Installation Manual - ThermoKing · Installation Manual Providing equipment and services to manage...

Installation Manual

Providing equipment and services to manage controlled-temperature environments for food and other temperature-sensitive products, our Climate Control Technologies sector encompasses both transport and stationary refrigeration solutions. Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment.

www.thermoking.com www.hussmann.com www.ingersollrand.com

©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

SB-230 RR and SB-330 RRSingle Temperature System

For Domestic Refrigerated Containers (DRC),Trailer on Flat Car (TOFC) and Rail Box Car

(RBC) ApplicationsTK 54932-5-IM (Rev. 4, 06/12)

Installa

SB-230 R R Single Te emsFor Dome d Containers (DRC), Trailer on ) and Rail Box Car (RBC) ApplicationsTK 54932-5-IM (Re

t© 2011 Ther A. U.S.A.

CopyrighPrinted in

tion Manual

R and SB-330 Rmperature Syststic Refrigerate Flat Car (TOFC

v. 4, 06/12)

mo King Corp., Minneapolis, MN, U.S.

2

d it UNIT CHECK LIST.

tion and Cable Routing warnings and cautions.

el Level Sensor (UFLS) into the fuel tank.

hes.

Release HistoryReleased (4/11)

Rev. 1 (4/11)Pages 71-72 - Revised content of SYSTEM CHECK LIST and rename

Rev. 2 (11/11) Page 6 - Revised Safety Precautions to include new Battery Installa

Rev. 3 (01/12) 8 - Added information on installing the optional Ultrasonic Fu

Rev. 4 (06/12) Page 58 - added note about installing CargoLink wireless door swic

3

Single Temperature Rail Ready units onto cifically designed and built for refrigerated

s warranties express or implied, with respect to ld not be regarded as all-inclusive or covering t should be consulted.

aintained, repaired or altered as, in the

ty damage or any other direct, indirect, y information, recommendations or

Introduction

This manual was written to assist with the installation of the Thermo King SB-230 RR and SB-330 RR Domestic Refrigerated Container (DRC), Trailer on Flat Car (TOFC) and Rail Box Car (RBC) that are speapplications.

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

• Are an experienced mechanic

• Can safely lift 34 kilos (75 lbs.)

• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems

• Have a basic understanding of electricity and electrical wiring

• Have the necessary tools and equipment to complete the installation.

This manual is published for informational purposes only. Thermo King makes no representationthe information recommendations and descriptions contained herein. Information provided shouall contingencies. If further information is required, Thermo King Corporation Service Departmen

Thermo King’s warranty shall not apply to any equipment which has been “so installed, mmanufacturer’s judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, properspecial, or consequential damages whatsoever, arising out of the use of this manual or andescriptions contained herein.

4

Table of Contents

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Application Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Swing Radius and King Pin Requirements . . . . . . . . . . . . . . . . . . . . . . . . 8

SB-230 RR and SB-330 RR Unit Dimensions . . . . . . . . . . . . . . . . . . . . . 9

Evaporator Opening Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mounting Hardware Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Bulkhead Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Battery Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Group 31 Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Surface Mounted Status Light Dimensions (Option) . . . . . . . . . . . . . . . 20

Flush Mounted Status Light Opening Dimensions (Option) . . . . . . . . . 21

Rear Remote Controller Dimensions (Option) . . . . . . . . . . . . . . . . . . . . 22

Door Switch Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Unit Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installing the Exhaust Pipe Extension (DRC Option) . . . . . . . . . . . . . . . 32

Installing the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installing the Fuel Tank - 120 Gal., Alum. - DRC Only . . . . . . . . . . . . . 36

Installing the UFLS (Option) - TOFC Only . . . . . . . . . . . . . . . . . . . . . . 38

Installing the Fuel Tank - 50 Gallon, 22'' Dia., Aluminum . . . . . . . . . . . 40

Installing the Fuel Lines - DRC and RBC Only . . . . . . . . . . . . . . . . . . . 44

Installing the Fuel Lines - TOFC Only . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the Fuel Level Sensor Harness - DRC Only . . . . . . . . . . . . . . 48

Installing the UFLS Harness (Option) - TOFC Only . . . . . . . . . . . . . . . 50

Installing the Status Light (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installing the Rear Remote Controller (Option). . . . . . . . . . . . . . . . . . . . 54

Installing the Door Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CargoWatch™ Sensor Locations (Option) . . . . . . . . . . . . . . . . . . . . . . . 62

Connecting the CargoWatch™ Sensors (Option) . . . . . . . . . . . . . . . . . . 64

Installing the Bulkhead (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Installing the Bottom Pan - TOFC and RBC Only . . . . . . . . . . . . . . . . . 70

Programming the SR-3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

UNIT CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

5

rtant:

red,

red,

red,

our hands away from fans and belts unning. This should also be considered closing the compressor service valves.

sure gauge manifold hoses are in good et them come in contact with a belt, fan ny hot surface.

sure all mounting bolts are tight and are or their particular application

drill holes in the unit unless absolutely drilled into the unit may weaken ents. Holes drilled into electrical wiring

explosion.

using ladders to install or service ms, always observe the ladder fety labels and warnings. A work ommended method for installations.

ed coil fins are very sharp and can cause s.

Safety Precautions

The symbol appears next to a point that is particularly impo

DANGER: Addresses a circumstance that, if encountewill lead to death or serious injury

WARNING: Addresses a circumstance that, if encountemight lead to death or serious injury.

CAUTION: Addresses a circumstance that, if encountemay cause damage to equipment or minor injury.

DANGER: Never operate the unit with the discharge valve closed because it could cause the compressor to explode, causing death or serious injury.

DANGER: Never apply heat to a sealed refrigeration system or container because it could explode, causing death or serious injury

DANGER: Fluorocarbon refrigerants, in the presence of an open flame or electrical short, produce toxic gases that are severe respiratory irritants capable of causing death.

DANGER: Be careful when working with a refrigerant or refrigeration system in any enclosed or confined area with a limited air supply (i.e., a trailer, container or the hold of a ship). Refrigerant tends to displace air and can cause oxygen depletion which may result in death by suffocation.

WARNING: Always wear goggles or safety glasses. Refrigerant liquid, refrigeration oil, and battery acid can permanently damage the eyes (see First Aid under Refrigeration Oil).

WARNING: Keep ywhen the unit is rwhen opening and

WARNING: Make condition. Never lmotor pulley, or a

WARNING: Make of correct length f

WARNING: Nevernecessary. Holes structural componcan cause fire or

WARNING: When refrigeration systemanufacturer’s saplatform is the rec

WARNING: Expospainful laceration

6

)

frost bite, the objectives of First Aid are to rther injury, to warm the affected area tion.

, immediately flush eyes with large amounts al attention.

mounts of lukewarm water. Do not apply othing and shoes. Wrap burns with dry, ct from infection/injury. Get medical clothing before reuse.

o fresh air and use CPR or mouth-to-mouth ith victim until arrival of emergency

t, immediately flush with plenty of water A PHYSICIAN. Wash skin with soap and

luorocarbon refrigerants are classified ertain precautions must be observed r servicing a unit in which they are

to the atmosphere in the liquid state, nts evaporate rapidly, freezing anything

geration oil contact with the eyes. Avoid contact of refrigeration oil with skin or ghly after handling refrigeration oil to

Safety Precautions (continued

Battery Installation and Cable Routing Refrigerant

First Aid

FROST BITE: In the event ofprotect the frozen area from furapidly and to maintain respira

EYES: For contact with liquidof water and get prompt medic

SKIN: Flush area with large aheat. Remove contaminated clsterile, bulky dressing to proteattention. Wash contaminated

INHALATION: Move victim tventilation, if necessary. Stay wmedical personnel.

Refrigeration Oil

First Aid

NOTE: In case of eye contacfor at least 15 minutes. CALLwater.

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.

WARNING: Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire!

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty!

CAUTION: Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries. Battery acid can cause serious burns when exposed to eyes or skin. If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters your eye, immediately flood it with running cold water for at least twenty minutes and get medical attention immediately.

CAUTION: Always cover battery terminals to prevent them from making contact with metal components during battery installation. Battery terminals grounding against metal could cause the battery to explode.

WARNING: Although fas safe refrigerants, cwhen handling them oused. When released fluorocarbon refrigerathey contact.

WARNING: Avoid refriprolonged or repeatedclothing. Wash thorouprevent irritation.

7

742 kg (1635 lbs.)dware

f the unit mounting bolts in the front wall s critical for proper unit installation. See equirements” on page 12.

arance must be provided to allow for nance of the Thermo King unit. 0 RR Unit Dimensions” on page 9.

g

ns

rance

mounting hardware other than specified igeration unit could result in severe t, void the warranty or cause personal

erly installed fuel tank could lead to th! Consult your DRC, TOFC or RBC cific details on proper fuel tank

mmendations.

um distance from the king pin to the st be at least 1025 mm (40.35 in.) or equipment will result. VERIFY THIS INSTALLING UNIT! See see “Swing

Requirements” on page 8.

um clearance required for the swing 2 mm (65.52 in.) or severe damage to the . VERIFY THIS DIMENSION BEFORE ee “Swing Radius and King Pin ge 8.

Application RequirementsApproximate Weight

SB-230 RR or SB-330 RR (refrigeration unit only) = Front Wall RequirementsDomestic Refrigerated Container (DRC) Requirements

Trailer on Flat Car (TOFC) Requirements

Rail Box Car (RBC)

Evaporator Opening RequirementsIMPORTANT: The location of the evaporator opening in the front wall of the DRC, TOFC or RBC is critical to the proper installation and operation of the Thermo King unit. See See “Evaporator Opening Requirements” on page 10.

Unit Mounting Har

IMPORTANT: The location oof the DRC, TOFC or RBC iSee “Mounting Hardware R

Unit DimensionsIMPORTANT: Adequate cleroutine service and mainteSee “SB-230 RR and SB-33

Fuel Tank Mountin

King Pin Dimensio

Swing Radius Clea

DANGER: The front wall of the container must be structurally strong enough to safely support the combined weight of the Thermo King refrigeration unit, the fuel tank with mounting hardware, and the full capacity of diesel fuel!

DANGER: The front wall of the trailer must be structurally strong enough to safely support the weight of the Thermo King refrigeration unit.

DANGER: The front wall of the rail box car must be structurally strong enough to safely support the combined weight of the Thermo King refrigeration unit, the fuel tank with mounting hardware, and the full capacity of diesel fuel!

DANGER: The use offor installing the refrdamage to equipmeninjury or death!

DANGER: An impropserious injury or deamanufacturer for speinstallation and reco

CAUTION: The minimfront of the trailer musevere damage to theDIMENSION BEFORERadius and King Pin

CAUTION: The minimradius must be 1664.equipment will resultINSTALLING UNIT! sRequirements” on pa

8

rements
Swing Radius and King Pin Requi

9

imensions
SB-230 RR and SB-330 RR Unit D

10

ements
Evaporator Opening Requir
Evaporator Opening RequirementsIMPORTANT: The location of the evaporator opening in the front wall is critical for the proper installation and operation of the Thermo King unit. VERIFY ALL DIMENSIONS BEFORE INSTALLING UNIT!

1. The evaporator opening must be square and the diagonal measurements must be ±3.0 mm (0.12 in.)

2. The gasket surface around the opening must be at least 76.2 mm (3.00 in.) wide, be flat ±3.2 mm (0.05 in.) and free of rivets, seams or bolt heads.

11

ments
Evaporator Opening Require

12

ments
Mounting Hardware Require
Mounting Bolts

IMPORTANT: The location of the unit mounting bolts in the front wall is critical for proper unit installation.

All UNIT mounting hardware must be:

• Mounting bolts must be square with front wall and securely fastened to allow mounting nuts to be torqued to 82 N•m (60 ft. lbs.) from outside the container.

• Mounting bolts must be 1/2-13 UNC- 28 rolled thread, grade 5, medium carbon steel, zinc plated with dichromate finish.

• Mounting bolts are to extend a minimum 57.2 mm (2.25 in.) and a maximum of 63.50 mm (2.50 in.) beyond the front wall.

• Matching locking nuts and flat washers (supplied) must be used to secure the unit.

DANGER: Eight mounting bolts must be installed to properly secure the unit to the front wall of the container, trailer or rail box car. Failure to do so could result in severe damage to equipment, void the warranty or cause personal injury or death!

13

ents
Mounting Hardware Requirem

14

tion)

ULKHEAD part number.

tiono keep the return airflow from being restricted if the head also prevents the load from shifting into the eway on the front wall of the inter modal container.

head Shown (dimensions are approximate).

Bulkhead Dimensions (Op

THERMO KING RECOMMENDS USING A BContact your Thermo King Dealer for specific

Return AirflowRestrictions of the return airflow adversely affects the performance of the unit. The area directly behind the evaporator return air inlet must not be restricted.

Bulkhead FuncA bulkhead is used tload shifts. The bulkreturn airflow passag

NOTE: Typical Bulk

15

ion)
Bulkhead Dimensions (Opt

16

e

ttery Selection and Maintenance.

gned for one 12 volt, Group 31 battery supplied by the

suitable for deep cycling, heavy duty and rated with a /hr.

g table for Thermo King approved batteries. lletin T&T 446 for more information regarding nd Maintenance.

CA Dry Cell (AGM)o King EON

03-550 Threaded Stud03-551 SAE Post

Cell (AGM) Technologyter suited for all applicationsh cranking power at lower bient temperaturesited for extreme temperaturest for high cycling applications cle-Sentry use) year expected life

perating environment and the atures and frequent discharges uirements.

Battery Selection Guid

Refer to Service Bulletin T&T 446 for more information regarding Ba

IMPORTANT: The specified battery, electrical wiring and electronic controls were designed to operate and maintain only the Thermo King refrigeration system and factory authorized Thermo King options.

Trailer units are desiinstaller.

The battery must be minimum of 95 amp

NOTE: See followinRefer to Service BuBattery Selection a

CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit! This could result in severe damage to equipment and void the warranty!

BATTERY APPLICATION TABLE

750 CCA Wet CellThermo King ReliaMax 750SP/N 203-731 Threaded StudP/N 203-730 SAE Post

925 CCA Wet CellThermo King ReliaMax 925NP/N 203-733 Threaded StudP/N 203-732 SAE Post

1150 CThermP/N 2P/N 2

• Wet Cell Technology • Better suited for warmer climates• Less cranking power at low

ambient temperatures• 18-24 month expected life *see

note below• Choose for southern climates

• Wet Cell Technology • Better suited for colder climates• High cranking power at low

ambient temperatures• 18-24 month expected life *see

note below• Choose for northern climates

• Dry• Bet• Hig

am• Su• Bes

(Cy• 5-7

* NOTE: Wet cell battery life and maintenance requirements are determined by the ocharge/discharge rate (cycles) while the battery is in service. Higher ambient temperwill shorten a wet cell battery’s overall life expectancy and increase maintenance req

17

ns
Group 31 Battery Dimensio

18

saterial: 76.2 mm (3.00 in.) x 12.7 mm (0.50 in.) mild

links and hooks, clevis and pins with strength equal to of hoist mechanism and meet all safety standards.

maximum strength and safety.

n

nks

Chain Link

Lifting Bar DimensionI. Recommended m

steel.

II. Use forged chaintotal lift capacity

III. Bolt together for

1. Forged Clevis Pi

2. Forged Chain Li

3. Locking Master

DANGER: Do not use a forklift to install the unit! This could result in severe damage to the equipment, void the warranty or cause personal injury or death!

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 (see Lifting Bar Dimensions).

WARNING: All hardware used to assemble the lifting bar must be DIN 931 class 10.9 (SAE grade 8). The use of hardware other than specified may cause personal injury, severe damage to the evaporator and void the warranty.

WARNING: The lifting bar and lifting device combined must be able to support minimum weight of 1360.8 kilos (1 1/2 tons).

19

Lifting Bar Dimensions

20

sions (Option)

part numbers.

Surface Mounted Status Light Dimen

Contact your Thermo King Dealer for specific

Standard Display and Fuel Combo Display

Triple Combo Display

21

ensions (Option)

art numbers.

uel Combo Display and Triple Combo Display.

Flush Mounted Status Light Opening Dim

Contact your Thermo King Dealer for specific p

NOTE: Dimensions shown will accommodate the flush mounted Standard Display, Standard and F

22

ns (Option)

part numbers.

Rear Remote Controller Dimensio


23

tion)art numbers.

Door Switch Dimensions (Op Contact your Thermo King Dealer for specific p

BLANK PAGE

24

Required Tools1. Safety Glasses

2. Drill

3. Drill Bits

4. Tape Measure

5. Mechanics Tools

6. Lifting Bar

7. Work Platform (Recommended)

8. Torque Wrench

9. Forged Eyebolts

NOTE: Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working condition and routinely calibrated to assure accurate readings.

25

Required Tools

26

ents
Unit Installation Compon1. Locking nuts 1/2-13
2. Washers 1/2 in.

3. Self tapping screws

4. Clamps

5. Cable ties

6. Fuel line fittings: 1/4 in. and 3/8 in.

7. Drain hose check valve

8. Exhaust pipe extension, hanger and clamps (DRC Option)

27

nts
Unit Installation Compone

28

Unitlastic stretch wrap from unit.

e top cardboard cover.

e outer cardboard wrap.

kit boxes, bottom panel, and any other loose ear of unit.

ds securing the fuel lines to the rear of the unit.

olts and 3 point lifting bar to unit.

olding unit to wooden pallet.

or installation.

Unpacking the Unit

Units are shipped attached to disposable wooden pallet and wrapped with protective cardboard and plastic stretch wrap.

• To avoid unnecessary damage to your unit, place the crated unit near the container prior to its removal.

• DO NOT use a sharp knife to remove the stretch wrap or cardboard wrap as damage to the exterior of the unit will result!

Unpacking the• Carefully remove p

• Carefully remove th

• Carefully remove th

• Remove installationcomponents from r

• Remove the tie ban

• Attach forged eyeb

• Remove hardware h

• Unit is now ready f

DANGER: Do not use a forklift to install the unit! This could result in severe damage to the equipment, void the warranty or cause personal injury or death!

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.

29

Unpacking the Unit

30

ing Holes (Detail II)

g hole through the hinged roadside grille.

nting hole through hinged roadside grille.

nting hole through hinged roadside panel and control

nting hole through hinged lower curbside door.

nting hole through hinged curbside panel.

nting hole through hinged curbside grille.

g hole through hinged curbside grille.

ting hole from top of the unit.

Installing the Unit

Unit InstallationNOTE: DRC APPLICATIONS ONLY. Unbolt and remove any upper cross bracing or supports from the container that interfere with the installation of the unit using the 3 point lifting bar. Reinstall after unit installation.

1. Install two 5/8-11 forged lifting eyebolts (installer supplied) into threaded holes located on the top of the unit (Detail I).

2. Attached the lifting bar to the both eyebolts and the unit support bracket. Lift unit up to the front wall opening:

• Align the eight mounting studs on the container with the mounting holes in the unit. Push the unit up flush with the front wall of the container.

• Install the supplied locking nuts and flat washers onto each mounting stud and tighten mounting hardware securely. See Access to Mounting Holes (Detail II).

NOTE: All nuts that hold the unit to the front wall should be elastic stop nuts (Nylock Type) provided in the installation kit.

Access to Mount

3. Top side mountin

4. Center side mou

5. Lower side moubox hole.

6. Center side mou

7. Lower side mou

8. Center side mou

9. Top side mountin

10. Top center moun

WARNING: Do not use a forklift to install the unit! This could result in severe damage to equipment, void the warranty or cause personal injury or death!

WARNING: Use only locking hooks to safely lift the unit! Failure to use locking hooks could result in severe damage to the equipment, void the warranty or cause personal injury or death! (Detail I).

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.

31

Installing the Unit

32

DRC Option)

iners without hanger support)oes not have a exhaust hanger support, one and installed. (See “Exhaust Hanger n page 33.) The dimensions shown are

erify these dimensions with your particular ordingly.

er support.

aust pipe extension onto the end of the exhaust

nger and exhaust clamps as shown.

to secure the extension pipe onto the unit.

e exhaust hanger support on the container.

pport securely to the container.

mps securely.

Installing the Exhaust Pipe Extension (

Installation (containers with hanger support) 1. Install the exhaust hanger onto the exhaust hanger support located on

the container.

2. Install the extension pipe onto the end of the exhaust pipe of the unit.

3. Install exhaust clamps as shown and tighten securely.

Installation (contaNOTE: If your container dwill need to be fabricatedSupport Dimensions**” oreference only. Always vcontainer and adjust acc

1. Fabricate exhaust hang

2. Loosely install the exhpipe of the unit.

3. Position the exhaust ha

• Tighten the clamp

• Mark location of th

• Weld the hanger su

• Tighten exhaust cla

33

RC Option)

2

3

3

ntainer and adjust accordingly.

Installing the Exhaust Pipe Extension (D

1

Exhaust Hanger Support Dimensions**

**NOTE: The dimensions shown are reference only. Always verify these dimensions with your particular co

34

ed Container (DRC) Applications:

have the fuel tank mounted directly under the rferes with the drain hose routing. The drain off to one side, behind the fuel tank, and down

ff to one side behind the fuel tank. Drain hoses he unit with no kinks or sharp bends.

clamps provided in installation kit.

attach the drain hose check valves provided in the ends of each hose with cable ties.

Installing the Drain Hoses

InstallationTrailer on Flat Car (TOFC) and Rail Box Car (RBC) Applications:

1. Drain hoses should run straight down the trailer or rail box car wall from the unit with no kinks or sharp bends.

2. Secure with the screws and clamps provided in installation kit.

3. Cut off excess hose and attach the drain hose check valves provided in the installation kit onto each hose.

Domestic Refrigerat

DRC applications typicallyrefrigeration unit which intehoses will need to be routedthe container wall.

1. Route both drain hoses oshould run down from t

2. Secure with screws and

3. Cut off excess hose andthe installation kit onto

35

c Refrigerated Container (DRC)

Installing the Drain Hoses

Trailer on Flat Car (TOFC) and Rail Box Cars (RBC)

Domesti

36

um. - DRC Only

(DRC)n Instructions

Installing the Fuel Tank - 120 Gal., Al

Refer to TK 55012-4-IM

Domestic Refrigerated Container 120 Gallon Aluminum Fuel Tank Installatio

37

m. - DRC Only

RC) Instructions

Installing the Fuel Tank - 120 Gal., Alu

Refer to TK 55012-4-IM

Domestic Refrigerated Container (D120 Gallon Aluminum Fuel Tank Installation

38

Only

f the sensor, focus tube, gaskets and ymmetrical. The holes align only in one en the two mounting holes next to the rther away than the others. These two nce point to correctly align the

be pre-assembled before installing it into

cus tube to the flange making sure the pin tered between the two mounting holes next

r gasket in place, place the upper gasket ge, again making sure the pin hole in the ween the two mounting holes next to the

of the upper gasket with the harness tch on the focus tube flange. All holes

, lock washers and flat washers onto the gasket holes to hold the assembly together.

nk making sure the notch on the focus tube the tank flange. When installed correctly, ointed towards the fuel fill on the end of the

ounting screws in a criss-cross pattern 5 in-lbs (1.1-1.7 N•m).

he mounting hardware or damage to the t.

ady to be installed.

Installing the UFLS (Option) - TOFC

Important Installation InformationThe Ultrasonic Fuel Level Sensor (UFLS) should be installed into the fuel tank before the tank is installed onto the trailer.

If the fuel tank has already been installed, disconnect negative battery cable from unit, disconnect and cap all fuel lines, drain fuel from tank and remove tank from trailer.

• DO NOT connect power to the UFLS until it has been installed into the fuel tank.

• DO NOT use thread locking compounds as they can cause stress cracking of the plastic sensor.

• DO NOT apply any type of gasket sealer.

• USE ONLY the new gaskets supplied with the UFLS.

• DO NOT use power tools to tighten the mounting hardware or damage to the plastic sensor will result.

• DO NOT overtighten the mounting hardware or damage to the plastic sensor will result.

1. Remove and discard the access cover, gasket and hardware from the fuel tank. DO NOT reuse any of these parts.

• Confirm the gasket surface area on the tank flange is clean.

Pre-AssemblyNOTE: The mounting holes othe fuel tank flange are not sposition. The distance betwenotch (see illustration) are fuholes will be used as a referecomponents.

2. The UFLS assembly shouldthe fuel tank.• Slide a gasket up the fo

hole in the gasket is cento the notch as shown.

• While holding the loweonto the focus tube flangasket is positioned betnotch as shown.

• Place the sensor on toppointing towards the noshould now be aligned.

• Install the 10-32 screwssensor and through the

Installation in Tank3. Insert assembly into fuel ta

is aligned with the notch onthe sensor harness will be ptank.

• Hand tighten the five mand torque them to 10-1

• DO NOT overtighten tplastic sensor will resul

• The fuel tank is now re

39

C Only
Installing the UFLS (Option) - TOF

40

ia., AluminumT

and 701658 (90-399) are specifically designed to n fuel tank in a hanging position under a trailer ossmembers. Substitutions are not acceptable!

mmends the fuel tank be mounted 203.2 mm trailer as shown. Otherwise, the OEM or

ible to ensure the fuel tank position meets or ederal Highway regulations, when applicable.

Fuel tank straps must be positioned 673 mm shown.

ds be properly installed on both the mounting er pads must be installed onto the underside of lies to prevent metal to aluminum contact.

hardware is supplied. Substitutions are not

ware must be properly installed and torqued to isted.

Torque Specifications

5 42 N•m (31 ft-lb)

5 81 to 88 N•m (60-65 ft-lb)

48 N•m (35 ft-lb.)

Installing the Fuel Tank - 50 Gallon, 22'' DOPEN STYLE TANK MOUNTING BRACKE

IMPORTANT FUEL TANK INSTALLATION INFORMATIONEffective the first quarter of 2011, all 50 gallon, 22'' diameter, aluminum fuel tanks will come equipped with the mounting flange for the Ultrasonic Fuel Level Sensor (UFLS) option.

Open Style Tank Mounting Bracket - New fuel tank mounting kits were released November 1, 2008. Factory Kit 701635 and Aftermarket Kit 90-398 contain a new open style fuel tank mounting bracket. This new mounting bracket can be used to install either a 30 or 50 gallon, 22'' diameter fuel tanks onto a typical trailer with standard crossmember spacing of 6'', 8'', 10'' or 12''.

• Trailers with non-standard crossmember spacing of 9'', 15'' and 16'' will require the additional components found in Kit 701658 (90-399) to complete the installation.

• These new kits can not be used to install a 75, 90, 110 or 120 gallon, 22'' diameter fuel tanks. Those tanks require Kit 710278 (90-121).

• DO NOT substitute any components from Kits 701635 (90-398) and 701658 (90-399) with any previously supplied fuel tank mounting kits as they are not interchangeable.

• Kits 701635 (90-398) install a 30 or 50 galloattached to the floor cr

A. Fuel Tank Position• Thermo King reco

(8.00 in.) under theinstaller is responsexceeds DOT or F

B. Tank Strap Position • 50 Gallon Tanks -

(26.50 in.) apart as

C. Rubber Strips and Pa• Rubber strips must

bands and the rubbthe hanger assemb

D. Mounting Hardware• Grade 5 mounting

acceptable!• All mounting hard

the specifications l

DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your trailer manufacturer for specific details on proper fuel tank installation and recommendations.

CAUTION: The trailers crossmembers must be strong enough to safely support the combined weight of the mounting hardware, fuel tank and fuel.

Fuel Tank Capacity Combined Total Weight

50 Gallon Diesel 214 KG (471 lbs.)

Hardware Size

3/8-16 Grade

1/2 -13 Grade

1/2'' T-bolts

41

eter, Aluminum

e mounted on ide of trailer.

Flange

nting holes may change if other ed.

Installing the Fuel Tank - 50 Gallon, 22'' DiamOPEN STYLE TANK MOUNTING BRACKET

Standard crossmember spacing shown. For other crossmember spacing, refer to TK-54238-2-IM.Non-standard crossmember spacing of 9'', 15'' and 16'' also requires Kit 701658 (90-399)

Tank can beither s

NOTE: Location of moutrailer options are add

42

iameter, Aluminum

CKET

Installing the Fuel Tank - 50 Gallon, 22'' D

OPEN STYLE TANK MOUNTING BRA

Fuel Tank InstallationNOTE: Location of mounting holes may change if other trailer options are added.

1. Locate the existing sets of 10.3 mm (.406'' dia.) pre-punched holes in the crossmembers. See note above.

2. Align the two holes of each hanger bracket with the holes in the crossmember and secure with two, 3/8-16 screws, washers and locking nuts. Torque the hardware to 42 N•m (31 ft-lb).

3. Install each hanger assembly (facing each other as shown) onto the hanger brackets with 1/2-13 screws, washers and locking nuts. Torque the hardware to 81 to 88 N•m (60-65 ft-lb).

4. Install a self-adhesive rubber pad to the underside of each hanger assembly.

5. Loosely install the tank straps t-bolts onto the hanger assemblies with 1/2'' washers and locking nuts. Verify the rubber strips are properly installed on the mounting bands.

6. Install the fuel tank into the straps with the tank positioned vertically within plus or minus 5 degrees and tighten the tank straps to 48 N•m (35 ft-lb).

43

ameter, AluminumKET

e

NOTE: Location of mounting holes may change if other trailer options are added.

Installing the Fuel Tank - 50 Gallon, 22'' DiOPEN STYLE TANK MOUNTING BRAC

Open Style Bracket

Flang

Orient Tank Vertically

44

BC Only

ETURN line to the fuel tank:

the appropriate length and slide on the fuel

he fuel return fitting and then tighten the fuel

from the fuel vent and point the outlet to the

ount of fuel (1/4 tank) to allow the unit to g engine break-in and pre-delivery

Installing the Fuel Lines - DRC and R

Fuel Line Installation

1. Uncoil the fuel supply and return lines from the rear of the unit.

IMPORTANT: The fuel lines must remain routed through the provided insulated clamp as shown, then down to the fuel tank.

2. Route the 3/8” FUEL SUPPLY line to the fuel tank fitting:

• The supply line when installed into the tank must be no higher than 25.4 mm (1.00 in.) from the bottom of the tank. Determine this length and cut the supply line.

• Cut the end of the supply line at a 45 degree angle and slide on the fuel line fittings.

• Insert the supply line into the fuel pickup fitting until it is 25.4 mm (1.00 in.) from the bottom of the tank then tighten the fuel line fitting securely.

3. Route the 1/4” FUEL R

• Cut the return line toline fittings.

• Install the line onto tline fitting securely.

4. Remove the plastic cap rear of the container.

NOTE: Add a sufficient amrun for 8 to 12 hours durinprocedures.

DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free!

DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire!

45

RBC Only

3

Installing the Fuel Lines - DRC and

2

IMPORTANT: The fuel lines must remain routed through the provided insulated clamp as shown, then down to the fuel tank.

46

FC Only

nes with provided clamps (Detail III).

ly line from the unit to the fuel pump to the fuel pickup Install fuel line connector (provided in installation kit), ne at a 45 degree angle and insert into fuel pickup tube m (1.00 in.) from bottom of tank and tighten securely

n line from the unit to the fuel tank return fitting. onnectors and tighten securely.

ap from the fuel vent and point the outlet to the rear of

ient amount of fuel (1/4 tank) to allow the unit to rs during engine break-in and pre-delivery

Installing the Fuel Lines - TO

Fuel Line Installation

1. Install the fuel line bracket to the pre-drilled hole in the frame. This hole is located in the frame under the compressor (Detail I).

IMPORTANT: Verify the factory installed fuel line fittings are tight prior to mounting the bracket onto the frame.

2. Fuel lines should be routed in a protective housing with no kinks or sharp bends (Detail II).

3. Rubber grommets must be used when routing fuel lines through holes in metal (Detail II).

4. Secure all fuel li

5. Route fuel suppon the fuel tank. cut end of fuel liuntil it is 25.4 m(Detail IV).

6. Route fuel returAttach fuel line c

7. Remove plastic cthe trailer.

NOTE: Add a sufficrun for 8 to 12 houprocedures.

DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free!

DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire!

47

C Only
Installing the Fuel Lines - TOF
Verify the factory installed fuel line fittings are tight

prior to mounting the bracket onto the frame.

48

ess - DRC Only

se of the supplied crimp and solder style parate heat shrink tubing is required when l level sensor harness wires.

he harness to length and connect the harness wires to sor wires (wires are not polarity sensitive) by:

lied heat shrink tubing onto each wire and positioning om the joint.

ire ends, inserting them into the wire connectors and urely.

wires to the wire connectors with a soldering gun.

eat shrink tubing over the wire connectors and t with a heat gun.

le ties, clamps and screws to secure the harness as

is a “Float Style” fuel level sensor and the SR-3 programmed accordingly. See “Programming the n page 72 to enable the fuel level feature.

Installing the Fuel Level Sensor Harn

“Float Style” Fuel Level Sensor

Wire Routing and Connections

NOTE: The fuel level sensor harness 3-pin connector is located outside the control box. It is cable tied to other harnesses at the rear of the unit near the frame mounted ground plate and behind the battery tray.

1. Locate the short factory installed fuel level sensor harness with the 3-pin connector. See note above.

• Apply a light coating of Superlube (or equivalent) to this connector.

• Connect the 6 ft. (1.8 m) fuel level sensor harness to the mating 3-pin connector on the factory installed harness.

• Route the harness to the fuel tank.

IMPORTANT: The uconnectors with seconnecting the fue

2. At the tank, cut tthe fuel level sen

• Sliding suppthem away fr

• Striping the wcrimping sec

• Soldering the

• Sliding the happlying hea

3. Use supplied cabshown.

IMPORTANT: This Controller must beSR-3 Controller” o

DANGER: Do not route electrical wires with fuel lines as this could cause a fire!

49

ss - DRC Only
Installing the Fuel Level Sensor Harne

50

- TOFC Only

UFLS)

tionsf the supplied crimp and solder style te heat shrink tubing is required when arness to the UFLS.

arness to length and splice wires to the fuel

t shrink tubing onto each wire and position them

with wire connector and crimp securely.

re connectors with a soldering gun.

bing over each wire connector and applying heat

rn the heat shrink. If the heat shrink is burnt, from overheating, the wire connections must correctly.

s, clamps and screws to secure the harness.

Solid State” fuel level sensor and the SR-3 rammed accordingly. see “Programming the e 72 to enable the fuel level feature.

Interconnect HarnessOutside Control Box

Fuel Sensor Leads

PIN A GREEN RED

PIN B BLACK BLACK

PIN C WHITE YELLOW

Installing the UFLS Harness (Option)

“Solid State” Ultrasonic Fuel Level Sensor (

Harness Installation and RoutingNOTE: The Ultrasonic Fuel Level Sensor (UFLS) is an option for 22” 50 gallon fuel tanks only and requires Interconnect Harness Kit 702414.

1. Locate the short factory installed fuel level sensor harness with the 3-pin connector. This connector is located outside the control box and band wrapped to other harnesses at the rear of the unit near the frame mounted ground plate.

• Apply a light coating of Superlube or equivalent to this connector.

• Connect the 30 ft. (9.1 m) Interconnect Harness to the mating 3-pin connector on the factory installed harness.

2. Route the harness to the fuel tank using trailer’s harness conduit or chase to avoid interference with fifth wheel plate area.

NOTE: Thermo King recommends a conduit or chase with 1.00 in (25.4 mm) I.D. to accommodate the electrical harness.

Harness ConnecIMPORTANT: The use oconnectors with separaconnecting the sensor h

3. Cut the interconnect hsensor’s leads:

• Slide supplied heaaway from joint.

• Connect each wire

• Solder wires to wi

• Slide heat shrink tuwith a heat gun.

IMPORTANT: DO NOT bucharred, or has bubblesbe removed and redone

4. Use supplied cable tie

IMPORTANT: This is a “Controller must be progSR-3 Controller” on pag

DANGER: Do not route electrical wires with fuel lines as this could cause a fire!

J3 Connector at Controller

PIN 12 2PL

PIN 35 FUELN

PIN 23 FLL

51

ption)

)

Tubing

Crimp and Solder Style Connectors

s

Installing the UFLS Harness (O

Ultrasonic Fuel Level Sensor (UFLS

Heat Shrink

Interconnect Harnes

52

ion)

occupied use the CAN extender Harness o King Dealer.

ors are locked securely in place on the circuit

arness with tie bands to the main harness ay.

ure excess harness to battery cables or

Installing the Status Light (Opt

InstallationNOTE: Surface mounted status light installation shown, flush mounted light installs into recessed opening (see “Flush Mounted Status Light Opening Dimensions (Option)” on page 21) and electrical connections are made the same.

1. Mount the Status Light in a location so that is visible in the tractor mirror to the driver.

• Mark and drill the four mounting holes using a 3/16'' drill.

• Mount the status light in position with the supplied rivets.

2. Route harness as shown allowing a “drip-loop” to prevent water from migrating into the Status Light.

3. Secure harness to the bracket and trailer using the supplied clamps and rivets.

4. Connecting the Status Light harness:

STANDARD DISPLAY - connect harness to the matching 6-pin connector located outside the unit behind the battery tray and to the left of the control box.

• Secure any excess harness with tie bands to the main harness behind the battery tray.

FUEL COMBO and TRIPLE COMBO DISPLAYS - route the harness through the harness grommet and into the control box.

• Connect the 4-pin connector to the Remote Light port on the circuit board.

• Connect the 8-pin connector to CAN1 (J12). If this position is occupied use CAN2 (J13) or CAN3 (J14).

NOTE: If all CAN ports areavailable from your Therm

• Be sure the connectboard.

• Secure any excess hbehind the battery tr

IMPORTANT: DO NOT secrefrigeration lines.

53

ption)
Installing the Status Light (O
4-Pin

8-Pin

54

r (Option)

uivalent) to Remote Controller Harness curely to back of controller. Route harness ontroller to controller box with screws.

e Controller Harness from controller to host s.

nd strip wire ends.

ontroller Harness wires to the splice terface Harness.

uivalent) and securely connect the Interface r to the mating 8-pin Remote Controller e side of the evaporator housing.

Code Interface Harness(with 8-PIN connector

and splice ends)

Code

BLU PIN 3 BLU

GRN PIN 5 GRN

No Connection

PIN 7 No Connection

ORN PIN 6 ORN

YEL PIN 4 YEL

BRN PIN 8 BRN

BLK PIN 1 BLK

RED PIN 2 RED

Installing the Rear Remote Controlle

Foamed-In-Place InstallationNOTE: Verify mounting location and all dimensions before installing the remote controller.

A = 69.8 mm (2.75 in.)

B = 196.8 mm (7.75 in.)

Preferred Wire Routing (Steps 1,2, 6-10)

NOTE: The preferred routing of the electrical harness chase and interface harness is from the bottom of the controller box.

1. Connect the harness chase to the bottom of controller while providing a drip loop.

2. Install and route a 1/2 in. CPVC drain hose from the bottom of the controller box out of trailer floor.

Alternative Wire Routing (Steps 3-10)NOTE: The alternative routing of the electrical harness chase and interface harness is from the side of the controller box.

3. Drill an appropriate size hole in the controller box for the harness chase coupling.

4. Install harness chase coupling.NOTE: Coupling should not protrude more than 6.4 mm (0.25 in.) inside the controller box.

5. Install cap in bottom of controller box before foaming trailer wall.

6. Apply chalking to controller box and install securely into trailer wall.

Harness Connections7. Apply Superlube (or eq

connector and attach sethrough chase. Secure c

8. Route chase and Remotunit. Secure with clamp

9. Cut off excess harness a

• Attach the Remote Cconnectors on the In

.

10. Apply Superlube (or eqHarness 8-pin connectoconnector located on th

DANGER: Do not route electrical harness together with fuel lines as this could cause a fire resulting in death or serious injury!

CAUTION: Do not drill holes into refrigeration, electrical or mechanical components or severe damage to the equipment will result!

Remote Controller Harness

(with flat 8-PIN connector)

PIN 1

PIN 2

PIN 3

PIN 4

PIN 5

PIN 6

PIN 7

PIN 8

55

ler (Option)
Installing the Rear Remote Control

56

r (Option)

, measure and drill an appropriate size hole and to the trailer towards the unit.

ackside of the unit with clamps.

harness required for the harness to connect to the ler connector located on the side of the

ess and strip wire ends.

splice and use heat shrink covering.

quivalent) and securely connect the Interface or to the mating 8-pin Remote Controller f the evaporator housing.

)

Code Interface Harness(with 8-PIN connector

and splice ends)

Code

BLU PIN 3 BLU

GRN PIN 5 GRN

No Connection

PIN 7 No Connection

ORN PIN 6 ORN

YEL PIN 4 YEL

BRN PIN 8 BRN

BLK PIN 1 BLK

RED PIN 2 RED

Installing the Rear Remote ControlleRetro-Fit Installation

NOTE: Verify mounting location and all dimensions before installing the

1. Cut opening in trailer wall per dimensions shown.

A = 203 mm (8.0 in.)

B = 107.9 mm (4.25 in.)

C = 38 x 12.7 mm (1.5 x .5 in.)

2. Install and route a 1/2 in. CPVC drain hose and 0.88 O.D. harness chase from the bottom of the controller box out of the trailer.

3. Apply caulking to controller box and install securely in trailer wall.

NOTE: Make sure the drain hose and harness chase are connected properly.

Harness Connections4. Apply Superlube (or equivalent) to Remote Controller Harness

connector and attach securely to back of controller. Route harness through chase. Secure controller to controller box with screws.

5. Route harness under trailer through chase in floor or I-beam crossmembers towards the unit.

6. From inside the trailerroute the harness up in

7. Secure harness to the b

8. Measure the length of 8-Pin Remote Controlevaporator housing.

• Cut off excess harn

• Crimp into existing.

9. Apply Superlube (or eHarness 8-pin connectconnector on the side o

DANGER: Do not route electrical harness together with fuel lines as this could cause a fire resulting in death or serious injury!


CAUTION: Rubber grommets must be used when routing electrical harnesses through metal holes! Remote Controller

Harness (with flat 8-PIN connector

PIN 1

PIN 2

PIN 3

PIN 4

PIN 5

PIN 6

PIN 7

PIN 8

57

er (Option)
Installing the Rear Remote Controll

58

n)

Link Installation Manual.

ON NOTES:stalled away from traffic (i.e. forklifts) or

et must be installed parallel to each other, oss hair aligns to long cross hair.

um gap of 12.7 mm (0.50 in.) is maintained d the magnet. Shims may be required and

aterial (aluminum, wood, plastic, etc.) or the e properly.

ith the top edge of the door and secure with

the switch to the door sill parallel with the ss hairs” are aligned and that the maximum s maintained.

ith the bottom edge of the door and secure

the switch to the floor parallel with the ss hairs” are aligned and that the maximum s maintained.

stallationith the top edge of the door and secure with

the switch to the door sill parallel with the ss hairs” are aligned and that the maximum s maintained.

Installing the Door Switch (Optio

When installing CargoLink wireless door switches, see TK 55151 Cargo

NOTE: These instructions (pages 58-61) are intended as reference guide only to assist with a typical hard wired door switch installation. Your installation may be different depending on the trailer, the amount and types of doors and the customers particular requirements.

Door Switch ComponentsThe door switch consists of a magnet, a switch, non-magnetic mounting hardware and a interface harness to connect to the host unit.

• The magnet is always mounted on the door.

• The switch (with harness) is always mounted to a stationary location.

• Two short interface harnesses are available depending on your particular kit. One allows a single door switch in a single zone to activate a unit shutdown. The other allows two door switches in the same zone to each activate a unit shutdown.

Non-magnetic mounting hardware is included to install the switches. If alternate hardware is used it must also be non-magnetic or the door switch will not operate properly.

Installer is to supply and fabricate the harness connecting the interface harness to the door switch per the table below. The harness should be 18 AWG or better, 3 wires, color coded RED, BLACK and WHITE.

Mounting LocationsThe door switch can be mounted on the inside or outside of either swing out or roll-up doors and can be mounted in various positions to accommodate particular applications.

IMPORTANT INSTALLATI• The door switch must be in

protected from it.

• The door switch and magnnot perpendicular. Long cr

• It is important that a maximbetween the door switch anmust be a non-magnetic mdoor switch will not operat

(Detail A) Ceiling Mounted1. Mount the magnet flush w

supplied hardware.

2. Close the door and mount magnet, being sure the “crogap of 12.7 mm (0.50 in.) i

(Detail B) Floor Mounted 1. Mount the magnet flush w

with supplied hardware.


(Detail C) Outside Door In1. Mount the magnet flush w

supplied hardware.


Interface Harness Wiring Door Switch Wiring

RED = (12 Vdc) POWER RED = (12 Vdc) POWER

BLACK = (CH) GROUND BLACK = (CH) GROUND

WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT

59

ption)
Installing the Door Switch (O
Right Angle Mounting

Top x Top Mounting

Side x Side Mounting

60

n)

umbers.

may be located one of two places:

mounted ground plate and behind the

ation / Single Zone (Detail B)

lent) and securely connect the interface onnector. See note above.

taller Supplied) from the interface harness mum Two Doors. Connect matching wires ED, WHITE/WHITE, BLACK/

ch using splice connectors. Crimp splice ply heat with a heat gun.

talled, routed and properly secured to

door switch operation.

ring Door Switch Wiring

RED = (12 Vdc) POWER

WHITE = (DS) OUTPUT

BLACK = (CH) GROUND

Installing the Door Switch (Optio

Contact your Thermo King Dealer for specific part n

NOTE: Depending on which Rail Ready model you have, the Door Switch Harness 3-pin connector

• on the side of the evaporator housing.

• outside the control box, cable tied to other harnesses at the rear of the unit near the framebattery tray.

Single Door Switch Activation / Single Zone (Detail A)

1. Apply Superlube (or equivalent) and securely connect the interface harness to the door switch connector. See note above.

2. Route a 3 wire harness (Installer Supplied) from the interface harness to a single door switch. Connect matching wires per the table below (RED/RED, WHITE/WHITE, BLACK/BLACK) to the door switch using splice connectors. Crimp splice connectors securely and apply heat with a heat gun.

3. All harnesses should be installed, routed and properly secured to protect from damage.

• Operate unit and verify door switch operation.

Multiple Door Switch Activ

1. Apply Superlube (or equivaharness to the door switch c

2. Route a 3 wire harness (Insto each door switch - Maxiper the table below (RED/RBLACK) to each door switconnectors securely and ap

3. All harnesses should be insprotect from damage.

• Operate unit and verify





Interface Harness Wi

RED = (12 Vdc) POWER

WHITE = (DS) OUTPUT

BLACK = (CH) GROUND

61

ption)

s

Installing the Door Switch (O









Single Door Switch

Multiple Door Switche

62

s (Option)

uired by customer.

CargoWatch™ Sensor Location

Sensor locations for Domestic Applications as req1. Sensor #1 is located in the evaporator side return opening near unit

return air sensor (factory installed).

2. Sensor #2 as required by customer.

63

(Option)
CargoWatch™ Sensor Locations

64

sors (Option)

an Be Used.pin connector may be located one of two places:

the frame mounted ground plate and behind the

in connector and wire into correct connection until it n (Detail I). The wire side of the connector is shown.

end (3) back onto connector (2), apply a light coating lectrical connections and plug sensor back into mating Sensor Harness (1).

goWatch Sensor Harness to the sensor using the splice p splice connectors securely and apply heat with a : The CargoWatch Sensor wires are not polarity

ith appropriate clamps.

5 White into #5

6 White into #6

SENSOR PLUGS

1 Black into #12

2 Black into #11

3 Black into #10

4 Black into #9

5 Black into #8

6 Black into #7

SENSOR PLUGS

Connecting the CargoWatch™ Sen

IMPORTANT: ONLY CargoWatch Sensors CNOTE: Depending on which Rail Ready model you have, the CargoWatch Sensor Harness 12-

• on the side of the evaporator housing.

• outside the control box, cable tied to other harnesses at the rear of the unit near battery tray.

CONNECTING SENSORS

NOTE: The sensor are not polarity sensitive.

1. Locate the short factory installed CargoWatch Sensor Harness with the 12-pin connector.

2. Unplug the blank connector from the harness.

3. Removes orange end from connector.

4. Remove only the plugs from the connector holes for the sensors you are connecting. Unused holes must remain plugged.

5. Insert WHITE pin connector and wire into correct connection until it locks into position (Detail I). The wire side of the connector is shown.

6. Insert BLACK plocks into positio

Reinstall orangeof Superlube to econnector on the

7. Connect the Carconnectors. Crimheat gun. NOTEsensitive.

8. Secure sensor w

SENSOR PLUGS

1 #1 and #12

2 #2 and #11

3 #3 and #10

4 #4 and #9

5 #5 and #8

6 #6 and #7

SENSOR PLUGS

1 White into #1

2 White into #2

3 White into #3

4 White into #4

65

ors (Option)
Connecting the CargoWatch™ Sens

66

ption)ULKHEAD

part numbers.

Installing the Bulkhead (OTHERMO KING RECOMMENDS USING A B


Installation

1. Find and mark the front trailer wall support posts, the top six mounting holes should align with the trailer wall posts.

2. Set the bulkhead on the trailer floor and fit it over the evaporator. DO NOT cut the top of the bulkhead. It is designed to fit all wide post unit evaporators (65 inch wide evaporators).

3. Use two of the included self drilling screws to attach the bulkhead to the trailer wall support posts using the top two holes only.

4. Cut the side flanges to activate the bulkhead hinges.

5. Use eight screws to finish mounting the bulkhead, four in the large pockets and four in the bottom flange.

6. For evaporator service, remove the 2 screws holding the top portion of the bulkhead and fold it down.


67

tion)

Typical trailer wall support posts.

Installing the Bulkhead (Op

Attach bulkhead with the top two mounting holes.

Four mounting holes in large pockets

Four mounting holes in bottom flange

Remove the two screws holding the top portion of the bulkhead and fold it down to

service the evaporator.

68

y into the tray.

hold down bracket and rods. Loosely install hardware

old down rods must fit into the notch located on the battery. You may have to move the electrical access this notch.

the battery hold down bracket over the two existing e support channel.

ounting bolts and flat washers through the hold down ort channel. Torque hardware to 13.5 N•m

battery hold down rods to 2.25 N•m (20 in -lbs.)ghten as this may crack or distort the battery!

battery cable on the positive battery post first to ntal electrical shorting. Tighten the bolt securely.

battery cable on negative battery post second to ntal electrical shorting. Tighten the bolt securely.

Installing the Battery

Important Battery InformationIMPORTANT: See Safety Precautions - “Battery Installation and Cable Routing” on page 6 for additional information.

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.

Installation1. Install the batter

2. Install the batteryonto the rods.

NOTE: One of the hthe channel under harness slightly to

3. Align the tab of holes in the fram

4. Install the two mbracket and supp(120 in-lbs).

5. Tighten the two DO NOT over ti

6. Install positive +minimize accide

7. Install negative -minimize accide

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 a 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.

69

Installing the Battery

70

nd RBC Only
Installing the Bottom Pan - TOFC a
InstallationNOTE: Anti-seize lubricant applied to the threads of the stainless steel mounting hardware is recommended.

1. Remove the four 1/4-20 x .75 screws, lock washers and flat washers attached to the front of the bottom pan. These will be re-installed in Step #3.

2. Rear Mounting Bolts - Position the bottom pan under the unit and align the four holes in the rear of the bottom pan with the four holes in the rear of the frame.

• From under the unit, attach the rear of the bottom pan with the four 1/4-20 x 1.00'' torx head screws, 1/4” lock washers and 1.00'' diameter flat washers supplied in the installation kit.

3. Front Mounting Bolts - Open the center curbside and roadside doors to access the bottom pan front mounting tabs.

• From inside the unit, secure the bottom pan with the four 1/4-20 x .75'' screws, lock washers and flat washers removed in Step #1.

4. Torque all eight bottom pan mounting bolts to 30 in-lb.

5. Close and secure all doors.

71

d RBC Only
Installing the Bottom Pan - TOFC an

72

troller

ough OptiSet™

llite Device (if applicable)d Access Menu.

select: Remote Device Enable/Disable.

ble then press the + key then the YES key

t key.

ow programmed to accept remote satellite ons.

Programming the SR-3 Con

NOTE: These procedures can also be done thr

Fuel Level SensorNOTE: The Guarded Access Menu is not available if the engine is running.

1. Turn off the engine.

2. Go to the Guarded Access Menu.

3. Scroll down to and select the Unit Configuration.

4. Scroll down to and select Fuel Level Sensor.

The choices are: NONE, SOLID STATE or FLOAT.

• USFLS STYLE - scroll to SOLID STATE by pressing + key then YES key.

• FLOAT STYLE - scroll to FLOAT by pressing + key then YES key.

• Fuel Level Percent will now be in the gauge menu.

• The unit is now programed, press the exit key.

Remote Sate1. Enter the Guarde

2. Scroll down andThe choices are:

• Scroll to Ena

• Press the exi

• The unit is ncommunicati

73

(REMOTE EVAPORATORS)

r(s) sections for cleanliness.

necting tubing.

e, loose or missing bolts and hardware on remote

installation of drain tubes, drain kazoos and drain .ly routed refrigerant lines wiring harnesses for r(s). Check for properly routed harnesses for remote

installation of remote evaporator guards if

rness wiring plugs in the host evaporator.

nnections, and terminals in the remote

ent bulk head(s) for proper fit if equipped.

NIT NITS START ONLY THE HOST UNIT)

oil pressure, coolant temperature, oil, fuel, or

charge.

d ensure the unit functions in the correct modes and rs are working.

s run with thermostat set point at 32 F (0 C) and run C).

UNIT CHECK LISTUNIT 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.

Visually inspect the unit for the following: Loose or improperly fitting bolts, brackets, hardware, hose connections and hose routing.

Inspect all wiring connections and routing.

Check defrost drain hoses and kazoos.

Check unit mounting hardware for tightness.

Check compressor and engine mounts.

Check compressor clutch if equipped.

Install refrigeration gauge manifold. (Multi-Temp units only)

Check engine oil level.

Check condenser and evaporator section for cleanliness and signs of refrigerant leaks.

Check front bulkhead and air chute if equipped.

Check damper door, bushings and springs.

MULTI-TEMP UNITS

Check evaporato

Leak test intercon

Check for damagevaporator(s).

Check for propertube heater wiresCheck for properremote evaporatocontroller.Check for properequipped.Check remote ha

Check wiring, coevaporator(s).Check compartm

START AND RUN U(ON MULTI-TEMP U

Check for propercoolant leaks.

Check alternator

Cycle the unit anthe mode indicato

Set for continuouthe unit to 32 F (0

74

ued)mpartment bulk head(s) if equipped.

continuous run. Continue to run the unit with the back ternating between high speed cool and heat until at10 hours preferred) are shown on the engine run time ensure complete break in of the engine, time for the moving parts to take out the initial tension and

BY OPERATIONAL CHECKS

ical contacts and connections by connecting to AC ning.

ect electric motor rotation.

tat and check for correct modes of operation.

not available to test AC.

units leak test interconnecting tubing.

djust all belt tensions using TK belt gauge 204-427.

fuel, coolant, refrigerant and exhaust leaks.

oil and coolant level.

nit for loosened hardware and fittings.

ust all skin, door and panels for correct alignment and

commissioning registration process.

UNIT CHECK LIST (continObserve 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.

For Single Temp units perform a controlled check of the refrigerant level. For Multi-temps check the charge per multi-temp unit procedures.

MULTI-TEMP UNITS

Install the compartment bulk head(s) if equipped.

Check for correct rotation of remote evaporator fans.

Check for correct cycling and operation of remote evaporator fans.

ALL UNITS

Initiate and check defrost operation and termination.Check operation and adjustment of damper door and remote fans. Each zone on multi-temps must be checked for proper operation.

Set the unit for Cycle Sentry Operation.

Check for proper operation of all door switches.

Remove the co

Set the unit fordoors open, alleast 6 hours (hour meter to belts and otheradjustment.

ELECTRIC STAND

Test AC electrpower and run

Check for corr

Cycle thermos

Power source

STOP UNIT

On Multi-temp

Check and rea

Check for oil,

Check engine

Check entire u

Check and adjoperation.

Complete the

Release unit.

Installation Manual

Providing equipment and services to manage controlled-temperature environments for food and other temperature-sensitive products, our Climate Control Technologies sector encompasses both transport and stationary refrigeration solutions. Our product brands include Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a manufacturer of refrigeration and food merchandising equipment.

www.thermoking.com www.hussmann.com www.ingersollrand.com

©2008 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper

SB-230 RR and SB-330 RRSingle Temperature System

For Domestic Refrigerated Containers (DRC),Trailer on Flat Car (TOFC) and Rail Box Car

(RBC) ApplicationsTK 54932-5-IM (Rev. 4, 06/12)

Installation Manual - ThermoKing · Installation Manual Providing equipment and services to manage...

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Transcript of Installation Manual - ThermoKing · Installation Manual Providing equipment and services to manage...