TK 55212-1-IM (Rev. 2, 03/13) T-570R, T-800M and T-1000M (with TSR Controller) T-600, T-600R, T-800, T-800R, T-1000, T-1000R (with SR-3 Controller) Truck Edition (TSA, ESA and AP) Single Temperature Systems Installation Manual Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally.
Installation Manual Truck Edition (TSA, EMEIA and AP) Single Temperature Systems T-580R, T-800M and T-1000M (with TSR Controller) T-680S, T-880S, T-1080S (with SR-3 Controller) T-600R, T-680R, T-800R, T-880R, T-1000R and T-1080R (with SR-3 Controller) T-1200R (EMEIA Only with SR-3 Controller) TK 55212-1-IM (Rev. 2, 03/13) Copyright© 2011 Thermo King Corp., Minneapolis, MN, U.S.A.
Installation Manual for T-Series Systems Release History Original (09/11) Released Rev. 1 (02/13) Pages 20, 21, 23, 27 and 29 - Changed art to show revised lifting bar with forged clevis and pins, forged connecting links and forged locking hooks used for lifting the unit. Rev. 2 (03/13) Updated manual to include new Tier IV units.
Installation Manual for T-Series Systems 3
Introduction This manual was written to assist with the installation of Thermo King T-Series Systems onto truck bodies specifically designed and built for these applications. 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.
Table of Contents Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Unit Dimensions - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Unit Dimensions T-1000M, T-1000R, T-1080R, T-1080S and T-1200R . 9 Service Area - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions The symbol appears next to a point that is particularly important: DANGER: Addresses a circumstance that, if encountered, will lead to death or serious injury WARNING: Addresses a circumstance that, if encountered, might lead to death or serious injury. CAUTION: Addresses a circumstance that, if encountered, may cause damage to equipment or minor injury.
Safety Precautions (continued) Battery Installation and Cable Routing WARNING: Improperly installed battery could result in a fire or explosion! A Thermo King approved battery must be installed and properly secured to the battery tray. WARNING: Improperly installed battery cables could result in fire or explosion! Battery cables must be installed, routed and secured properly to prevent them from rubbing, chaffing or making contact with hot, sharp or rotating components.
Unit Dimensions - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S NOTE: The top of the unit to be mounted flush with the top of the cargo box when possible. The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling. The dimension from the top of the cargo box to the evaporator cutout will vary depending on the type of box, truck cab tilt clearance. etc. T-580 through T-880 series units minimum dimension = 107 mm (4.25 in.
Unit Dimensions T-1000M, T-1000R, T-1080R, T-1080S and T-1200R NOTE: The top of the unit to be mounted flush with the top of the cargo box when possible. The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling. The dimension from the top of the cargo box to the evaporator cutout will vary depending on the type of box, truck cab tilt clearance. etc. T-1000 through T-1200 series minimum dimension = 147 mm (5.75 in.
Service Area - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S 10
Service Area - T-1000M, T-1000R, T-1080R, T-1080S and T-1200R 11
Remote Power Receptacle Dimensions (OPTION) NORTH AMERICAN MODELS INTERNATIONAL MODELS 12
Battery Box Dimensions (OPTION) 13
Remote Status Light Dimensions (OPTION) 14
HMI Controller Dimensions HMI Controller (LED Display) HMI Controller (Graphics Display) 15
Truck Body Opening Dimensions Installing a New Unit onto a New Truck Box NOTE: The top of the unit to be mounted flush with the top of the cargo box when possible. The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling. The dimension from the top of the cargo box to the evaporator cutout will vary depending on the type of box, truck cab tilt clearance. etc. T-580 through T-880 series minimum dimension = 107 mm (4.25 in.
Truck Body Opening Dimensions Retrofitting a New Unit onto a Older Truck Box 349.3 mm (13.75 in.) Enlarge Opening as shown (See NOTE) NOTE: Existing opening same as RD-II, TS-500 and TS-600 units and does not require modifications. Opening must only be enlarged when changing from a TS-200, TS-300, MD-100, MD-200, MD-300, MD-II or KD-II to a new T series unit. Important Installation Requirements: • Gasket sealing surface of 50.8 mm (2.00 in.) wide is required around the unit opening.
Unit Weights CAUTION: The truck wall must be structurally strong enough to support the weight of the refrigeration unit. Model 30 Units (approximate weight) Model 50 Units (approximate weight) T-580R 434 kg (957 lbs.) T-580R 459 kg (1012 lbs.) T-600R 443 kg (977 lbs.) T-600R 468 kg (1032 lbs.) T-680R 437 kg (963 lbs.) T-680R 462 kg (1018 lbs.) T-680S 447 kg (985 lbs.) T-680S 472 kg (1040 lbs.) T-800R 443 kg (977 lbs.) T-800R 468 kg (1032 lbs.) T-880R 437 kg (963 lbs.
Lifting Bar Details IMPORTANT: All T-580 through T-1200 series truck units require a new lifting bar. This new bar must be used to safely lift and install these series units. This new lifting bar can also be used to install earlier series truck units. WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided. WARNING: All hardware used to assemble the lifting bar must be DIN 931 class 10.9 (SAE Grade 8).
Lifting Bar Details 8 7 UNIT TYPE D 6 FRONT CHAIN LIFT HOLE LOCATION ENTIRE UNIT CLEVIS LIFTING HOLE LOCATION TS 200/300/500/600 - 30 LEFT HOLE 1 TS 200/300/500/600 - 50 LEFT HOLE 2 SPECTRUM TS LEFT HOLE 4 MD II, MD 200, MD 300 - 30 RIGHT HOLE 1 MD II, MD 200, MD 300 - 50 RIGHT HOLE 2 KD II - 30 RIGHT HOLE 1 KD II - 50 RIGHT HOLE 2 RD II - 30 RIGHT HOLE 1 RD II - 50 RIGHT HOLE 2 T SERIES - 30/50 LEFT HOLE 3 T SERIES SPECTRUM LEFT HOLE 5 5 4 3 2 1 REVISIONS CHANGE
Lifting Bar Details 8 7 6 RELEASED 14/Jan/2013 5 4 3 2 1 54.2 27.1 25.1 2X 58° 3.5 3.5 D D .50 THICK 7.9 2X 58° 4.0 .534 4.0 1.75 2.1 2.1 .534 .50 THICK 2X 3.4 (30.3) 2X .8 50.20 2X 58° C 23.50 I R1.25 11.2 I 17.2 3.5 I 4.0 31.7 1.75 (1.6) 1.75 I 3X .534 26.60 I C 4X 28.70 I 2X 2X .75 .75 .875 SCALE 0.250 REAR MEMBER 3.5 1.75 1.75 (1.4) 1.75 1.0 SCALE 0.250 CENTER MEMBER 1.0 B B 21.1 5.0 21.1 8.85 5.0 (2X 122° ) FRONT MEMBER 8.85 11.45 11.
Required Tools 1. Safety Glasses 2. Drill 3. Drill Bits 4. Tape Measure 5. Mechanics Tools 6. Lifting Bar (New Style Design Required) with forged clevis and pins, forged connecting links and forged locking hooks. 7.
Required Tools 23
Installation Components 1. Unit Mounting Washers 1.250 x 0.188 THK 15. Self Tapping Screws #10 HWHSM 2. Locking Nuts 1/2-13 16. In-Line Fuse Holder 3. Torx Head Screws 17. Fuse 60 amp 4. Hose Management Cap s 18. Terminal Connector Splice 5. Hold Down Clamps 19. Heat Shrink Sleeving 3.00'' 6. #14 Sheet Metal Screws 20. Terminal Red 3/8'' 7. Drain Hose Check Valves 21. Terminal Lug 3/8'' 8. Fuel Pump 22. Cable Ties 9. Fuel Pump Bracket 23. Muffler Gasket 10. Screws HH 1/4-20 SS 24.
Installation Components 25
Uncrating the Unit Important Unit Lifting Information Uncrating the Unit NOTE: All T-580 through T-1200 series truck units require a new lifting bar. This new bar must be used to safely lift and install these series units. This new bar must be used to safely lift and install these series units. See “Lifting Bar Details” on page 19. Carefully remove the top and side crate member and remove the bottom panel and installation kit components shipped with the unit.
Uncrating the Unit 27
Installing the Unit Important Unit Lifting Information Installing the unit NOTE: All T-580 through T-1200 series truck units require a new lifting bar. This new bar must be used to safely lift and install these series units. This new bar must be used to safely lift and install these series units. See “Lifting Bar Details” on page 19. NOTE: The muffler must not be installed before mounting the unit. WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units.
Installing the Unit 29
Installing the Hose Management Caps Hose Management Caps (STANDARD) Curbside Cap Hose management caps provide a exit point under each side of the unit for routing the individual drain hoses, fuel lines, electrical cables. The caps are provided with cutout guide marks. Always remove any sharp edges after cutting the caps. 2. Route the following items out of the curbside cutout of the bottom pan and down the front exterior wall of the cargo box: Roadside Cap 1.
Installing the Hose Management Caps Cutout Guide Marks Front of Unit 31
Installing the Hose Management System (OPTION) Hose Management System (OPTION) 2. Install the funnel cap into the bottom pan securely. The hose management system organizes the routing of the drain hoses, electrical cables and fuel lines down the truck wall. White plastic covers protect these components from damage while providing a cleaner, finished installation. 3. Mark a line from the center of the funnel cap down the truck box wall. 4.
Installing the Hose Management System (OPTION) Front of Unit 33
Securing the Oil Drain Hose Oil Drain Hose 1. Secure the oil drain hose directly under the unit to the cargo box with the two supplied retaining clips and self tapping screws as shown. 2. Ensure there is no contact and adequate clearance between the oil drain hose and the hose management caps. The cutout in the hose management cap should be as large as possible with no sharp edges. 3. Lower retaining clip should be positioned in an location easily accessible for servicing the unit.
Securing the Oil Drain Hose The cutouts in the hose management cap should be as large as possible with no sharp edges.
Securing the Evaporator Drain Hoses IMPORTANT: Evaporator drain hoses must be installed without any sharp bends or kinks to allow for proper water drainage. 1. Route drain hoses from under the unit, through the Hose Management Caps and down the front wall of the truck box. 2. Secure drain hoses with supplied self tapping screws and clamps. 3. Cut off excess drain hose and install a check valve onto each drain hose securely with tie bands.
Securing the Evaporator Drain Hoses 37
Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank NOTE: The fuel pickup tube supplied in the installation kit will not be needed when installing an optional Thermo King aluminum fuel tank. The aluminum tank is already equipped with fuel inlet, fuel outlet and vent fittings. DANGER: Diesel fuel vapors are potentially explosive. Use extreme caution when drilling in or around the diesel fuel tank. Sparks from an electric drill or drill bit could cause an explosion.
Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank 39
Installing the Fuel Pickup Tube Into a Plastic Tank DANGER: Diesel fuel vapors are potentially explosive. Use extreme caution when drilling in or around the diesel fuel tank. Sparks from an electric drill or drill bit could cause an explosion. Do not smoke while working near the diesel fuel tank. Drain all diesel fuel from the tank and use nitrogen or an inert gas to purge the diesel fuel vapors from the tank prior to drilling. Keep the diesel tank filled with inert gas while drilling. 1.
Installing the Fuel Pickup Tube Into a Plastic Tank 41
Installing the Steel Fuel Tank DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your truck’s chassis manufacturer for specific details on proper fuel tank installation and recommendations. IMPORTANT: Observe the positioning of existing OEM fasteners on the vehicle frame. The four fasteners used to install the fuel tank brackets must be located on the frame no higher and no lower than any existing OEM fasteners. 1.
Installing the Steel Fuel Tank 1 2 4 3 43
Installing the Aluminum Fuel Tank (OPTION) DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your truck’s chassis manufacturer for specific details on proper fuel tank installation and recommendations. IMPORTANT: Observe the positioning of existing OEM fasteners on the vehicle frame. The four fasteners used to install the fuel tank brackets must be located on the frame no higher and no lower than any existing OEM fasteners. 1.
Installing the Aluminum Fuel Tank (OPTION) 1 2 3 4 45
Installing the Fuel Pump and Fuel Lines DANGER: The Thermo King fuel pump should be installed onto the supplied mounting bracket. The fuel pump and fuel lines should be installed a safe distance away from the extreme heat generated by the Diesel Particulate Filter (DPF) or exhaust system components on the truck.
Installing the Fuel Pump and Fuel Lines 47
Installing the ServiceWatch™ Remote Download Port (OPTION) Choose an appropriate location to mount the ServiceWatch port that provides for safe and easy access for connecting the download cable. The download port can be rotated to fit your particular installation. 1. Attach the download port securely to the truck box with four TEK screws. 2. Provide a drip loop and secure the harness with supplied clamps and screws.
Installing the ServiceWatch™ Remote Download Port 49
Installing the Remote Power Receptacle (OPTION) DANGER: To prevent serious injury or death, the electric standby power cord must not be connected to the unit during installation! Choose an appropriate location to mount the power receptacle that provides for safe and easy access for connecting the power cord. North American Units (Detail A) 1. Measure and drill three 13 mm (.500 in.) holes into truck body. 2. Insert the supplied rubber blind nuts into each hole in truck body. 3.
Installing the Remote Power Receptacle (OPTION) 51
Installing the Remote Status Light (OPTION) Installation 1. Mount the Status Light in a location so that is visible to the driver in the truck’s mirror. • Mark and drill the four mounting holes using a 3/16'' drill. • Mount the status light securely with the supplied rivets. 2. Provide a “drip-loop” to prevent water from migrating into the Status Light and route the harness towards the bottom of the unit. 3. Secure harness to the truck box using the supplied clamps and rivets. 4.
Installing the Remote Status Light (OPTION) 53
Installing the HMI Controller NOTE: Route and secure the controller harness to prevent rubbing, chafing or making contact with sharp, moving or hot components. Allow excess harness for tilt cab applications. The supplied rubber grommets must be used when routing harness through sheet metal holes. Inside Cab DIN Mounting 1. Install DIN (ISO 7736) mounting sleeve into driver panel DIN opening. Bend the mounting sleeve tabs to secure. 2.
Installing the HMI Controller NOTE: HMI with LED Display shown, HMI with Graphics Display installs the same.
Installing the Battery Box (OPTION) CAUTION: Battery boxes and covers must be installed securely with proper hardware to prevent them from falling off. CAUTION: Battery cables must be properly routed and secure to prevent rubbing, chafing or making contact with sharp, moving or hot components. 1. Secure battery in place with hold down bracket and rod. 2. Rubber grommets must be used where cables and fuse holder enter box. 3. DO NOT install protective battery cover. This will be installed later.
Installing the Battery Box (OPTION) 57
Battery Connections Important Battery Information Fuel Pump Harness IMPORTANT: See Safety Precautions - “Battery Installation and Cable Routing” on page 7 for additional information. 3. Route and connect the fuel pump harness to the fuel pump. NOTE: Thermo King units are designed for one 12 volt, group 31 battery. The battery must be suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr. Positive Cable 1. At the unit, locate the large black cable marked POS+.
Battery Connections 59
Installing the Door Switch (OPTION) When installing CargoLink wireless door switches, see TK 55151 CargoLink Installation Manual. NOTE: These instructions are intended as reference guide only to assist with a typical door switch installation. Your installation may be different depending on the cargo box, the amount and types of doors and the customers particular requirements.
Installing the Door Switch (OPTION) Right Angle Mounting Top x Top Mounting Side x Side Mounting 61
Installing the Door Switch (OPTION) NOTE: The Door Switch Harness Connectors are located at the rear of the host unit. 1. Attach the interface harness to matching door switch connector located at the rear of the host unit. 2. Route a 3 wire harness (INSTALLER SUPPLIED) from the interface harness to a door switch. Connect matching wires per the table below (RED/RED, WHITE/WHITE, BLACK/BLACK) to each door switch using splice connectors. Crimp splice connectors securely and apply heat with a heat gun.
Installing the Door Switch (OPTION) Interface Harness Wiring Door Switch Wiring RED = (DSP) POWER RED = (DSP) POWER BLACK = (CH) GROUND BLACK = (CH) GROUND WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT 63
UNIT CHECK LIST UNIT CHECK LIST Visually inspect the unit for transit and handling damage. File claim with delivery carrier. Install the unit as outlined in the Thermo King Installation Manual. If the unit has a separate fuel tank add 10 gallons of fuel to the tank. BEFORE STARTING THE UNIT Check battery and battery cable installation. Inspect fuel line routing checking for rubbing, chaffing or laying on hot surfaces.
UNIT CHECK LIST (continued) Observe and record refrigerant operating pressures in relation to ambient and box temperatures. Verify the readings above are correct for the conditions. When box reaches 32 F (0 C) check calibration of thermostat, thermometer and data logger. Run unit for 30 minutes at 32 F (0 C). During this period check for correct cycling. Reset thermostat to 50 F (10 C). Check throttling valve while in the heat cycle. Check operation of Modulation system if equipped.
TK 55212-1-IM (Rev. 2, 03/13) T-570R, T-800M and T-1000M (with TSR Controller) T-600, T-600R, T-800, T-800R, T-1000, T-1000R (with SR-3 Controller) Truck Edition (TSA, ESA and AP) Single Temperature Systems Installation Manual Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally.
