Installation Manual · Trailer Edition Precedent™ C-600*, C-600M, S-600, S-700, S-600M and...

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©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.

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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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

ower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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




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 - Cha

8

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 - Charge

10

01215 (continued)
Access 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)

12

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)

14

01215 (continued)

H2

2

2

2

2

3

3

3

4 ControllerSR4 Controller / Trouble Shooting” on page 74 ion.


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.


• 1-pin connector (WRPM-02)


• 2-pin connector (SENSE, EXC)

• Terminal ring (CHA-01)

• Terminal ring (2A-01)



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.



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.


7. Install alternator onto bracket with supplied hardware.



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 - Al

20

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.




3. Remove alternator belt.



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 On

22

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


wires:





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) - Char

24





25

ger 401210 (continued)
C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Char

26



er onto each stud.

er onto studs.


onnector (BAT-LOAD-01, BAT-GND-01) to CU/ALT) from battery cable to ECU unit.


BAT-01) to ground plate 6 GND PLT




Low Voltage Harness Installation11. Inside the Control Box, connect the battery charger harness:


• Single power wire (2L-01) to 2A stud on controller board.


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.





18. Connect the 2-pin cmating connector (E


• Single wire (CH

• Single wire (CH


27

rger 401210 (continued

28

rger 40-1210 (continued

SR4 Controller. SR4 Controller / Trouble Shooting” on page 74 to n.


High Voltage Battery Charger Harness Installation21. Route high voltage harness attached to battery charger into the


22. Open cover and remove the blind grommet inside box and install harness conduit fitting and nut securely.





25. Early Production Units Only - Check fuse size and change if needed.

• Replace the 10 amp fuses with the 15 Amp fuses supplied.


27. Reinstall door hinge bracket.



Programming theSee “Reconfiguring thecomplete the installatio

29

rger 401210 (continued

30

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-pin connector (SENSE, EXC)

• Terminal ring (CHA-01)

• Terminal ring (2A-01)


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.



• 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 40-1

32

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.



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.


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).


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



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 460

34

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.





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



• 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.



Supplemental Pow(Using existing 12IMPORTANT: Disconnect abattery or charging systemalternator. Failure to rewire

Sense Harness Installati

6. Attach sense harness 2-p







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 S

36

(continued)
S-600M Model 30 - Charger 401261




37

(continued)

38

(continued)

emoval (if exists)ans Control Box door and disconnect 2-pin

rent sensor.



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.



connector from cur

• Remove sensor.

NOTE: The empty

39

(continued)

40

(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.


er onto each stud.

er onto studs.



BC-01) to ground plate 6 GND PLT




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:



• 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:



• 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






• Single wire (CH

• Single wire (CH


41

(continued)

42

(continued)

SR4 Controller

SR4 Controller / Trouble Shooting” on page 74 to n.


High Voltage Battery Charger Harness Installation31. Route high voltage harness attached to battery charger to the











Programming the

See “Reconfiguring thecomplete the installatio

43

(continued)

Ground Stud


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.


ividual components (not supplied) are e charger applications. Contact your Thermo s. See “Liftgate Charger Wiring

d wraps.

.


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.


. Install alternator onto bracket with supplied hardware.



. 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


NOTE: Additional kits or indrequired to complete liftgatKing dealer for available kitRequirements” on page 75.


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 - Alternator

46

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:


. 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 Power

48

) Charger 401263 nued)

S-600M / S-610M / DE / Model 50 - (230 Volt OnlyOptional Supplemental Power (conti





49



50



m current sensor.











2-pin connector fro

• Remove sensor.

NOTE: The empty

51



52



) to connection A.

) to connection B.

) to connection C.




er onto each stud.

er onto studs.



















• wire (2-03) from 2A on SR-4 controller board to 2 on relay board



• wire (CHBC-02

• wire (LOAD-01

• wire (BATT-01








• Single wire (CH

• Single wire (CH


53



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


31. Open cover and remove the blind grommet inside box and install harness conduit fitting and nut securely.






35. Reinstall door hinge bracket.



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).


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.








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

58

8 (continued)


m current sensor.




wires:






2-pin connector fro

• Remove sensor.

NOTE: The empty

59

8 (continued)

60

8 (continued)




61

8 (continued)

62

8 (continued)

emoval (if exists)ans Control Box door and disconnect 2-pin

rent sensor.











connector from cur

• Remove sensor.

NOTE: The empty

63

8 (continued)

64

8 (continued)


connection A.

) to connection B.

) to connection C.




er onto each stud.

er onto studs.



















• wire (2-03) from 2A on control board to 2 on relay board.



• (CHBC-02) to

• wire (LOAD-01

• wire (BATT-01








• Single wire (CH

• Single wire (CH


65

8 (continued)

66

8 (continued)

SR4 Controller

SR4 Controller / Trouble Shooting” on page 74 to n.


High Voltage Battery Charger Harness Installation33. Route high voltage harness attached to battery charger to the











Programming the

See “Reconfiguring thecomplete the installatio

67

(continued)

Ground Stud


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.


ividual components (not supplied) are charger applications. Contact your lable kits. See “Liftgate Charger Wiring

d wraps.


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.



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.


7. Install alternator onto bracket with supplied hardware.



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


NOTE: Additional kits or indrequired to complete liftgateThermo King dealer for avaiRequirements” on page 75.


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 40

70

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.


ire to accessory positive (+) battery power. DO t’s battery.



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.


3. Install belt. See note above.

4. Install alternator with supplied hardware and adjust belt to proper tension.



Sense Harness Ins5. Attach sense harness 2-p




7. Route single (SENSE) wNOT connect this to uni



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



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.





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.


. Install belt. See note above.

. Install alternator with supplied hardware and adjust belt to proper tension.



Sense Harness Ins5. Attach sense harness 2-p







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) Al

74

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

Installation Manual · Trailer Edition Precedent™ C-600*, C-600M, S-600, S-700, S-600M and...

Documents

Transcript of Installation Manual · Trailer Edition Precedent™ C-600*, C-600M, S-600, S-700, S-600M and...