Maintenance Manual T-680S,SB-210+ T-880S, T-1080SAdditional text informationSeries withto be placed SR-3 here TK 5XXXX-X-PL Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for TK 55635-1-MM (Rev. 5, 11/16) customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes. Distributed by: Thermo King Corporate 314 West 90th Street Minneapolis, MN 55420 Direct (952) 887-2200 TK 55635-1-MM ©2013 Ingersoll Rand Company Printed in U.S.A. T-680S, T-880S, T-1080S Series with SR-3 TK 55635-1-MM (Rev. 5, 11/16) Copyright© 2013 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A. The maintenance information in this manual covers unit models: SYSTEM T-680S 30 SR (902385) SYSTEM T-680S 50 SR 230/3/60 (902386) SYSTEM T-680S 50 SR 460/3/60 (902387) SYSTEM T-880S 30 SR (902388) SYSTEM T-880S 50 SR 230/3/60 (902389) SYSTEM T-880S 50 SR 460/3/60 (902391) SYSTEM T-1080S 30 SR (902392) SYSTEM T-1080S 50 SR 230/3/60 (902393) SYSTEM T-1080S 50 SR 460/3/60 (902394) For further information, refer to: T-680R, T-880R, T-1080R, T-680S, T-880S, T-1080S with Standard Display Operator’s Manual TK 55665 T-680R, T-880R, T-1080R, T-680S, T-880S, T-1080S with Premium Display Operator’s Manual TK 55667 T-680S Parts Manual TK 55630 T-880S Parts Manual TK 55631 T-1080S Parts Manual TK 55632 SR-3 Truck Single Temp Diagnostic Manual TK 55208 T-Series Truck Single Temperature Systems Installation Manual TK 55212 Diagnosing TK Refrigeration System TK 5984 Truck Open Drive Scroll Compressor Diagnostic Manual TK 51205 TK270, TK370, TK374F, TK376, and TK380F Engine Overhaul Manual TK 53163 Tool Catalog TK 5955 Evacuation Station Operation and Field Application TK 40612 The information in this manual is provided to assist owners, operators and service people in the proper upkeep and maintenance of Thermo King units. Revision History Rev. 0 – 55635-1-MM (Rev. 0, 02/13) Original release. Rev. 1 – 55635-1-MM (Rev. 1, 09/13) Revise MIS page 20 and Adjust Engine Valve Clearance page 103 to indicate engine valve adjustment interval of 1,000 hours. Rev. 2 – 55635-1-MM (Rev. 2, 06/14) Update Oil Fill Procedure, Coolant MIS, and other general updates. Rev. 3 – 55635-1-MM (Rev. 3, 12/14) Update engine oil viscosity specifications. Rev. 4 – 55635-1-MM (Rev. 4, 03/15) Change voltage/phase/frequency on page 19 from 208-230/3/60 to 230/3/60 for 7.2 hp (5.4 kW) electric motor. Rev. 5 – 55636-1-MM (Rev. 5, 11/16) Revise for cooling system update and new style ETV. This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation should be consulted. 2 Sale of product shown in this manual is subject to Thermo King’s terms and conditions including, but not limited to, the Thermo King Limited Express Warranty. Such terms and conditions are available upon request. Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manufacturer’s plants as, in the manufacturer’s judgment, to effect its stability.” No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure. Recover Refrigerant At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere. We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere. In addition, service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians. For additional information on regulations and technician certification programs, contact your local Thermo King dealer. R-404A WARNING: Use only Polyol Ester-based refrigeration compressor oil in R-404A. See Thermo King Parts Manual for part number. Do not mix Polyol Ester and standard synthetic compressor oils. Keep Polyol Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes contaminated with moisture or standard oils, dispose of properly–DO NOT USE. When servicing Thermo King R-404A unit, use only those service tools certified for and dedicated to R-404A refrigerant and Polyol Ester compressor oils. Residual non-HFX refrigerants or oils will contaminate R-404A systems. 3 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 http://irco.az1.qualtrics.com/SE/?SID=SV_2octfSHoUJxsk6x to complete the survey. 4 Table of Contents Safety Precautions . 11 General Practices . 11 Auto Start/Stop . 12 Battery Installation and Cable Routing . 12 Battery Removal . 12 Refrigerant Hazards . 12 Refrigerant Oil Hazards . 13 Electrical Hazards . 13 High Voltage . 13 Low Voltage . 14 Microprocessor Service Precautions . 14 Welding Precautions . 14 First Aid . 15 First Aid, Refrigerant . 15 First Aid, Refrigerant Oil . 15 First Aid, Engine Coolant . 15 First Aid, Electrical Shock . 15 Specifications . 16 Engine . 16 Belt Tension . 17 Engine Clutch . 17 Refrigeration System . 17 Electrical Control System . 17 Fuses . 18 Electrical Components . 18 Electrical Standby (Model 50 Units Only) . 19 T-680S and T-880S Electric Motor and Overload Relay . 19 T-1080S Electric Motor and Overload Relay . 19 Electric Heater Strips (Optional) . 19 Standby Power Requirements . 19 Maintenance Inspection Schedule . 20 Unit Description . 22 General Description . 22 Design Features . 22 Unit Options . 23 Engine . 23 ELC (Extended Life Coolant) . 23 Clutch . 23 Scroll Compressor . ..