Ingersoll-Rand Thermo King T-500R Installation Manual
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Ingersoll-Rand Thermo King T-500R Installation Manual

Single temperature systems
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Installation Manual
Truck Edition (TSA, ESA and AP)
Single Temperature Systems
T-500R/T-Dairy (ESA Only)
T-570R, T-600 and T-600R
T-800, T-800R and T-800M
T-1000, T-1000R and T-1000M
T-1200R, T-1200R Inter-modal (ESA Only)
TK 61441-1-IM (Rev. 0, 08/16)
©
Copyright
2016 Ingersoll Rand Climate Solutions - EMEIA - Printed in Ireland

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  • Page 1 Installation Manual Truck Edition (TSA, ESA and AP) Single Temperature Systems T-500R/T-Dairy (ESA Only) T-570R, T-600 and T-600R T-800, T-800R and T-800M T-1000, T-1000R and T-1000M T-1200R, T-1200R Inter-modal (ESA Only) TK 61441-1-IM (Rev. 0, 08/16) © Copyright 2016 Ingersoll Rand Climate Solutions - EMEIA - Printed in Ireland...
  • Page 2 Installation Manual for T-Series Systems Release History Original (8/16) Released...
  • Page 3 Installation Manual for T-Series Systems...
  • Page 4 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. •...

  • Page 5: Table Of Contents

    Table of Contents Safety Precautions ......... . .6 Installing the Hose Management Caps .

  • Page 6: Safety Precautions

    Safety Precautions 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.
  • Page 7 Safety Precautions (continued) Battery Installation and Cable Routing Refrigerant WARNING: Improperly installed battery could result in a fire or WARNING: Although fluorocarbon refrigerants are classified explosion! A Thermo King approved battery must be installed as safe refrigerants, certain precautions must be observed and properly secured to the battery tray.

  • Page 8: Unit Dimensions - T-500R/T-Dairy

    Unit Dimensions – T-500R/T-Dairy 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.

  • Page 9: Unit Dimensions - T-570R, T-600, T-600R, T-800, T-800R, T-800M

    Unit Dimensions – T-570R, T-600, T-600R, T-800, T-800R and T-800M 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.

  • Page 10: Unit Dimensions T-1000, T-1000R, T-1000M And T-1200R

    Unit Dimensions T-1000, T-1000R, T-1000M 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.

  • Page 11: Service Area - T-500R/T-Dairy

    Service Area – T-500R/T-Dairy...

  • Page 12: Service Area - T-570R, T-600, T-600R, T-800, T-800R And T-800M

    Service Area – T-570R, T-600, T-600R, T-800, T-800R and T-800M...

  • Page 13: Service Area - T-1000, T-1000R, T-1000M And T-1200R

    Service Area – T-1000, T-1000R, T-1000M and T-1200R...

  • Page 14: Remote Power Receptacle Dimensions (Option)

    Remote Power Receptacle Dimensions (OPTION) INTERNATIONAL MODELS NORTH AMERICAN MODELS...

  • Page 15: Battery Box Dimensions (Option)

    Battery Box Dimensions (OPTION)

  • Page 16: Hmi Controller Dimensions

    HMI Controller Dimensions NOTE: For all except T-1200R Inter-modal HMI Controller (LED Display) HMI Controller (Graphics Display)

  • Page 17: Hmi T-1200R Inter-Modal Controller Dimensions

    HMI T-1200R Inter-modal Controller Dimensions...

  • Page 18: Truck Body Opening Dimensions

    Truck Body Opening Dimensions Installing a New Unit onto a New Truck Box T-500R/T-Dairy 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.
  • Page 19 Truck Body Opening Dimensions Installing a New Unit onto a New Truck Box (all except T-500R/T-Dairy) 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.
  • Page 20 Truck Body Opening Dimensions Retrofitting a New Unit onto a Older Truck Box T-500R/T-Dairy NOTE: Existing opening same as MD-100, MD-200 units and does not require modifications. Cannot be retrofitted from any other existing Truck body. Important Installation Requirements: • Gasket sealing surface of 50.8 mm (2.00 in.) wide is...
  • Page 21 Truck Body Opening Dimensions Retrofitting a New Unit onto a Older Truck Box (all except T-500R/T-Dairy) 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...

  • Page 22: Unit Weights

    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-500R/T-Dairy 370 kg (816 lbs.) T-500R/T-Dairy 400 kg (882 lbs.) T-570R 440 kg (971 lbs.) T-570R 465 kg (1026 lbs.)

  • Page 23: Lifting Bar Details

    Lifting Bar Details IMPORTANT: The T-500R/T-Dairy, T-570R, T-600, T-600R, T-800, T-800R, T-800M, T-1000, T-1000R, T-1000M and T-1200R 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.
  • Page 24 Lifting Bar Details Entire Unit Clevis Unit Type Lift Hole Position Lifting Hole Position TS 200/300/500/600 – 30 6 (Front Chain – Left Hole) TS 200/300/500/600 – 50 6 (Front Chain – Left Hole) SPECTRUM TS 6 (Front Chain – Left Hole) MD II, MD 200, MD 300 –...
  • Page 25 Lifting Bar Details...

  • Page 26: Required Tools

    Required Tools 1. Safety Glasses 2. Drill 3. Drill Bits 4. Tape Measure 5. Mechanics Tools 6. Lifting Bar (New Style Design Required) 7. Work Platform (Recommended)
  • Page 27 Required Tools...

  • Page 28: Installation Components

    Installation Components 1. Unit Mounting Washers 1.250 x 0.188 THK 17. Fuse 60 amp 2. Locking Nuts 1/2-13 18. Terminal Connector Splice 3. Torx Head Screws 19. Heat Shrink Sleeving 3.00'' 4. Hose Management Cap s 20. Terminal Red 3/8'' 5.
  • Page 29 Installation Components...

  • Page 30: Uncrating The Unit

    Uncrating the Unit Important Unit Lifting Information Uncrating the Unit NOTE: The T-500R/T-Dairy, T-570R, T-600, T-600R, T-800, T-800R, 1. Remove: T-800M, T-1000, T-1000R, T-1000M and T-1200R series truck units • Outer round bars from crate require a new lifting bar. This new bar must be used to safely lift and install these series units.
  • Page 31 Uncrating the Unit...

  • Page 32: Installing The Unit

    Installing the Unit Important Unit Lifting Information Installing the unit NOTE: The T-500R/T-Dairy, T-570R, T-600, T-600R, T-800, T-800R, 1. Use the new 3 point lifting bar to carefully lift the unit up to the truck T-800M, T-1000, T-1000R, T-1000M and T-1200R series truck units opening.
  • Page 33 Installing the Unit...

  • Page 34: Installing The Hose Management Caps

    Installing the Hose Management Caps Hose Management Caps (STANDARD) Curbside Cap 2. Route the following items out of the curbside cutout of the bottom pan Hose management caps provide a exit point under each side of the unit for and down the front exterior wall of the cargo box: routing the individual drain hoses, fuel lines, electrical cables.
  • Page 35 Installing the Hose Management Caps Cutout Guide Marks Front Unit...

  • Page 36: Installing The Hose Management System (Option)

    Installing the Hose Management System (OPTION) NOTE: Not applicable for T-1200R Inter-modal 2. Install the funnel cap into the bottom pan securely. 3. Mark a line from the center of the funnel cap down the truck box wall. Hose Management System (OPTION) 4.
  • Page 37 Installing the Hose Management System (OPTION) Front Unit...

  • Page 38: Securing The Oil Drain Hose

    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.
  • Page 39 Securing the Oil Drain Hose The cutouts in the hose management cap should be as large as possible with no sharp edges. NOTE: Ensure oil drain hose does not rub on any part of the frame on the inside of the unit...

  • Page 40: Securing The Evaporator Drain Hoses

    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.
  • Page 41 Securing the Evaporator Drain Hoses...

  • Page 42: Installing The Fuel Pickup Tube Into A Steel Or Aluminum Tank

    Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank NOTE: The fuel pickup tube supplied in the installation kit will not be 1. Tape the paper template (supplied with pickup tube) to the desired needed when installing an optional Thermo King aluminum fuel tank. location on the diesel fuel tank and center punch the three holes.
  • Page 43 Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank...

  • Page 44: Installing The Fuel Pickup Tube Into A Plastic Tank

    Installing the Fuel Pickup Tube Into a Plastic Tank 3. Cut the end of the pickup tube so approximately 25 mm (1.00 in.) is DANGER: Diesel fuel vapors are potentially explosive. Use above the bottom of the fuel tank. extreme caution when drilling in or around the diesel fuel tank. 4.
  • Page 45 Installing the Fuel Pickup Tube Into a Plastic Tank...

  • Page 46: Installing The Steel Fuel Tank

    Installing the Steel Fuel Tank 2. Install each fuel tank mounting bracket securely onto the truck’s frame DANGER: An improperly installed fuel tank could lead to serious with two, 1/2 -13, Grade 5 bolts, flat washers and locking nuts. injury or death! Consult your truck’s chassis manufacturer for Substitutions are not acceptable! specific details on proper fuel tank installation and recommendations.
  • Page 47 Installing the Steel Fuel Tank...

  • Page 48: Installing The Aluminum Fuel Tank (Option)

    Installing the Aluminum Fuel Tank (OPTION) 2. Install each fuel tank mounting bracket securely onto the truck’s frame DANGER: An improperly installed fuel tank could lead to serious with two, 1/2 -13, Grade 5 bolts, flat washers and locking nuts. injury or death! Consult your truck’s chassis manufacturer for Substitutions are not acceptable! specific details on proper fuel tank installation and...
  • Page 49 Installing the Aluminum Fuel Tank (OPTION)

  • Page 50: Installing The Fuel Pump And Fuel Lines

    Installing the Fuel Pump and Fuel Lines NOTE: See following pages for T-1200R Inter-modal 5. Remove the protective plugs from each of the fuel pick up tubes on the fuel tank and install fuel line fittings. DANGER: The Thermo King fuel pump should be installed onto 6.
  • Page 51 Installing the Fuel Pump and Fuel Lines Note: Example shown here is for a Steel Tank.

  • Page 52: Installing The Fuel Pump And Fuel Lines (T-1200R Inter-Modal)

    Installing the Fuel Pump and Fuel Lines (T-1200R Inter-modal) 5. Remove the protective plugs from each of the fuel pick up tubes on the DANGER: The Thermo King fuel pump should be installed onto fuel tank and install fuel line fittings. the supplied mounting bracket.
  • Page 53 Installing the Fuel Pump and Fuel Lines (T-1200R Inter-modal...

  • Page 54: Installing The Hmi Controller

    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.
  • Page 55 Installing the HMI Controller NOTE: HMI with LED Display shown, HMI with Graphics Display installs the same. NOTE: T-1200R Inter-modal only.

  • Page 56: Installing The Servicewatch™ Download Port (Option Emeia)

    Installing the ServiceWatch™ Download Port (Option EMEIA) 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.
  • Page 57 Installing the ServiceWatch™ Download Port (Option EMEIA)

  • Page 58: Cargowatch Sensor Locations

    CARGOWATCH Sensor Locations Sensor Location Recommendations 5. Secure Sensor in place with appropriate Clamps. SENSOR WIRE SPLICE European Applications SP1 & SN1 Each cargo area requires a minimum of two sensors. SN2 & SN2 SP3 & SN3 1. Sensor #1 located in the evaporator side return opening near unit return air sensor (factory installed).

  • Page 59: Installing The Remote Power Receptacle (Option)

    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.
  • Page 60 Installing the Remote Power Receptacle (OPTION)

  • Page 61: Installing The Battery Box

    Installing the Battery Box OPTION TSA 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.
  • Page 62 Installing the Battery Box (OPTION TSA)

  • Page 63: Battery Connections

    Battery Connections TSA Option Fuel Pump Harness 3. Route and connect the fuel pump harness to the fuel pump. CAUTION: All battery connections and electrical wires must be properly routed and secured to prevent rubbing, chafing or making Negative Cable contact with sharp, moving or hot components.
  • Page 64 Battery Connections...

  • Page 65: Installing The Door Switch (Option)

    Installing the Door Switch (OPTION) 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. Door Switch Components IMPORTANT INSTALLATION NOTES: •...

  • Page 66: Unit Check List

    UNIT CHECK LIST UNIT CHECK LIST MULTI-TEMP UNITS (REMOTE EVAPORATORS) Visually inspect the unit for transit and handling damage. File claim Check evaporator(s) sections for cleanliness. with delivery carrier. Leak test interconnecting tubing. Install the unit as outlined in the Thermo King Installation Manual. Check for damage, loose or missing bolts and hardware on remote If the unit has a separate fuel tank add 10 gallons of fuel to the tank.
  • Page 67 UNIT CHECK LIST (continued) Observe and record refrigerant operating pressures in relation to Remove the compartment bulk head(s) if equipped. ambient and box temperatures. Set the unit for continuous run. Continue to run the unit with the back Verify the readings above are correct for the conditions. doors open, alternating between high speed cool and heat until at least 6 hours (10 hours preferred) are shown on the engine run time When box reaches 32 F (0 C) check calibration of thermostat,...

This manual is also suitable for:

Thermo king t-dairyThermo king t-570rThermo king t-600Thermo king t-600rThermo king t-800Thermo king t-800r ... Show all

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