Thermo King CargoLink™ Installation guide

Thermo King has a policy of coninuous product and data improvements and reserves the right to change design and specications 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

TK 55151-11-MM Jan 2016

Installation Manual

Truck and Trailer Edition

CargoLink™ Installation Manual

January 2016

Revision 4

TK-55151-11-IM

Installation Manual

Truck and Trailer Edition

CargoLink™ Installation Manual

TK 55151-11-IM (Rev. 4, 01/16)

2

Installation Manual

Printing History

Rev. 0 (06/12) Released.

Rev. 1 (07/12) Page 28 - Made minor corrections to Unpairing Door Sensor procedures.

Rev. 2 (03/14) Added Carrier trailer unit installation instructions and fuel sensor installation instructions.

Rev. 3 (05/14) Pages 18, 22: Added Safety warnings regarding diesel fuel.

Rev. 4 (01/16) Removed reference to fuel and temp sensors.

3

Introduction

This manual was written to assist with the installation of Thermo King CargoLink™ Communications System remote wireless door sensors onto Thermo King

truck and trailer refrigeration units and Carrier© X Series trailer units. The CargoLink door system utilizes remote wireless door sensors that automatically shut off

the refrigeration unit or remote evaporator(s) anytime a cargo door is opened and resumes normal operation when the cargo door is closed. The system can operate up

to 32 remote wireless sensors between 3 zones in a temperature environment of -40 C to 85 C (-40 F to 185 F). The sensors can also be used to control higher current

loads (maximum 150 mA) such as trailer interior lighting when used with relay kit 40-1139.

SYSTEM COMPONENTS

The system consists of a coordinator module, interconnect harness, antenna, wireless door sensors and magnets. The coordinator module is not intended for outdoor

use and must be installed inside the refrigeration unit and connected to the unit’s control system. The coordinator module operates with 12 volts from the unit’s power

supply and is protected by a separate 2 amp fuse. The weatherproof antenna is installed outside the control box and connected to the coordinator module with a

coaxial cable. Weatherproof wireless door sensors are individually paired to the coordinator module and then installed in specific zones in the cargo area of the truck

or trailer.

SYSTEM OPERATION

Door sensors - When a cargo door is opened a wireless signal is sent to the coordinator module: the module receives the signal and shuts the host unit or remote

evaporator(s) off. When the door is closed a wireless signal is again sent to the coordinator module: the module receives the signal and turns the host unit or remote

evaporator(s) back on.

Due to its complexity, you should not attempt this installation unless you:

• Are an experienced mechanic.

• 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.

• CargoLink service tool diagnostic manual (TK 55733-11-OD) is also available to address diagnostic issues. Contact your Thermo King dealer for details.

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.

4

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation - Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation - CargoLink Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation - Antenna (TK Trailer Units) . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation - Antenna (TK Truck Units) . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation - Harness Connections (TK Trailer Units) . . . . . . . . . . . . . . 14

Installation - Harness Connections (TK Truck Units) . . . . . . . . . . . . . . . 24

Installation - Antenna (Carrier X Series Trailer Units) . . . . . . . . . . . . . . 26

Installation - Harness Connections (Carrier X Series Trailer Units) . . . 28

Installation - Pairing Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Unpairing Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Installation - Door Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Configuration Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

LED Indicator Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

IMPORTANT NOTICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Installation - Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5

BLANK PAGE

6

Installation - Required Tools

1. Safety Glasses

2. Anti-Static Wrist Strap

3. Drill with 5/16” Drive Socket

4. 1/2” and 9/16” Open End Wrench

5. Wire Cutter/crimper

6. Heat Gun

7. #1 or #2 Phillips Screw Driver

8. Rubber or Plastic Mallet

7

Installation - Required Tools

8

Installation - CargoLink Components

DOOR SENSOR COMPONENTS AND HARDWARE

Item Trailer Unit

P/N Truck Unit

P/N Description Qty

1. 42-0228 42-0228 Coordinator Module 1

2. 42-0240 42-0240 Interconnect Harness 1

3. 51-0757 51-0757 Band Wrap, 4.00 in. long 2

4. 55-2330 55-2330 Band Wrap, 16.00 in. long 4

5. 41-0125 41-0125 Connector, butt splice, 14-16 ga. 5

6. 44-2791 44-2791 Connector, ring terminal, 14-16 ga. 2

7. 42-0238 SB and Carrier)

42-0239 (Precedent)

42-0239 Antenna 1

8. 92-9333 (SB and Carrier)

93-0860 (Precedent)

92-9334 Bracket, antenna mounting 1

9. 55-4829 not required Screw, self-drilling, 1.00 in. long 4

10. 42-0475 42-0475 Connector, terminal splice 6

11. 42-0229 42-0229 Sensor door, wireless *

12. 401143A 401143A Magnet, slim line *

13. 51-1321 51-1321 Screw, TRHSM #10, SS 0.75 in. long *

14. 55-8421 55-8421 Screw, TRHSM #10, SS 1.00 in. long *

15. 55-2001 55-2001 Washer, flat, #10 SS *

16. 51-0176 51-1076 Install clamp 1

* Door sensor and hardware quantity varies per your installation

9

Installation - CargoLink Components

DOOR SENSOR COMPONENTS AND HARDWARE

10

Installation - Antenna (TK Trailer Units)

Installation Procedures

IMPORTANT: Always wear an Anti-Static wrist strap when working

with the microprocessor or printed circuit boards to prevent static

discharge from causing damage to these components.

1. Install the antenna onto the bracket:

• Remove retaining nut from the antenna and route the cable down

through the hole in the bracket.

• Place the antenna onto the bracket.

• Slide the retaining nut (with points facing up) back up the antenna

cable and attach it securely onto the bottom of the antenna as

shown.

• Tighten to 6.8 Nm. (5 ft-lb) Do not over tighten or damage to the

antenna will result!

SB Units

2. Open the roadside door:

• Position the antenna and bracket onto the front wall of the trailer

approximately 25.4 mm (1.00 in.) above the control box.

IMPORTANT: The antenna must be installed as close to the control

box and coordinator module as possible for best wireless signal

reception.

• Secure to the trailer wall with the four self-tapping screws

provided.

• Secure the antenna cable to an existing harness with a tie band

approximately 203 mm (8.00 in.) from the base of the antenna.

This will provide a “strain relief” for the cable.

3. Open the control box door:

• Route the antenna cable into the control box through the main

harness access hole.

Precedent Units

4. Remove top two bolts on fuel filter. Install bracket on top of fuel filter

housing using existing hardware.

5. Route antenna harness to control box as shown.

6. Bandwrap harness away from moving parts.

7. Install clamp as shown to secure harness.

WARNING: Before proceeding with the CargoLink installation,

disconnect the positive (+) battery cable at the battery to avoid an

electrical shock and to prevent the unit from starting causing

personal injury!

WARNING: Units equipped with an electric standby must be

disconnected from the electrical supply source to avoid an

electrical shock and to prevent the unit from starting causing

personal injury!

11

Installation - Antenna (TK Trailer Units)

SB Trailer Units Precedent Trailer Units

12

Installation - Antenna (TK Truck Units)

Installation Procedures

IMPORTANT: Always wear an Anti-Static wrist strap when working

with the microprocessor or printed circuit boards to prevent static

discharge from causing damage to these components.

1. Install the antenna onto the bracket:

• Remove retaining nut from the antenna and route the cable down

through the hole in the bracket.

• Place the antenna onto the bracket.

• Slide the retaining nut (with points facing up) back up the antenna

cable and attach it securely onto the bottom of the antenna as

shown.

• Tighten to 6.8 Nm. (5 ft-lb) Do not over tighten or damage to the

antenna will result!

2. Install the antenna bracket onto the two inserts located at the rear of the

frame with 1/4-20 (installer supplied) hardware.

IMPORTANT: The antenna must be installed as close to the control

box and coordinator module as possible for best wireless signal

reception.

NOTE: On units equipped with a top cover or top screen, place the

antenna bracket under the existing standoff bracket and reinstall

hardware.

• Secure the antenna cable to an existing harness with a tie band

approximately 203 mm (8.00 in.) from the base of the antenna.

This will provide a “strain relief” for the cable.

3. Open the curbside access door:

• Route the antenna cable into the control box through the main

harness access hole.

WARNING: Before proceeding with the CargoLink installation,

disconnect the positive (+) battery cable at the battery to avoid an

electrical shock and to prevent the unit from starting causing

personal injury!

WARNING: Units equipped with an electric standby must be

disconnected from the electrical supply source to avoid an

electrical shock and to prevent the unit from starting causing

personal injury!

13

Installation - Antenna (TK Truck Units)

NOTE: On units equipped with a top cover or

top screen, place the antenna bracket under

the existing standoff bracket and reinstall

hardware.

14

Installation - Harness Connections (TK Trailer Units)

Single and Multi-Temperature Units with SR-4 Controllers

Installation Procedures - Door Sensors

1. Attach antenna cable to coordinator module and tighten to

135 to 170 N•cm (12 to15 in-lb).

2. Attach interconnect harness securely to coordinator module.

3. Attach GND terminal ring to CH ground stud.

4. Attach VIN terminal ring to 2A circuit.

5. Locate DSP-01 wire (Pin 2A) at J3 on controller board:

• Cut DSP-01 wire approximately 102 mm (4.00 in.) down from

connector.

• Strip 7mm (0.25 in.) from ends of DSP-01 wires and from end of

RS wire from interconnect harness.

• Splice RS and both DSP-01 wires together with a butt splice

connector as shown and crimp securely.

• Use a heat gun to shrink and seal connector.

6. Locate DS-01 wire (Pin 30) at J3 on the controller board:

• Cut DS-01 wire approximately 102 mm (4.00 in.) down from

connector.

• Strip 7mm (0.25 in.) from ends of DS -01 wire and from DS1 wire

from interconnect harness.

• Splice the single DS-01 wire from the connector to the DS1 wire

from interconnect harness with a butt splice and crimp securely.

• Use a heat gun to shrink and seal connector.

• Attach terminal splice cap onto the end of the unused DS wire.

7. SINGLE-TEMPERATURE UNITS - Locate wires DS2 and DS3 at

interconnect harness:

• These wires are not used. Attach terminal splice caps onto ends of

wires.

8. MULTI-TEMP UNITS - Locate connector wires DS2-INT2-01 and

DS3-INT3-01.

• Cut DS2-01 and DS3-01 wires approximately 102 mm (4.00 in.)

down from connector.

• Strip 7mm (0.25 in.) from end of each wire coming from connector.

• Connect DS2 wire from interconnect harness to DS2-01 wire from

connector with a butt splice and crimp securely.

• Connect DS3 wire from interconnect harness to DS3-01 wire from

connector with a butt splice and crimp securely.

• Attach terminal splice caps onto other ends of DS2 and DS3 wires.

ALL UNITS

9. Attach terminal splice caps onto ends of remaining unused interconnect

harness wires FI1, FI2, FLR and FLS.

•Bundle and secure wires inside control box with band wraps.

• Secure coordinator module with band wraps to main harness inside

control box.

10. Reconnect positive (+) battery cable at battery and set unit controls to

OFF.

11. Proceed to “Installation - Pairing Sensors” on page 30.

15

Installation - Harness Connections (TK Trailer Units)

Single and Multi-Temperature Units with SR-4 Controllers

Not Used on

Single Temp

Not Used

Not Used to 2A

to DSP-01

to DS-01

to CH

NOTE: Connect only if using

wireless fuel sensor option

16

Installation - Harness Connections (TK Trailer Units)

Single and Multi-Temperature Units with SR-2 or SR-3 Controllers

Installation Procedures

1. Attach antenna cable to coordinator module and tighten to

135 to 170 N•cm (12 to15 in-lb).

2. Attach interconnect harness securely to coordinator module.

3. Attach GND terminal ring to CH ground stud J23 on controller board.

4. Attach VIN terminal ring to 2A circuit J25 on controller board.

5. Locate DSP wire (Pin 20) at J7 on controller board:

• Cut DSP wire approximately 102 mm (4.00 in.) down from

connector.

• Strip 7mm (0.25 in.) from ends of DSP wires and from end of RS

wire from interconnect harness.

• Splice RS and both DSP wires together with a butt splice connector

as shown and crimp securely.

• Use a heat gun to shrink and seal connector.

6. Locate DS wire (Pin 21) at J7 on the controller board:

• Cut DS wire approximately 102 mm (4.00 in.) down from

connector.

• Strip 7mm (0.25 in.) from ends of DS wire and from DS1 wire from

interconnect harness.

• Splice the single DS wire from the connector to the DS1 wire from

interconnect harness with a butt splice and crimp securely.

• Use a heat gun to shrink and seal connector.

• Attach terminal splice cap onto the end of the unused DS wire.

7. SINGLE-TEMPERATURE UNITS - Locate wires DS2 and DS3 at

interconnect harness:

• These wires are not used. Attach terminal splice caps onto ends of

wires.

8. MULTI-TEMP UNITS - Locate wires DS2 (Pin 33) and DS3 (Pin 35)

at J1 on control box door:

• Cut DS2 and DS3 wires approximately 102 mm (4.00 in.) down

from connector.

• Strip 7mm (0.25 in.) from end of each wire coming from connector.

• Connect DS2 wire from interconnect harness to DS2 wire from

connector with a butt splice and crimp securely.

• Connect DS3 wire from interconnect harness to DS3 wire from

connector with a butt splice and crimp securely.

• Attach terminal splice caps onto other ends of DS2 and DS3 wires.

ALL UNITS

9. Attach terminal splice caps onto ends of remaining unused interconnect

harness wires FI1, FI2, FLR and FLS.

• Bundle and secure wires inside control box with band wraps.

• Secure coordinator module with band wraps to main harness inside

control box.

10. Reconnect positive (+) battery cable at battery and set unit controls to

OFF.

11. Proceed to “Installation - Pairing Sensors” on page 30.

17

Installation - Harness Connections (TK Trailer Units)

Single and Multi-Temperature Units with SR-2 or SR-3 Controllers

Not Used on

Single Temp Units

Not Used

to 2A

to DSP

to DS

to CH

18

Installation - Harness Connections (TK Trailer Units)

Single Temperature Units with MP-V and MP-IV+ Controllers

Installation Procedures

1. Attach antenna cable to coordinator module and tighten to

135 to 170 N•cm (12 to15 in-lb).

2. Attach interconnect harness securely to coordinator module.

3. Attach GND terminal ring to CH ground stud below relay board.

4. Attach VIN terminal ring to 2A circuit on top of relay board.

5. Locate 8E wire and J9 on controller board:

• Cut 8E wire approximately 102 mm(4.00 in.) down from connector.

• Strip 7mm (0.25 in.) from ends of the 8E wires and RS wire from

interconnect harness.

•Splice RS and both 8EP wires together with a butt splice connector

as shown and crimp securely.

• Use a heat gun to shrink and seal connector.

6. Locate DS wire (Pin 27) at J3 on controller board:

• Cut DS wire approximately 102 mm (4.00 in.) down from

connector.

• Strip 7mm (0.25 in.) from both ends of DS wire and from the DS1

wire from interconnect harness.

• Splice the single DS wire from the connector to the DS1 wire from

interconnect harness with a butt splice and crimp securely.

• Use a heat gun to shrink and seal connector.

• Attach terminal splice cap onto the end of unused DS wire.

7. Attach terminal splice caps onto ends of remaining unused interconnect

harness wires FI1, FI2, FLR, FLS, DS2 and DS3.

• Bundle and secure wires inside control box with band wraps.

• Secure coordinator module with band wraps to main harness inside

control box.

8. Reconnect positive (+) battery cable at battery and set unit controls to

OFF.

9. Proceed to “Installation - Pairing Sensors” on page 30.

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Thermo King CargoLink™ Installation guide

Thermo King CargoLink™ Installation guide

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