Installation Manual. Trailer Edition Precedent. Battery Charger Kits and Supplemental Power Package Retrofit Kits

Transcription

1 Installation Manual Trailer Edition Precedent C-600*, C-600M, S-600, S-700, S-600M & S-610M/DE Battery Charger Kits and Supplemental Power Package Retrofit Kits *C-600 CANNOT HAVE SUPPLEMENTAL POWER PACKAGE INSTALLED TK IM (Rev. 7, 05/18)

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3 Installation Manual Trailer Edition Precedent C-600*, C-600M, S-600, S-700, S-600M and S-610M/DE Battery Charger Kits and Supplemental Power Package Retrofit Kits TK IM (Rev. 7, 05/18) *C-600 CANNOT HAVE SUPPLEMENTAL POWER PACKAGE INSTALLED Copyright 2013 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.

4 Release History Released (06/13) Rev. 0 Rev. 1 (08/13) Cover, pages,3, 18,32, 34; Changed text from stand alone alternator to supplemental power package. Rev. 2 (12/13) Cover, deleted text, equipped with Yanmar diesel engines, pages 16, 18, 30 and 32; changed text from Excite Harness to Sense 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. Customer Satisfaction Survey Let your voice be heard! Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser. Scan the Quick Response (QR) code or click or type the web address to complete the survey. 2

5 Introduction This installation manual was written to assist with the installation of the Thermo King Battery Charger and Supplemental Power Package Retrofit Kits onto Precedent C-600*, C-600M, S-600, S-700, S-600M and S-610/DE units. Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page 75. *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 representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted. Thermo King s warranty shall not apply to any equipment which has been so installed, maintained, repaired or altered as, in the manufacturer s judgment, to affect its integrity. Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect, special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or descriptions contained herein. 3

6 Table Of Contents NOTE: Match up the part number and conversion that you are doing with the table of contents page for that conversion. IAvailable Conversion Kits C-600 / S-600 / S-700 Model 30 - Charger S-600 / S-700 Model 30 - Charger Alternator S-600 / S-610M/DE / S-700 Model 30 - Alternator C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger S-600 / S-700 Model 50 (230 Volt Only) - Charger Alternator S-600 / S-610M/DE / S-700 Model 50 (230 and 460 Volt) - Alternator S-600M Model 30 - Charger Optional Supplemental Power S-600M Model 30 - Alternator S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power S-610M Model 30 - Charger C-600M Model 30 - Alternator C-600M Model 50 (230 and 460 Volt) - Alternator S-600M Model 50 - (230 and 460 Volt) Alternator Reconfiguring the SR4 Controller / Trouble Shooting Liftgate Charger Wiring Requirements

7 Available Conversion Kits Convert Alternator Unit to Battery Charger: Model Battery Charger Kit C-600, S-600, S-700 model 30 30A * C-600, S-600, S-700 model V 30A S-600M model A S-610M model A S-600M, S-610M/DE model V 120A C-600M 120A Std. w/battery charger Any model V Not available IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary items to it. Excite Harnesses Battery Cable Kits 9 ft ft ft ft Convert Alternator Unit to Battery Charger and add Supplemental Power Alternator: Model BC and Supp Alt Kit + Alternator + Excite Harness + Battery Cable Kit C-600 Not Available S-600, S-700 model 30 30A, 120A & Excite Harness Battery Cable Kit S-600, S-700 model V 30A, 120A & Excite Harness Battery Cable Kit S-600M, S-610M/DE model A, 120A Reuse 120A from unit Excite Harness Battery Cable Kit S-600M, S-610M/DE model V 120A, 120A Reuse 120A from unit Excite Harness Battery Cable Kit C-600M 120A, 65A below Std. w/battery charger. See chart below to add supplemental power Any model V Not Available Add Supplemental Power Alternator to a Battery Charger Unit: Model Suppl Alt Kit + Excite Harness + Battery Cable Kit +Other C-600 Not Available Excite Harness Battery Cable Kit S-600, S-700, S-610M/DE model A Excite Harness Battery Cable Kit * S-600, S-700, S-610M/DE model V or 460V 12 hp 120A Excite Harness Battery Cable Kit * S-600, S-700, S-610M/DE model V 19hp 120A Excite Harness Battery Cable Kit & * S-600 model A Excite Harness Battery Cable Kit S-600M model V or 460V 12 hp 120A Excite Harness Battery Cable Kit S-600M model V 19hp 120A Excite Harness Battery Cable Kit & C-600M model 30 (65A only) 65A Excite Harness Battery Cable Kit C-600M model V 460V 12hp (65A only) 65A Excite Harness Battery Cable Kit C-600M model V 19hp 65A Excite Harness Battery Cable Kit & * Customer selects correct belt from kit. 5

8 C-600 / S-600 / S-700 Model 30 - Charger 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). IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish to also install an EON power pack wired to the supplemental alternator. Alternator and Belt Removal 1. 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 Pulley and Belt Installation 6. Remove c-clip from center of tensioner. Slide smooth pulley off tensioner and discard. 7. Install new grooved pulley onto tensioner. Reinstall c-clip onto tensioner. 8. Install new belt and adjust to proper tension Belt S Belt S Belt C-600 6

9 C-600 / S-600 / S-700 Model 30 - Charger

10 C-600 / S-600 / S-700 Model 30 - Charger (continued) 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 Removal (if exists) 10. Open Blower and Fans Control Box door and disconnect 2-pin connector from current sensor. Remove sensor. NOTE: The empty connector and sensor will no longer be needed. 8

11 C-600 / S-600 / S-700 Model 30 - Charger (continued) 9

12 C-600 / S-600 / S-700 Model 30 - Charger (continued) Access to Battery Charger Mounting Studs 11. 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. 10

13 C-600 / S-600 / S-700 Model 30 - Charger (continued) 11

14 C-600 / S-600 / S-700 Model 30 - Charger (continued) Low Voltage Harness Installation 15. 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 connector (BCE-02) 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 Installation 18. Attach nameplate onto battery charger box cover. 19. Install a nylon washer onto each stud. 20. Install battery charger onto studs. 21. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely. 22. Connect the 2-pin connector (BAT-LOAD-01, BAT-GND-01) to mating connector (ECU/ALT) from battery cable to ECU unit. 23. Route the two ground wires to the unit ground plate located behind the control box and connect as follows: Single wire (CHBAT-01) to ground plate 6 GND PLT Single wire (CHBC-01) to ground plate 6 GND PLT Secure temperature sensor on frame member with a clamp. 12

15 C-600 / S-600 / S-700 Model 30 - Charger (continued) 13

16 C-600 / S-600 / S-700 Model 30 - Charger (continued) High Voltage Battery Charger Harness Installation 25. Route high voltage harness attached to battery charger to the Blower and Fans Control Box. 26. Open cover and remove the blind grommet inside box. Install harness conduit fitting and nut securely. 27. Route and attach wires to the Evaporator Fan High Speed contactor high voltage terminals on the bus bar: Wire (L1) to connection marked L1 Wire (L2) to connection marked L2 Wire (L3) to connection marked L3 28. Attach ground wire (GND) to ground stud inside box. 29. Close and secure the Control box and Blower and Fans Control box covers. 30. Reinstall door hinge brackets. 31. Reinstall roadside door panel. 32. Close and secure roadside and curbside doors. Programming the SR4 Controller See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation. 14

17 C-600 / S-600 / S-700 Model 30 - Charger (continued) Ground Stud 15

18 S-600 / S-700 Model 30 - Charger Alternator IMPORTANT: Sense Harness ( and ) is required and must be ordered separately. 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). 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 Removal 1. 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 Installation 5. 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 Installation 7. Attach 2-pin connector (SENSE, EXC) onto alternator. 8. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery charger harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 9. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page 75. NOTE: Follow the procedures on pages 8-15 to complete this installation. 16

19 S-600 / S-700 Model 30 - Charger Alternator

20 S-600 / S-610M/DE / S-700 Model 30 - Alternator IMPORTANT: Your unit must already be equipped with a Battery Charger to install the supplemental power package. Sense Harness ( and ) is required and must be ordered separately. 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). 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. 120 Amp Alternator Installation 1. 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 Installation 9. Attach sense harness 2-pin connector (SENSE, EXC) onto alternator. 10. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery charger harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 11. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page Secure all wiring with band wraps. 13. Close and secure all doors. Programming the SR4 Controller See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation Belt S-600 / S-610M/DE Belt S

21 S-600 / S-610M/DE / S-700 Model 30 - Alternator

22 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger 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). IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish to also install an EON power pack wired to the supplemental alternator. Alternator and Belt Removal 1. 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. 20

23 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger

24 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued) 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 Removal (if exists) 6. Open Blower and Fans Control Box door and disconnect 2-pin connector from current sensor. Remove sensor. NOTE: The empty connector and sensor will no longer be needed. 22

25 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued) 23

26 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued) Access to Battery Charger Mounting Studs 7. 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. 24

27 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued) 25

28 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued) Low Voltage Harness Installation 11. 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 connector (BCE-02) 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 Installation 14. Attach nameplate onto battery charger box cover. 15. Install a nylon washer onto each stud. 16. Install battery charger onto studs. 17. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely. 18. Connect the 2-pin connector (BAT-LOAD-01, BAT-GND-01) to mating connector (ECU/ALT) from battery cable to ECU unit. 19. Route the two ground wires to the unit ground plate located behind the control box and connect as follows: Single wire (CHBAT-01) to ground plate 6 GND PLT Single wire (CHBC-01) to ground plate 6 GND PLT Secure temperature sensor on frame member with a clamp. 26

29 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued 27

30 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued High Voltage Battery Charger Harness Installation 21. 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: Wire (L1) to connection marked L1 Wire (L2) to connection marked L2 Wire (L3) to connection marked L3 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 the SR4 Controller. See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation. 28

31 C-600 / S-600 / S-700 Model 50 (230 Volt Only) - Charger (continued 29

32 S-600 / S-700 Model 50 (230 Volt Only) - Charger Alternator 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). 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 Removal 1. 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 Installation 4. 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 Installation 6. Attach 2-pin connector (SENSE, EXC) onto alternator. 7. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery Charger Harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 8. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page 75. NOTE: Follow the procedures on pages to complete this installation. 30

33 S-600 / S-700 Model 50 (230 Volt Only) - Charger Alternator

34 S-600 / S-610M/DE / S-700 Model 50 (230 and 460 Volt) - Alternator IMPORTANT: Your unit must already be equipped with a Battery Charger to install the supplemental power package. Sense Harness ( and ) is also required and must be ordered separately. 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). 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. Alternator Installation NOTE: 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 Belt, 12 hp S Belt, 12 hp S-610M / DE Belt, 12 hp S Belt, 19 hp Pulley, 19 hp (Pulley and belt must be purchased separately) 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 Installation 5. Attach sense harness 2-pin connector (SENSE, EXC) to alternator. 6. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery Charger Harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 7. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page Secure all wiring with band wraps. 9. Close and secure all doors. Programming the SR4 Controller. See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation. 32

35 S-600 / S-610M/DE / S-700 Model 50 (230 and 460 Volt) - Alternator

36 S-600M Model 30 - Charger Optional Supplemental Power 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). IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish to also install an EON power pack wired to the supplemental alternator. If you want supplemental power, skip steps 1-5 below. Charger Only Alternator and Belt Removal 1. 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 Power (Using existing 120 amp alternator) 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. Sense Harness Installation 6. Attach sense harness 2-pin connector (SENSE, EXC) to alternator. 7. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery Charger Harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 8. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page

37 S-600M Model 30 - Charger Optional Supplemental Power 35

38 S-600M Model 30 - Charger (continued) Access to Battery Charger Mounting Studs 9. 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. 36

39 S-600M Model 30 - Charger (continued) 37

40 S-600M Model 30 - Charger (continued) Removing Wires Inside 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 Removal (if exists) 18. Open Blower and Fans Control Box door and disconnect 2-pin connector from current sensor. Remove sensor. NOTE: The empty connector and sensor will no longer be needed. 38

41 S-600M Model 30 - Charger (continued) 39

42 S-600M Model 30 - Charger (continued) 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 connector (BCE-02) 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 following wires onto the battery charger: 23. Remove the two screws from the charger cover, loosen connectors and install the following wires from the battery charger power harness: (CHBC-02) to connection A. wire (LOAD-01) to connection B. wire (BATT-01) to connection C. Reinstall cover, tighten screws and connectors. 24. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on Battery Charger. Battery Charger Installation 25. Attach nameplate onto battery charger box cover. 26. Install a nylon washer onto each stud. 27. Install battery charger onto studs. 28. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely. 29. Route the two ground wires to the unit ground plate located behind the control box and connect as follows: Single wire (CHBC-01) to ground plate 6 GND PLT Single wire (CHBC-02) to ground plate 6 GND PLT Secure temperature sensor on frame member with a clamp. 40

43 S-600M Model 30 - Charger (continued) 41

44 S-600M Model 30 - Charger (continued) High Voltage Battery Charger Harness Installation 31. 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: Wire (L1) to connection marked L1 Wire (L2) to connection marked L2 Wire (L3) to connection marked L3 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 SR4 Controller See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation. 42

45 S-600M Model 30 - Charger (continued) Ground Stud 43

46 S-600M Model 30 - Alternator IMPORTANT: Your unit must already be equipped with a Battery Charger to install the supplemental power package. Sense Harness ( or ) is required and must be ordered separately. 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). 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. 120 Amp Alternator Installation 1. Open front curbside and roadside door panels. 2. 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). 3. Installed supplied pulley onto alternator. Tighten M16 nut to 61 N m (45 ft-lb). 4. 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). 5. Install new belt and adjust to proper tension. Sense Harness Installation 6. Attach sense harness 2-pin connector (SENSE, EXC) onto alternator. 7. Route wires into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery Charger Harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 8. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page Secure all wiring with band wraps. 10. Close and secure all doors. Programming the SR4 Controller See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to finish the installation. 44

47 S-600M Model 30 - Alternator

48 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power 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). IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish to also install an EON power pack wired to the supplemental alternator. If you want supplemental power, skip steps 1-4 below. Alternator and Belt Removal 1. 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. Supplemental Power (Using existing 120 amp alternator) 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. Sense Harness Installation 5. Attach sense harness 2-pin connector (SENSE, EXC) to alternator. 6. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery Charger Harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 7. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page

49 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power 47

50 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) Access to Battery Charger Mounting Studs 8. 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. 48

51 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) 49

52 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) Removing Wires Inside 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 Removal (if exists) 17. Open Blower and Fans Control Box door and disconnect 2-pin connector from current sensor. Remove sensor. NOTE: The empty connector and sensor will no longer be needed. 50

53 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) 51

54 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) 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 connector (BCE-02) 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 following wires onto the battery charger: 22. Remove the two screws from the charger cover, loosen connectors and install the following wires from the battery charger power harness: wire (CHBC-02) to connection A. wire (LOAD-01) to connection B. wire (BATT-01) to connection C. Reinstall cover, tighten screws and connectors. 23. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on Battery Charger. Battery Charger Installation 24. Attach nameplate onto battery charger box cover. 25. Install a nylon washer onto each stud. 26. Install battery charger onto studs. 27. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely. 28. Route the two ground wires to the unit ground plate located behind the control box and connect as follows: Single wire (CHBC-01) to ground plate 6 GND PLT Single wire (CHBC-02) to ground plate 6 GND PLT Secure temperature sensor on frame member with a clamp. 52

55 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) 53

56 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued)) High Voltage Battery Charger Harness Installation 30. 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: Wire (L1) to connection marked L1 Wire (L2) to connection marked L2 Wire (L3) to connection marked L3 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 the SR4 Controller. See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation. 54

57 S-600M / S-610M / DE / Model 50 - (230 Volt Only) Charger Optional Supplemental Power (continued) 55

58 S-610M Model 30 - Charger 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). IMPORTANT: Liftgates or auxiliary items cannot be wired to unit battery or any part of TRU system when battery charger is installed. You must install the supplemental power alternator package and wire liftgates and auxiliary items to it. You may wish to also install an EON power pack wired to the supplemental alternator. New Tensioner Pulley and Belt Installation 6. Remove c-clip from center of tensioner. Slide smooth pulley off tensioner and discard. 7. Install new grooved pulley onto tensioner. Reinstall c-clip onto tensioner. 8. Install new belt and adjust to proper tension. Alternator and Belt Removal 1. 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. 56

59 S-610M Model 30 - Charger

60 S-610M Model 30 - Charger (continued) 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 Removal (if exists) 10. Open Blower and Fans Control Box door and disconnect 2-pin connector from current sensor. Remove sensor. NOTE: The empty connector and sensor will no longer be needed. 58

61 S-610M Model 30 - Charger (continued) 59

62 S-610M Model 30 - Charger (continued) Access to Battery Charger Mounting Studs 11. 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. 60

63 S-610M Model 30 - Charger (continued) 61

64 S-610M Model 30 - Charger (continued) Removing Wires Inside 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 Removal (if exists) 20. Open Blower and Fans Control Box door and disconnect 2-pin connector from current sensor. Remove sensor. NOTE: The empty connector and sensor will no longer be needed. 62

65 S-610M Model 30 - Charger (continued) 63

66 S-610M Model 30 - Charger (continued) 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 connector (BCE-02) 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 following wires onto the battery charger: 25. Remove the two screws from the charger cover, loosen connectors and install the following wires from the battery charger power harness: (CHBC-02) to connection A. wire (LOAD-01) to connection B. wire (BATT-01) to connection C. Reinstall cover, tighten screws and connectors. 26. Route low voltage harness out of control box and connect the 8-pin connector to mating connector on Battery Charger. Battery Charger Installation 27. Attach nameplate onto battery charger box cover. 28. Install a nylon washer onto each stud. 29. Install battery charger onto studs. 30. Install a M6 flat washer and M6 locking nut onto each stud and tighten nuts securely. 31. Route the two ground wires to the unit ground plate located behind the control box and connect as follows: Single wire (CHBC-01) to ground plate 6 GND PLT Single wire (CHBC-02) to ground plate 6 GND PLT Secure temperature sensor on frame member with a clamp. 64

67 S-610M Model 30 - Charger (continued) 65

68 S-610M Model 30 - Charger (continued) High Voltage Battery Charger Harness Installation 33. 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: Wire (L1) to connection marked L1 Wire (L2) to connection marked L2 Wire (L3) to connection marked L3 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 SR4 Controller See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation. 66

69 S-610M Model 30 - Charger (continued) Ground Stud 67

70 C-600M Model 30 - Alternator IMPORTANT: Your unit must already be equipped with a Battery Charger to install the supplemental power package. Sense Harness ( and ) is required and must be ordered separately. 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). 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. 65 Amp Alternator Installation 1. 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 Installation 9. Attach sense harness 2-pin connector (SENSE, EXC) onto alternator. 10. Route single (EXC) wire into control box: Insert (EXC) wire into pin C on the 3-pin connector (BCE-02) located on the battery charger harness installed earlier. Attach 3-pin connector (BCE-02) to the mating connector (2Y-02, EXC-02) located inside the control box. 11. Route single (SENSE) wire to accessory positive (+) battery power. DO NOT connect this to unit s battery. IMPORTANT: Connect SENSE wire to the closest accessory battery if using multiple batteries. NOTE: Additional kits or individual components (not supplied) are required to complete liftgate charger applications. Contact your Thermo King dealer for available kits. See Liftgate Charger Wiring Requirements on page Secure all wiring with band wraps. 13. Close and secure all doors. Programming the SR4 Controller See Reconfiguring the SR4 Controller / Trouble Shooting on page 74 to complete the installation Belt S-600 / S-610M/DE Belt S