplemental power alternator package and wire liftgates and auxiliary items to it. Youwired to the supplemental alternator.
Alternator and Belt Removal1. Open front curbside and roadside door panels.
2. Disconnect following alternator harness connections:
• 1-pin connector (WRPM-02)• 2-pin connector (WRPM-02)• 2-pin connector (SENSE, EXC)• Terminal ring (CHA-01)• Terminal ring (2A-01)
3. Loosen adjusting bolt for pulley tensioner.
4. Remove and discard belt.
5. Remove alternator bolts and alternator.
NOTE: Alternator will no longer be used.
New Tensioner P6. Remove c-clip from
• Slide smooth p
7. Install new grooved
• Reinstall c-clip
8. Install new belt and
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position athe unit’s battery. Disconnect the remote power supply at its source and remove power cab
57
01348
S-610M Model 30 - Charger 458
8 (continued)
emoval (if exists)ans Control Box door and disconnect
m current sensor.
connector and sensor will no longer be needed.
S-610M Model 30 - Charger 40134
Alternator Harness Removal 9. Open Control Box door and disconnect following alternator harness
wires:
• Power wire (2A-01) from the 2A stud on the SR-4 controller board.
• Alternator ground wire (CHA-01) from the ground stud on frame.
• 3-pin connector (2Y-02, EXC-02) from main harness.
• Carefully remove complete alternator harness from unit and discard.
Current Sensor R10. Open Blower and F
2-pin connector fro
• Remove sensor.
NOTE: The empty
59
8 (continued)
S-610M Model 30 - Charger 4013460
8 (continued)
S-610M Model 30 - Charger 40134Access to Battery Charger Mounting Studs11. Remove roadside door panel.
12. Remove 5 bolts securing door hinge bracket.
13. Remove 3 bolts holding battery charger box cover.
14. Remove cover to expose four studs on panel.
61
8 (continued)
S-610M Model 30 - Charger 4013462
8 (continued)
emoval (if exists)ans Control Box door and disconnect 2-pin
rent sensor.
connector and sensor will no longer be needed.
S-610M Model 30 - Charger 40134
Removing WiresInside the Control Box disconnect and remove the following wires:
15. Power wire (2A-01) from 2A stud on SR4 controller board and 2A stud on expansion module.
16. Power wire (2A-03) from 2 stud on relay board and 2A stud on expansion module.
17. Alternator harness power wire (2A-02) from the 2A stud on the expansion module board.
18. Alternator 3-pin connector (2Y-02, EXC-02) from main harness.
19. Remove alternator ground wire (CHA-01) from the ground stud on frame.
• Carefully remove complete alternator harness from unit and discard.
Current Sensor R20. Open Blower and F
connector from cur
• Remove sensor.
NOTE: The empty
63
8 (continued)
S-610M Model 30 - Charger 4013464
8 (continued)
ng wires onto the battery charger:rews from the charger cover, loosen connectors and wires from the battery charger power harness:
connection A.
) to connection B.
) to connection C.
tighten screws and connectors.
arness out of control box and connect the 8-pin connector on Battery Charger.
Installationnto battery charger box cover.
er onto each stud.
er onto studs.
sher and M6 locking nut onto each stud and tighten
nd wires to the unit ground plate located behind the nect as follows:
BC-01) to ground plate 6 GND PLT
BC-02) to ground plate 6 GND PLT-01
sensor on frame member with a clamp.
S-610M Model 30 - Charger 40134
Install the following harnesses inside the control box: 21. Diode Harness:
• wire (2ASR4-02) to 2A on SR-4 controller board.
• wire (2AEXP-02) to 2A on expansion module.
22. Battery Charger Harness:
• 4-pin connector (JCANH-01, JCANL-01, JSH-02, JCH-01) to J33 on SR-4 controller board.
• 3-pin (ALT. CONNECTOR) to mating connector (2Y-02, ECX-02) from the main harness.
• Route 8-pin connector, temperature sensor and ground wire out of control box. These will be connected in a later step.
23. Battery Charger Power Harness:
• wire (2AEXP-01) to 2A on expansion module.
• wire (2ASR4-01) to 2A on SR-4 controller board.
• Route remaining wires out of the control box.
24. Jumper Wire Installation:
• wire (2-03) from 2A on control board to 2 on relay board.
Install the followi25. Remove the two sc
install the following
• (CHBC-02) to
• wire (LOAD-01
• wire (BATT-01
• Reinstall cover,
26. Route low voltage hconnector to mating
Battery Charger 27. Attach nameplate o
28. Install a nylon wash
29. Install battery charg
30. Install a M6 flat wanuts securely.
31. Route the two groucontrol box and con
• Single wire (CH
• Single wire (CH
32. Secure temperature
65
8 (continued)
S-610M Model 30 - Charger 4013466
8 (continued)
SR4 Controller
SR4 Controller / Trouble Shooting” on page 74 to n.
S-610M Model 30 - Charger 40134
High Voltage Battery Charger Harness Installation33. Route high voltage harness attached to battery charger to the
Blower and Fans Control Box.
34. Open cover and remove the blind grommet inside box. Install harness conduit fitting and nut securely.
35. Route and attach wires to the Evaporator Fan High Speed contactor high voltage terminals on the bus bar:
• Attach one wire to L1, L2 and L3.
NOTE: The wires can be put in any order onto the contactor since the battery charger rectifies the 3 phase, however the ground wire must only be attached to the ground stud.
36. Attach ground wire (GND) to ground stud inside box.
37. Close and secure the Control box and Blower and Fans Control box covers.
38. Reinstall door hinge brackets.
39. Reinstall roadside door panel.
40. Close and secure roadside and curbside doors.
Programming the
See “Reconfiguring thecomplete the installatio
67
(continued)
Ground Stud
S-610M Model 30 - Charger 401348
68
341
he supplemental power package.
e them to the supplemental alternator.
allation connector (SENSE, EXC) onto alternator.
nto control box:
ly into pin C of 3-pin (ALT. CONNECTOR) harger harness.
NNECTOR) to the mating connector ed inside the control box.
e to accessory positive (+) battery power. nit’s battery.
E wire to the closest accessory battery if
ividual components (not supplied) are charger applications. Contact your lable kits. See “Liftgate Charger Wiring
d wraps.
Controllerontroller / Trouble Shooting” on page 74 to
ve the Positive (+) battery cable from the (if applicable).
C-600M Model 30 - Alternator 401
IMPORTANT: Your unit must already be equipped with a Battery Charger to install tSense Harness (422188 and 422189) is required and must be ordered separately.
IMPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewirFailure to rewire will result in battery charger fault.
65 Amp Alternator Installation1. Open front curbside and roadside door panels.
2. Loosen adjusting bolt for pulley tensioner.
3. Remove and discard belt.
4. Remove c-clip from center of tensioner.
• Slide grooved pulley off tensioner and discard.
5. Install new smooth pulley onto tensioner.
• Reinstall c-clip onto tensioner.
6. Installed supplied pulley from kit onto alternator.
• Tighten M16 nut to 61 N•m (45 ft-lb).
7. Install alternator onto bracket with supplied hardware.
• Tighten M8 alternator bolt s to 23 N•m (17 ft-lb).
• Tighten M10 alternator bolts to 30 N•m (22 ft-lb).
8. Install new belt and adjust to proper tension.
Sense Harness Inst9. Attach sense harness 2-pin
10. Route single (EXC) wire i
• Insert (EXC) wire firmlocated on the battery c
• Attach 3-pin (ALT. CO(2Y-02, EXC-02) locat
11. Route single (SENSE) wirDO NOT connect this to u
IMPORTANT: Connect SENSusing multiple batteries.
NOTE: Additional kits or indrequired to complete liftgateThermo King dealer for avaiRequirements” on page 75.
12. Secure all wiring with ban
13. Close and secure all doors.
Programming the SR4See “Reconfiguring the SR4 Ccomplete the installation.
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remounit’s battery. Disconnect the remote power supply at its source and remove power cable from unit
781876 - Belt S-600 / S-610M/DE
781857 - Belt S-700
69
1341
C-600M Model 30 - Alternator 4070
ator 401342 the supplemental power package. ely.
ire them to the supplemental alternator.
tallationin connector (SENSE, EXC) to alternator.
into control box:
mly into pin C of 3-pin (ALT. CONNECTOR) charger harness.
ONNECTOR) to the mating connector ated inside the control box.
ire to accessory positive (+) battery power. DO t’s battery.
SE wire to the closest accessory battery if
dividual components (not supplied) are te charger applications. Contact your ailable kits. See “Liftgate Charger Wiring .
nd wraps.
s.
4 Controller. Controller / Trouble Shooting” on page 74 to
ove the Positive (+) battery cable from the it (if applicable).
C-600M Model 50 (230 and 460 Volt) - AlternIMPORTANT: Your unit must already be equipped with a Battery Charger to installSense Harness (422188 and 422189) is also required and must be ordered separat
IMPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewFailure to rewire will result in battery charger fault.
65 Amp Alternator InstallationNOTE: Different belts and pulleys are required for 12 hp and 19 hp units. Be sure you have the correct ones for your particular unit.
1. Open front curbside and roadside door panels.
2. Install pulley onto alternator. See note above.
• Tighten M16 nut to 61 N•m (45 ft-lb)
3. Install belt. See note above.
4. Install alternator with supplied hardware and adjust belt to proper tension.
• Tighten M10 alternator hardware to 23 N•m (17 ft-lb).
• Tighten M8 alternator hardware to 30 N•m (22 ft-lb).
Sense Harness Ins5. Attach sense harness 2-p
6. Route single (EXC) wire
• Insert (EXC) wire firlocated on the battery
• Attach 3-pin (ALT. C(2Y-02, EXC-02) loc
7. Route single (SENSE) wNOT connect this to uni
IMPORTANT: Connect SENusing multiple batteries.
NOTE: Additional kits or inrequired to complete liftgaThermo King dealer for avRequirements” on page 75
8. Secure all wiring with ba
9. Close and secure all door
Programming the SRSee “Reconfiguring the SR4complete the installation.
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remunit’s battery. Disconnect the remote power supply at its source and remove power cable from un
781865 - Belt, 12 hp773103 - Pulley, 12 hp(Pulley and belt must be purchased separately)
781866 - Belt, 19 hp773085 - Pulley, 19 hp(Pulley and belt must be purchased separately)
71
- Alternator 401342
C-600M Model 50 Model 50 (230 and 460 Volt)72
nator 40-1264I the supplemental power package. S .
I ire them to the supplemental alternator. F
AN1
1
2
3
4
tallationin connector (SENSE, EXC) to alternator.
into control box:
mly into pin C of 3-pin (ALT. CONNECTOR) charger harness.
ONNECTOR) to the mating connector ated inside the control box.
ire to accessory positive (+) battery power. unit’s battery.
SE wire to the closest accessory battery if
dividual components (not supplied) are te charger applications. Contact your ailable kits. See “Liftgate Charger Wiring .
nd wraps.
s.
4 Controller. Controller / Trouble Shooting” on page 74.
ove the Positive (+) battery cable from the it (if applicable).
S-600M Model 50 - (230 and 460 Volt) AlterMPORTANT: Your unit must already be equipped with a Battery Charger to installense Harness (42-975 or 42-976) is also required and must be ordered separately
MPORTANT: Disconnect any liftgate or auxiliary items from the unit battery or charging system and rewailure to rewire will result in battery charger fault.
lternator InstallationOTE: Different alternator pulleys and belts are required for 12 hp and 9 hp units. Be sure you have the correct ones for your particular unit.
. Open front curbside and roadside door panels.
. Install pulley onto alternator. See note above.
• Tighten M16 nut to 61 N•m (45 ft-lb)
. Install belt. See note above.
. Install alternator with supplied hardware and adjust belt to proper tension.
• Tighten M10 alternator hardware to 30 N•m (22 ft-lb).
• Tighten M8 alternator hardware to 23 N•m (17 ft-lb).
Sense Harness Ins5. Attach sense harness 2-p
6. Route single (EXC) wire
• Insert (EXC) wire firlocated on the battery
• Attach 3-pin (ALT. C(2Y-02, EXC-02) loc
7. Route single (SENSE) wDO NOT connect this to
IMPORTANT: Connect SENusing multiple batteries.
NOTE: Additional kits or inrequired to complete liftgaThermo King dealer for avRequirements” on page 75
8. Secure all wiring with ba
9. Close and secure all door
Programming the SRSee “Reconfiguring the SR4
DANGER: To prevent serious injury or death, switch the unit controls to the OFF position and remunit’s battery. Disconnect the remote power supply at its source and remove power cable from un
Unit Voltage Alt. Pulley Alt. Belt
230 or 460 Volt 12 hp (pulley and belt supplied in kit)
77-3114 78-1868
460 Volt 19 hp (pulley and belt must be purchased separately)
77-3103 78-1869
73
ternator 40-1264
S-600M Model 50 - (230 and 460 Volt) Al74
uble Shooting
ngte or auxiliary items are connected to the unit system when using the battery charger.
r auxiliary items to the supplemental alternator rger.
n of the battery charger or supplemental alternator nected.
Reconfiguring the SR4 Controller / Tro
Reconfiguring the SR4 ControllerThe unit will need to be reconfigured after removing an alternator and installing a battery charger or when adding supplemental power package.
1. In HMI Guarded Access go to Hardware Configuration.
2. Select Choices (NONE, 30 Amp, 120 Amp)
• Select NONE - If the unit is equipped with an alternator.
• Select 30 Amp - If the unit is equipped with a 30 Amp battery charger.
• Select 120 Amp - If the unit is equipped with a 120 Amp battery charger.
NOTE: If no choice is selected, the default is NONE.
3. If you installed the supplemental power 120A stand alone alternator you must go to the Aftermarket Alternator and turn it on.
Trouble Shooti1. Make sure no liftga
battery or charging
2. Rewire all liftgate owhen using the cha
3. Make sure no portiosystem are intercon
4. Check all wiring.
75
ements
red to complete liftgate battery er for available kits.
Thermo King Recommends:
7 Type SGX insulation rating 125C (257F).
Plastic conduit is not acceptable unless it is rated to
ust also have an insulation rating of 125C (257F). duit.
Liftgate Charger Wiring Requir
Additional kits or individual components (not supplied) are requicharging applications. Contact your Thermo King deal
For safety under all conditions especially high ambient and high load or fault conditions,
• Liftgate battery charging battery cables to be 2 gauge cross linked polyethylene wire per SAE J112
• Liftgate battery charging battery cables be protected in a metal conduit per National Electric Code.125C (257F).
• Only the positive, negative and battery sense cables can be run in the same conduit. These wires mDo not run the fuel pump power, the fuel level sensor wires, or the fuel lines through the same con
• Positive cable to be equipped with a 100 amp slow blow fuse.
Thermo King has a policy of coninuous product and data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.
Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com
©2020 Trane Technologies TK55681-11-IM Jan 2020
Installation Manual
Trailer EditionPrecedent™C-600*, C-600M, S-600, S-700, S-600M and S-610M/DEBattery Charger Kits and SupplementalPower Package Retrofit Kits*C-600 CANNOT HAVE SUPPLEMENTAL POWER PACKAGE INSTALLED
January 2020
Revision 9
TK-55681-11-IM