Ingersoll-Rand THERMO KING Trailer Precedent S-600 Installation Manual
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Ingersoll-Rand THERMO KING Trailer Precedent S-600 Installation Manual

Ingersoll-Rand THERMO KING Trailer Precedent S-600 Installation Manual

Single temperature systems
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Installation Manual
Trailer Edition
Precedent S-600 and S-700
Single Temperature Systems
TK 55496-2-IM (Rev. 3, 02/13)

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Summary of Contents for Ingersoll-Rand THERMO KING Trailer Precedent S-600

  • Page 1 Installation Manual Trailer Edition Precedent S-600 and S-700 Single Temperature Systems TK 55496-2-IM (Rev. 3, 02/13)
  • Page 2 Installation Manual Trailer Edition ™ Precedent S-600 and S-700 Single Temperature Systems TK 55496-2-IM (Rev. 3, 02/13) Copyright© 2012 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 3 Release History Released (11/12) Rev. 1 (11/12) Pages 60-61; Changed bulkhead mounting screw lengths. Rev. 2 (01/13) Pages 14-15; added dimensions for SmartPower option, pages 20-21; added base to lifting bar, page 42; added important note regarding using the correct fuel fittings, pages 66-67; added additional mounting screw inside the unit to secure bottom pan.
  • Page 4 Introduction This manual was written to assist with the installation of the Thermo King Precedent S-600 and S-700 Single Temperature refrigeration systems onto trailers specifically designed and built for refrigerated applications. Due to its complexity, you should not attempt this installation unless you: •...

  • Page 5: Installation Summary For Precedent S-600 And S-700 Systems

    Installation summary for Precedent S-600 and S-700 Systems The Precedent installs the same as the current SB with the following 8. The Ultrasonic Fuel Level Sensor harness (TK Supplied) will need to be exceptions: routed from the fuel tank to the bottom of the unit through the same conduit or chase (see #6) as the fuel pump harness.

  • Page 6: Table Of Contents

    Table of Contents Installation summary for Precedent S-600 and S-700 Systems ..4 Installing the Unit .........32 Safety Precautions.

  • Page 7: 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 8 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 9: Trailer Requirements

    Trailer Requirements Approximate Weight of Precedent transport temperature control units: S-600 and S-700 = 842 kg (1857 lbs.) with SmartPower 12 HP/230V = 946 kg (2086 lbs.) with SmartPower 12 HP/460V = 962 kg (2121 lbs.) with SmartPower 19 HP/460V = 962 kg (2121 lbs.) Front Wall Requirements Fuel Tank Mounting DANGER: The front wall of the trailer must be structurally...

  • Page 10: Swing Radius And King Pin Requirements

    Swing Radius and King Pin Requirements...

  • Page 11: Evaporator Opening Requirements

    Evaporator Opening Requirements Evaporator Opening DANGER: The front trailer wall must be structurally strong enough to support the weight of the refrigeration unit! IMPORTANT: The location of the unit mounting bolts and evaporator opening in the front wall is critical. VERIFY ALL DIMENSIONS BEFORE INSTALLING UNIT! NOTE: It may be necessary to relocate the trailer’s front corner clearance lights to the corner radius of the trailer to prevent damage.
  • Page 12 Evaporator Opening Requirements NOTE: The Precedent unit is 152.4 mm (6.00 in.) wider than the SB. Verify adequate clearance is available for trailer fresh air exchange doors if applicable...

  • Page 13: Mounting Hardware Requirements

    Mounting Hardware Requirements Mounting Bolts Mounting Bolt Specifications DANGER: Eight mounting bolts must be installed to properly DANGER: The use of mounting bolts other than those secure the unit to the trailer front wall! Failure to do so could specified could result in severe damage to equipment, void result in severe damage to equipment, void the warranty or the warranty or cause personal injury or death! cause personal injury or death!
  • Page 14 Mounting Hardware Requirements NOTE: Depending on your particular installation, these two mounting bolts lengths may need to be trimmed to 57.20 mm (2.25 in.) long or they may interfere with the back of the control box and engine.

  • Page 15: Unit Dimensions

    Unit Dimensions...
  • Page 16 Unit Dimensions...

  • Page 17: Bulkhead Dimensions (Option)

    Bulkhead Dimensions (Option) THERMO KING RECOMMENDS USING A BULKHEAD Contact your Thermo King Dealer for specific part number Bulkhead Function Return Airflow A bulkhead is used to keep the return airflow from being restricted if the Restrictions of the return airflow adversely affects the performance of the load shifts.
  • Page 18 Bulkhead Dimensions (Option)

  • Page 19: Battery Selection Guide

    Battery Selection Guide Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance options. CAUTION: Do not connect other manufacturer’s equipment or accessories to the Thermo King unit! This could result in Trailer units are designed for one 12 volt, Group 31 battery supplied by the severe damage to equipment and void the warranty! installer.

  • Page 20: Group 31 Battery Dimensions

    Group 31 Battery Dimensions...

  • Page 21: Lifting Bar Dimensions

    Lifting Bar Dimensions IMPORTANT: Use forged clevis and pins, forged chain links and WARNING: Thermo King requires a 2 point lifting bar to safely forged locking hooks with strength equal to total lift capacity of hoist lift and install units. A lifting bar can be made from the mechanism and that meet all safety standards.
  • Page 22 Lifting Bar Dimensions NOTE: These instructions are provided for fabricating the lifting bar used to install Precedent units. Thermo King is not the manufacturer of the lifting bar and is not responsible for material used or failure of this lifting device.

  • Page 23: Surface Mounted Status Light Dimensions (Option)

    Surface Mounted Status Light Dimensions (Option) Contact your Thermo King Dealer for specific part numbers Standard Display and Fuel Combo Display Triple Combo Display...

  • Page 24: Flush Mounted Status Light Opening Dimensions (Option)

    Flush Mounted Status Light Opening Dimensions (Option) Contact your Thermo King Dealer for specific part numbers NOTE: Dimensions shown will accommodate the flush mounted Standard Display, Standard and Fuel Combo Display and Triple Combo Display.

  • Page 25: Rear Remote Controller Dimensions (Option)

    Rear Remote Controller Dimensions (Option) Contact your Thermo King Dealer for specific part numbers...

  • Page 26: Door Switch Dimensions (Option)

    Door Switch Dimensions (Option) Contact your authorized Thermo King Dealer for specific part numbers...

  • Page 27: Required Tools For Installation

    Required Tools for Installation 1. 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 (5/8-11) 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.
  • Page 28 Required Tools for Installation...

  • Page 29: Installation Components

    Installation Components 1. Unit Mounting Kit 2. Defrost Drain Tube Kit 3. Fuel Pump Kit 4. Top Covers and Bottom Pan Kit 5. Battery Mounting Kit 6. UFLS Harness Kit 7. Top Fairing Kit (Option on some models) 8. (OPTION) SmartPower Kit...
  • Page 30 Installation Components (Option on some models)

  • Page 31: Unpacking The Unit

    Unpacking the Unit Unpacking the Unit WARNING: Thermo King requires a 2 point lifting bar to safely lift and install the unit. see “Lifting Bar Dimensions” on page • Carefully remove plastic stretch wrap from unit. 20 and 21. • Carefully remove the top cardboard cover.
  • Page 32 Unpacking the Unit...

  • Page 33: Installing The Unit

    Installing the Unit Access to Mounting Bolts (Detail II) WARNING: Do not use a forklift to install the unit! This could result in severe damage to equipment, void the warranty or a. Top side mounting hole through the hinged roadside grille. cause personal injury or death! b.
  • Page 34 Installing the Unit...

  • Page 35: Installing The Drain Hoses

    Installing the Drain Hoses Installation 1. Drain hoses should run straight down the trailer wall from each side of the unit with no kinks or bends. 2. Secure with screws and clamps provided in installation kit. 3. Cut off excess hose and attach drain hose check valves provided in installation kit.
  • Page 36 Installing the Drain Hoses...

  • Page 37: Installing The Fuel Tank - 50 Gallon, 22'' Dia., Aluminum (Option)

    Installing the Fuel Tank - 50 Gallon, 22'' Dia., Aluminum (Option) OPEN STYLE TANK MOUNTING BRACKET IMPORTANT FUEL TANK INSTALLATION INFORMATION A. Fuel Tank Position • Thermo King recommends the fuel tank be mounted 203.2 mm DANGER: An improperly installed fuel tank could lead to (8.00 in.) under the trailer as shown.
  • Page 38 Installing the Fuel Tank - 50 Gallon, 22'' Dia., Aluminum (Option) OPEN 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) NOTE: Location of mounting holes may change if other trailer options are added.
  • Page 39 Installing the Fuel Tank - 50 Gallon, 22'' Dia., Aluminum (Option) OPEN STYLE TANK MOUNTING BRACKET Fuel Tank Installation NOTE: 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.
  • Page 40 Installing the Fuel Tank - 50 Gallon, 22'' Dia., Aluminum (Option) OPEN STYLE TANK MOUNTING BRACKET NOTE: Location of mounting holes may change if other trailer options are added. IMPORTANT: The fuel tank filler must be positioned straight up and down +/- 5 degrees for the Ultrasonic Fuel Level Open Style Bracket Sensor (UFLS) to read fuel level...

  • Page 41: Installing The Fuel Pump And Harness

    Installing the Fuel Pump and Harness Fuel Pump Installation Fuel Pump Harness Installation NOTE: The fuel pump must be installed in a location above the fuel DANGER: Do not route electrical wires with fuel lines as this tank in an area that protects it from road debris and allows for routine could cause a fire! filter removal.
  • Page 42 Installing the Fuel Pump and Harness Allow clearance for filter bowl removal NOTE: The fuel pump must be installed in a location above the fuel tank in an area that protects it from road debris and allows for routine filter bowl removal.

  • Page 43: Installing The Fuel Lines

    Installing the Fuel Lines Important Installation Requirements Fuel Line Installation 1. Route a fuel supply line from the fuel pump’s INLET fitting to the fuel DANGER: Leaking fuel lines could cause a fire resulting in pickup fitting on the fuel tank. death or serious injury! All fuel line fittings must be tight and leak free! •...
  • Page 44 Installing the Fuel Lines...

  • Page 45: Installing The Ufls Harness

    Installing the UFLS Harness “Solid State” Ultrasonic Fuel Level Sensor (UFLS) IMPORTANT: All electrical connections of the UFLS harness must be made with the supplied crimp and solder style connectors with separate heat shrink tubing. DO NOT burn the heat shrink. If the heat shrink is burnt, charred, or has bubbles from overheating, the wire connections must be removed and redone correctly.
  • Page 46 Installing the UFLS Harness “Solid State” Ultrasonic Fuel Level Sensor (UFLS) Connections inside Connections at Control Box Sensor BLACK to FUELN-01 BLACK to BLACK WHITE to FUEL-01 WHITE to YELLOW GREEN to 8F-01 GREEN to RED...

  • Page 47: Installing The Status Light (Option)

    Installing the Status Light (Option) Installation NOTE: If all CAN ports are occupied use the CAN extender Harness available from your Thermo King Dealer. NOTE: Surface mounted status light installation shown. Flush • Be sure the connectors are locked securely in place on the circuit mounted light installs into recessed opening (see “Flush Mounted board.
  • Page 48 Installing the Status Light (Option)

  • Page 49: Installing The Rear Remote Controller (Option)

    Installing the Rear Remote Controller (Option) Foamed-In-Place Installation Harness Connections 7. Apply Superlube (or equivalent) to Remote Controller Harness NOTE: Verify mounting location and all dimensions before installing connector and attach securely to back of controller. Route harness the remote controller. through chase.
  • Page 50 Installing the Rear Remote Controller (Option)
  • Page 51 Installing the Rear Remote Controller (Option) Retro-Fit Installation NOTE: Verify mounting location and all dimensions before installing Harness Connections the remote controller. 4. Apply Superlube (or equivalent) to Remote Controller Harness DANGER: Do not route electrical harness together with fuel connector and attach securely to back of controller.
  • Page 52 Installing the Rear Remote Controller (Option)

  • Page 53: Installing The Door Switch (Option)

    Installing the Door Switch (Option) When installing CargoLink wireless door switches, see TK 55151 CargoLink Installation Manual NOTE: These instructions (pages 52-55) are intended as reference IMPORTANT INSTALLATION NOTES: guide only to assist with a typical hard wired door switch installation. •...
  • Page 54 Installing the Door Switch (Option) Right Angle Mounting Top x Top Mounting Side x Side Mounting...
  • Page 55 Installing the Door Switch (Option) Contact your Thermo King Dealer for specific part numbers NOTE: The Door Switch Harness Connectors are located at the rear of the unit (See DETAIL C). Single Door Switch Activation / Single Zone (Detail A) Multiple Door Switch Activation / Single Zone (Detail B) 1.
  • Page 56 Installing the Door Switch (Option) 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 Interface Harness Wiring Door Switch Wiring RED = (12 Vdc) POWER RED = (12 Vdc) POWER...

  • Page 57: Cargowatch™ Sensor Locations (Option)

    CargoWatch™ Sensor Locations (Option) Sensor locations for Domestic Applications as required by customer 1. Sensor #1 is located in the evaporator side return opening near unit return air sensor (factory installed). 2. Sensor #2 location as required by customer.
  • Page 58 CargoWatch™ Sensor Locations (Option)

  • Page 59: Connecting The Cargowatch™ Sensors (Option)

    Connecting the CargoWatch™ Sensors (Option) NOTE: ONLY CargoWatch Sensors Can Be Used CONNECTING SENSORS 6. Insert BLACK pin connector and wire into correct connection until it locks into position (Detail I). The wire side of the connector is shown. NOTE: The sensor are not polarity sensitive. SENSOR PLUGS 1.
  • Page 60 Connecting the CargoWatch™ Sensors (Option)

  • Page 61: Installing The Precedent Bulkhead (Option)

    Installing the Precedent Bulkhead (Option) THERMO KING RECOMMENDS USING A BULKHEAD Contact your Thermo King Dealer for specific part numbers of bulkhead and mounting hardware. Installation CAUTION: Do not drill holes into refrigeration, electrical or mechanical components or severe damage to the equipment will result! 1.
  • Page 62 Installing the Precedent Bulkhead (Option) Typical trailer wall support posts. Three long mounting screws on each side. Cut the side flanges to activate the hinge feature. For evaporator service, remove the screws on each side securing the top portion of the bulkhead and fold down. Five short mounting screws along bottom.

  • Page 63: Installing The Power Receptacle (Option)

    Installing the Power Receptacle (Option) Power Receptacle Installation Optional SmartPower units have the power receptacle and cable factory wired and secured inside the unit with tie bands for shipment. 1. Remove tie bands securing receptacle to unit. • Attach receptacle bracket under the roadside of the unit with the two supplied screws.
  • Page 64 Installing the Power Receptacle (Option)

  • Page 65: Installing The Battery

    Installing the Battery Important Battery Information Battery Installation IMPORTANT: See Safety Precautions - “Battery Installation and Cable IMPORTANT: Care should be taken to prevent direct metal contact to Routing” on page 7 for additional information. the battery’s positive post when installing the battery. 1.
  • Page 66 Installing the Battery...

  • Page 67: Installing The Top Covers, Top Fairing And Bottom Pan

    Installing the Top Covers, Top Fairing and Bottom Pan Top Covers Bottom Pan 1. Position the Roadside and Curbside covers onto the top of the unit and 3. Position the bottom pan under the unit and align the mounting holes align the mounting holes with the holes in the frame.
  • Page 68 Installing the Top Covers, Top Fairing and Bottom Pan NOTE: The Top Fairing increase the height of the unit by approximately 76 mm (3.00 in.). Tractor trailer height restrictions differ from state to state. The total height of the unit installed onto your particular trailer should not exceed these height restrictions.
  • Page 69 STOP Only trained and qualified individuals should operate the unit. Refer to Precedent Operators Manual TK 55538-2-OP High Voltage Safety Precautions Unit Fan Operation Safety Precautions DANGER: High voltage is present whenever the unit is DANGER: The unit’s Condenser fans and Evaporator fans may operating on either diesel or electric standby power.
  • Page 70 STOP Only trained and qualified individuals should operate the unit. Refer to Precedent Operators Manual TK 55538-2-OP Condenser Motors Evaporator Motor High Voltage Evaporator Motor Heater Strips (across coil) High Voltage Distribution Box High Voltage Junction Box High Voltage Control Box All high voltage wiring is identified by Electric Standby Motor AC Generator...

  • Page 71: Priming The Fuel Pump And Programming The Controller

    Priming the Fuel Pump and Programming the Controller Priming the Fuel Pump Programming the SR-4 Controller for Fuel Level NOTE: These procedures can also be done through OptiSet™ The Precedent unit is equipped with a remote fuel pump near the fuel tank. This fuel pump needs to be primed and the fuel system bled of air before Programming Procedures the diesel engine can be started for the first time.

  • Page 72: 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, fuel tank, fuel pump and lines as outlined in the Check for damage, loose or missing bolts and hardware on remote Thermo King Installation Manual.
  • Page 73 UNIT CHECK LIST START AND RUN UNIT MULTI-TEMP UNITS (On Multi-temp units start only the host unit) Install the compartment bulk head(s) if equipped. Check for proper oil pressure, coolant temperature, oil, fuel, or Check for correct rotation of remote evaporator fans. coolant leaks.
  • Page 74 UNIT CHECK LIST ELECTRIC STANDBY OPERATIONAL CHECKS STOP UNIT Test AC electrical contacts and connections by connecting to AC On Multi-temp units leak test interconnecting tubing. power and running. Check and readjust all belt tensions using TK belt gauge 204-427. Check for correct electric motor rotation.
  • Page 76 Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy efficient heating, ventilating and air conditioning systems, building and contracting services, parts support and advanced controls for commercial buildings and homes. ©2012 Ingersoll-Rand Company Printed in U.S.A. on Recycled Paper...

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Thermo king trailer precedent s-700

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