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Trane Technologies THERMO KING UT-1290 Installation Manual

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Installation Manual
UT–1290
Single Temperature Systems
Revision A
T T K K 5 5 7 7 2 2 3 3 2 2 - - 1 1 - - I I M M - - E E N N
November 2023

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  • Page 1 Installation Manual UT–1290 Single Temperature Systems Revision A T T K K 5 5 7 7 2 2 3 3 2 2 - - 1 1 - - I I M M - - E E N N November 2023...
  • Page 2 Your feedback will help improve our manuals. The survey is accessible through any internet-connected device with a web browser. Scan the Quick Response (QR) code or click Technical Publications TK Americas Feedback to complete the survey. ©2023 Trane Technologies TK 57232-1-IM-EN...

  • Page 3: Table Of Contents

    Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ................................5 5 Danger, Warning, Caution, and Notice .
  • Page 4 T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Transverse Drain (Option) ..............30 Evaporator Cap Plugs .

  • Page 5: Danger, Warning, Caution, And Notice

    Safety Precautions Danger, Warning, Caution, and Notice Safety advisories appear throughout this manual as required. Your personal safety and the proper installation of this unit depend upon the strict observance of these precautions. The four types of advisories are defined as follows: D D a a n n g g e e r r H H a a z z a a r r d d ! ! I I n n d d i i c c a a t t e e s s a a n n i i m m m m i i n n e e n n t t l l y y h h a a z z a a r r d d o o u u s s s s i i t t u u a a t t i i o o n n w w h h i i c c h h , , i i f f n n o o t t a a v v o o i i d d e e d d , , w w i i l l l l r r e e s s u u l l t t i i n n d d e e a a t t h h o o r r s s e e r r i i o o u u s s i i n n j j u u r r y y .

  • Page 6: Refrigerant Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W a a r r n n i i n n g g H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! ! N N e e v v e e r r c c l l o o s s e e t t h h e e c c o o m m p p r r e e s s s s o o r r d d i i s s c c h h a a r r g g e e s s e e r r v v i i c c e e v v a a l l v v e e w w h h e e n n t t h h e e u u n n i i t t i i s s o o p p e e r r a a t t i i n n g g .
  • Page 7 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W a a r r n n i i n n g g E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e a a n n d d R R i i s s k k o o f f I I n n j j u u r r y y ! ! I I m m p p r r o o p p e e r r l l i i f f t t i i n n g g o o f f a a r r e e f f r r i i g g e e r r a a t t i i o o n n u u n n i i t t d d u u r r i i n n g g i i n n s s t t a a l l l l a a t t i i o o n n c c a a n n b b e e d d a a n n g g e e r r o o u u s s .

  • Page 8: Fuel System Component Installation Hazards

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Fuel System Component Installation Hazards D D a a n n g g e e r r C C o o m m b b u u s s t t i i b b l l e e H H a a z z a a r r d d ! ! A A n n i i m m p p r r o o p p e e r r l l y y i i n n s s t t a a l l l l e e d d f f u u e e l l p p u u m m p p o o r r f f u u e e l l l l i i n n e e s s c c o o u u l l d d l l e e a a d d t t o o s s e e r r i i o o u u s s i i n n j j u u r r y y o o r r d d e e a a t t h h .

  • Page 9: First Aid

    S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W a a r r n n i i n n g g F F i i r r e e H H a a z z a a r r d d ! ! D D o o n n o o t t a a t t t t a a c c h h f f u u e e l l l l i i n n e e s s t t o o b b a a t t t t e e r r y y c c a a b b l l e e s s o o r r e e l l e e c c t t r r i i c c a a l l h h a a r r n n e e s s s s e e s s .
  • Page 10 S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Take IMMEDIATE action after a person has received an electrical shock. Get quick medical assistance, if possible. The source of the shock must be quickly stopped, by either shutting off the power or removing the victim.

  • Page 11: Condenser Dimensions

    Dimensions Condenser Dimensions Unit Weight = 454 kg (1001 lb.) 63.31 in (1608 mm) 24.96 in (634 mm) 28.32 in (719.3 mm) 19.44 in (493.7 mm) 18.90 in (480 mm) 19.62 in (498.4 mm) 58.58 in (1488 mm) 25.13 in (638.4 mm) 8.52 in (216.4 mm) 1.23 in (31.3 mm) 5.12 in (130.1 mm)

  • Page 12: Evaporator Dimensions And Weights

    D D i i m m e e n n s s i i o o n n s s Evaporator Dimensions and Weights Figure 1. S-3 + S-3 Dimensions and Weights 17.7 mm (0.70 in.) 1094.0 mm 1094.0mm 193.9 mm (43.07 in.) (43.07 in.) (7.63 in.)

  • Page 13: E-Evap (Funnel Evap) Dimensions

    D D i i m m e e n n s s i i o o n n s s E-Evap (Funnel Evap) Dimensions Unit Weight = 63.5 (140 lbs) E-Evap (Funnel Evap) Tilt Mount Dimensions Unit Weight = 63.5kg (140 lbs.) TK 57232-1-IM-EN...

  • Page 14: Battery Box Dimensions (Option)

    D D i i m m e e n n s s i i o o n n s s Battery Box Dimensions (Option) Figure 2. Battery Box Dimensions HMI Controller Dimensions Figure 3. Premium HMI Controller Shown 189.0 mm 60 mm (7.44 in.) (2.36 in.)

  • Page 15: Evaporator Location

    Important Installation Notes I I m m p p o o r r t t a a n n t t : : Please refer to (“Safety Precautions,” p. 5) prior to installing and servicing this product. Evaporator Location • The best airflow is achieved when the evaporator is installed an equal distance from each side wall.

  • Page 16: Door Curtains

    I I m m p p o o r r t t a a n n t t I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e s s Door Curtains It is always recommended to use good quality insulated curtains on all doors to limit the amount of warm, moist air from entering the load space during door openings.
  • Page 17 I I m m p p o o r r t t a a n n t t I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e s s RCS1147 5.
  • Page 18 I I m m p p o o r r t t a a n n t t I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e s s VIII RCS1149 10.

  • Page 19: Removing The Holding Charge

    I I m m p p o o r r t t a a n n t t I I n n s s t t a a l l l l a a t t i i o o n n N N o o t t e e s s Removing the Holding Charge I I m m p p o o r r t t a a n n t t : : Safety precautions must be followed.
  • Page 20 Required Tools 1. Safety Glasses 2. Drill 3. Drill Bits 4. Tape Measure 5. Mechanics Tools 6. Lifting Bar (Thermo King design) with forged links, clevises and pins. 7. Work Platform (recommended) Figure 4. Required Tools Shown RCS1081-3 TK 57232-1-IM-EN...
  • Page 21 Condensing Unit Installation Components N N o o t t e e : : The following installation components are provided to complete a standard condensing unit installation. Customer ordered options are not shown. Electric Fuel Pump Band Wraps (3 sizes) Preformed Evaporator Drain Hose Fuel Pump Harness Self-Tapping Screws...
  • Page 22 Uncrating Condenser W W a a r r n n i i n n g g E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e a a n n d d R R i i s s k k o o f f I I n n j j u u r r y y ! ! ! ! L L i i f f t t i i n n g g e e y y e e b b o o l l t t s s m m u u s s t t b b e e m m a a d d e e o o f f f f o o r r g g e e d d s s t t e e e e l l a a n n d d a a m m i i n n i i m m u u m m M M 1 1 2 2 o o r r 1 1 / / 2 2 i i n n c c h h d d i i a a m m e e t t e e r r .

  • Page 23: U U N N C C R R A A T T I I N N G G C C O O N N D D E E N N S S E E R

    U U n n c c r r a a t t i i n n g g C C o o n n d d e e n n s s e e r r TK 57232-1-IM-EN...
  • Page 24 Installing Condenser D D a a n n g g e e r r E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e a a n n d d R R i i s s k k o o f f I I n n j j u u r r y y ! ! M M o o u u n n t t t t h h e e c c o o n n d d e e n n s s e e r r o o n n l l y y t t o o t t h h e e t t r r u u c c k k b b o o x x s s u u p p p p o o r r t t c c h h a a n n n n e e l l s s .

  • Page 25: I I N N S S T T A A L L L L I I N N G G C C O O N N D D E E N N S S E E R

    I I n n s s t t a a l l l l i i n n g g C C o o n n d d e e n n s s e e r r TK 57232-1-IM-EN...
  • Page 26 Installing Fuel Pump and Fuel Lines I I m m p p o o r r t t a a n n t t : : Refer to (“Safety Precautions,” p. 5) before proceeding. 1. Install fuel pump as close to fuel tank as possible and no more than 762 mm (30.00 in.) above the fuel in fuel tank. I I m m p p o o r r t t a a n n t t : : Some installations will require the fuel pump harness to be extended.

  • Page 27: Components Shipped With S-3 Evaporators

    S-3 + S-3 Evaporators Components Shipped with S-3 Evaporators 1. Pre-Bent Tubes 2. Pre-formed Drain Hose 3. Hose Clamps 4. Water Drain Pipe 5. Water Drain Elbows 6. Terminal Forks 7. Terminal Rings 8. Refrigeration Oil 9. Mounting Spacers (3 sizes) 10.

  • Page 28: S S - - 3 3 + + S S - - 3 3 E E V V A A P P O O R R A A T T O O R R S

    S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s TK 57232-1-IM-EN...

  • Page 29: Defrost Drain Tube Connectors

    S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Defrost Drain Tube Connectors I I m m p p o o r r t t a a n n t t : : Follow the instructions below to prevent defrost drain tube water leaks.

  • Page 30: Transverse Drain (Option)

    S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Transverse Drain (Option) I I m m p p o o r r t t a a n n t t : : A transverse drain is required to drain on one side toward the front or back of the truck. Figure 6.

  • Page 31: Refrigeration Tubing Connections

    S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Refrigeration Tubing Connections W W a a r r n n i i n n g g H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! ! R R e e g g u u l l a a t t o o r r s s u u s s e e d d o o n n b b o o t t t t l l e e s s o o f f n n i i t t r r o o g g e e n n g g a a s s m m u u s s t t b b e e e e q q u u i i p p p p e e d d w w i i t t h h r r e e l l i i e e f f v v a a l l v v e e s s .
  • Page 32 S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s HG = Hot Gas S = Suction L= Liquid TK 57232-1-IM-EN...

  • Page 33: Wire Connections

    S S - - 3 3 + + S S - - 3 3 E E v v a a p p o o r r a a t t o o r r s s Wire Connections I I m m p p o o r r t t a a n n t t : : Refer to (“Safety Precautions,”...

  • Page 34: Es Evaporator Installation

    ES Evaporator ES Evaporator Installation 1. Fit the template according to the instructions given. 2. Mark the position of the drilled holes. Avoid any possible interference with electrical wires and parts of the vehicle chassis. 3. Drill blind holes to screw the evaporator unit in place. Screw in the bolts and washers supplied for the ceiling. Do not tighten.
  • Page 35 E E S S E E v v a a p p o o r r a a t t o o r r TK 57232-1-IM-EN...

  • Page 36: Installing E-Evap (Tilt Mount)

    E-Evap (Funnel) Evaporator (Tilt Mount) Installing E-Evap (Tilt Mount) N N o o t t e e s s : : 1. The ceiling must be flat and the mounting locations correct for proper evaporator installation and operation. 2. Thermo King recommends installing the evaporator with 12mm (1/2 in.) bolts or studs. 1.
  • Page 37 E E - - E E v v a a p p ( ( F F u u n n n n e e l l ) ) E E v v a a p p o o r r a a t t o o r r ( ( T T i i l l t t M M o o u u n n t t ) ) DETAIL I DETAIL II DETAIL III...

  • Page 38: Refrigeration Tubing Connection

    E E - - E E v v a a p p ( ( F F u u n n n n e e l l ) ) E E v v a a p p o o r r a a t t o o r r ( ( T T i i l l t t M M o o u u n n t t ) ) Refrigeration Tubing Connection W W a a r r n n i i n n g g H H a a z z a a r r d d o o f f E E x x p p l l o o s s i i o o n n ! !

  • Page 39: Electrical Connections

    E E - - E E v v a a p p ( ( F F u u n n n n e e l l ) ) E E v v a a p p o o r r a a t t o o r r ( ( T T i i l l t t M M o o u u n n t t ) ) HG = Hot Gas S = Suction L= Liquid...
  • Page 40 E E - - E E v v a a p p ( ( F F u u n n n n e e l l ) ) E E v v a a p p o o r r a a t t o o r r ( ( T T i i l l t t M M o o u u n n t t ) ) CH-10 DETAIL I DTN-01...
  • Page 41 HMI Controller Installation I I m m p p o o r r t t a a n n t t : : HMI should be installed in an area inside the cab that is accessible to the driver while not interfering with the safe operation of the truck.
  • Page 42 HMI Remote Control Box Installation (OPTION) N N o o t t e e : : 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 rubber grommets must be used when routing harness through sheet metal holes.

  • Page 43: H H M M I I R R E E M M O O T T E E C C O O N N T T R R O O L L B B O O X X I I N N S S T T A A L L L L A A T T I I O O N N ( ( O O P P T T I I O O N

    H H M M I I R R e e m m o o t t e e C C o o n n t t r r o o l l B B o o x x I I n n s s t t a a l l l l a a t t i i o o n n ( ( O O P P T T I I O O N N ) ) Figure 9.
  • Page 44 Battery Connections I I m m p p o o r r t t a a n n t t : : Refer to (“Safety Precautions,” p. 5) before proceeding. I I m m p p o o r r t t a a n n t t : : Battery cables must be routed in split loom protective sleeving with no kinks or sharp bends. N N o o t t e e : : Thermo King units are designed for one 12 volt, group 31 battery.

  • Page 45: B B A A T T T T E E R R Y Y C C O O N N N N E E C C T T I I O O N N S

    B B a a t t t t e e r r y y C C o o n n n n e e c c t t i i o o n n s s 10.00” (254mm) SPLICE WIRES TOGETHER AS SHOWN BELOW RCS1085-4 .50”...

  • Page 46: Tracking (Option)

    Auxiliary Electrical Accessories Thermo King does not recommend adding any auxiliary electrical accessories to the electrical system of a T-590, T-690, T-890 or T-1090 series units equipped with SR-3 controllers and Tier 4 engines unless approved by Thermo King. TracKing (OPTION) Units equipped with the factory installed TracKing option requires additional procedures to activate the system.

  • Page 47: System Leak Check

    System Leak Check Procedures System Leak Check Set–Up Unit Place SR-3 control system in evacuation mode to leak check, evacuate, and charge unit. With the control system in evacuation mode, all solenoid valves in the refrigeration system are open. This allows the refrigeration system to be properly evacuated.

  • Page 48: System Evacuation

    S S y y s s t t e e m m L L e e a a k k C C h h e e c c k k P P r r o o c c e e d d u u r r e e s s Evaporator Coil Dehydrator (Filter-Drier) Discharge Service Valve (DSV)
  • Page 49 S S y y s s t t e e m m L L e e a a k k C C h h e e c c k k P P r r o o c c e e d d u u r r e e s s 7.

  • Page 50: System Charging

    S S y y s s t t e e m m L L e e a a k k C C h h e e c c k k P P r r o o c c e e d d u u r r e e s s Two Stage Vacuum Pump To AC Power Micron Gauge...

  • Page 51: Final System Charge

    S S y y s s t t e e m m L L e e a a k k C C h h e e c c k k P P r r o o c c e e d d u u r r e e s s 9.

  • Page 52: Commissioning Form Overview

    Commissioning and PDI Forms Commissioning Form Overview All self-powered truck units come with the Commissioning Form (TK 56640) included in the documents package. This form is also available online at Thermo King ReqDirect. By completing the Commissioning Form, the i i n n s s t t a a l l l l e e r r confirms the installation was done per Thermo King’s Installation Manual and the unit operates as it should.
  • Page 53 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 10.
  • Page 54 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 11.
  • Page 55 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 12.

  • Page 56: Pre-Delivery Inspection (Pdi) Form Overview

    C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Pre-Delivery Inspection (PDI) Form Overview PDI Form (TK 56641) is also included in the documents package of all vehicle powered truck units.
  • Page 57 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 13.
  • Page 58 C C o o m m m m i i s s s s i i o o n n i i n n g g a a n n d d P P D D I I F F o o r r m m s s Figure 14.
  • Page 59 N N o o t t e e s s TK 57232-1-IM-EN...
  • Page 60 Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable transport temperature control solutions. Thermo King has been providing transport temperature control solutions for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since 1938.

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