Thermo King HK-430 Installation Manual
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Thermo King HK-430 Installation Manual

Trailer edition diesel units
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Installation Manual
Trailer Edition
HK-430 and HK-430 HO
Diesel Heating Units
TK 55186-2-IM (Rev. 0, 09/11)

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Summary of Contents for Thermo King HK-430

  • Page 1 Installation Manual Trailer Edition HK-430 and HK-430 HO Diesel Heating Units TK 55186-2-IM (Rev. 0, 09/11)
  • Page 2 Installation Manual Trailer Edition HK-430 and HK-430 HO Diesel Heating Units TK 55186-2-IM (Rev. 0, 09/11) Copyright© 2011 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 3 Release History Released Rev. 0, 09/11...
  • Page 4 Introduction This installation manual was written to assist with the installation of the Thermo King HK-430 and HK-430 HO diesel heating units onto trailers or intermodal containers specifically designed and built for these applications. Due to its complexity, you should not attempt this installation unless you: •...

  • Page 5: Table Of Contents

    Table of Contents Safety Precautions ......... . . 5 Group 31 Battery Dimensions .

  • 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 Battery terminals grounding against metal could CAUTION: Do not connect other manufacturer’s equipment or cause the battery to explode. accessories to the Thermo King unit. This could result in severe damage to equipment and void the warranty!

  • Page 8: Required Tools

    Required Tools 1. Safety Glasses 2. Drill 3. Drill Bits 4. Tape Measure 5. Mechanics Tools 6. Lifting Device 7. Two Forged Eyebolts (1/2-13 UNC) 8. Work Platform (Recommended) 9. Torque Wrench NOTE: Equipment such as torque wrenches should be in good working condition and routinely calibrated to assure accurate readings.

  • Page 9: Installation Components

    Installation Components HARDWARE KIT FUEL LINE KIT FUEL PUMP KIT Clamps Hose 1/4 OD x 40 ft. Fuel Pump Bandwraps Hose 3/8 OD x 40 ft. Hose Fitting 3/8'' Screw 1/4-20 SS Eyelet fitting 1/4'' Pump Bracket Nut 1/4-20 SS Eyelet Fitting 3/8'' Harness Nut 1/2-13...
  • Page 10 BLANK PAGE...

  • Page 11: Trailer / Container Requirements

    HK-430 HO unit! HK-430 or HK-430 HO unit and the 65 gallon fuel tank! IMPORTANT: Thermo King HK-430 and HK-430 HO diesel heating DANGER: An improperly installed fuel tank could lead to...
  • Page 12 Trailer / Container Requirements...

  • Page 13: Mounting Bolt Specifications And Installation Requirements

    Mounting Bolt Specifications and Installation Requirements Mounting Bolts Specifications Mounting Bolt Installation Requirements DANGER: The use of mounting bolts other than those DANGER: Four mounting bolts must be installed to properly specified could result in severe damage to equipment, void secure the unit to the trailer front wall! Failure to do so could the warranty or cause personal injury or death! result in severe damage to equipment, void the warranty or...
  • Page 14 Mounting Bolt Specifications and Installation Requirements...

  • Page 15: Unit Dimensions

    Unit Dimensions...

  • Page 16: Hmi Remote Mount Dimensions

    HMI Remote Mount Dimensions...

  • Page 17: Status Light Dimensions (Option)

    Status Light Dimensions (Option) Corner Mount Version Surface Mount Version...

  • Page 18: Flush Mount Status Light Opening Dimensions (Option)

    Flush Mount Status Light Opening Dimensions (Option) NOTE: Dimensions shown will accommodate the Surface Mount Standard Display version only.

  • Page 19: Battery Selection Guide

    CAUTION: Do not connect other manufacturer’s equipment or installer. accessories to the Thermo King unit! This could result in severe damage to equipment and void the warranty! The battery must be suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr.

  • Page 20: Group 31 Battery Dimensions

    Group 31 Battery Dimensions Threaded Stud Connections Lug Connections...

  • Page 21: Uncrating And Installing The Unit

    DANGER: Do not use a forklift to install the unit! This could result in severe damage to the equipment, void the warranty A zero cube installation kit is available from your Thermo King Dealer. or cause personal injury or death! The kit consists of a insulated collar that positions the HK unit outside the cargo area of the trailer.
  • Page 22 Uncrating and Installing the Unit...

  • Page 23: Installing The Remote Hmi

    Installing the Remote HMI NOTE: The installation views shown are for reference only. The actual locations chosen for installing the remote HMI may vary per your specific application and should not interfere with the operation of the trailer or container. Surface Mount Installation Flush Mount Installation NOTE: Installer to provide a recessed pocket in the trailer wall to...
  • Page 24 Installing the Remote HMI Surface Mount Installation Flush Mount Installation Recessed pocket shown (installer provided)

  • Page 25: Installing The Fuel Tank - Aluminum, 22'' Dia. 30 & 50 Gallon - (Option)

    DANGER: An improperly installed fuel tank could lead to • Thermo King recommends the fuel tank be mounted 203.2 mm serious injury or death! Consult your trailer manufacturer for (8.00 in.) under the trailer as shown. Otherwise, the OEM or specific details on proper fuel tank installation and recommendations.
  • Page 26 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) 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) Cross Member Spacing NOTE: Location of mounting holes may change if other trailer options are added.
  • Page 27 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) 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 28 Installing the Fuel Tank - Aluminum, 22'' dia. 30 & 50 Gallon - (Option) Open Style Bracket Orient Tank Vertically NOTE: Location of mounting holes may change if other trailer options are added.

  • Page 29: Installing The Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option)

    A. FUEL TANK POSITION NOTE: These instructions are written exclusively for, and are limited • Thermo King recommends the fuel tank be centered directly under to, the installation of the aluminum L-Shaped 65 gallon fuel tank, the HK heating unit.
  • Page 30 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option)
  • Page 31 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) Fuel Tank Installation 5. Install the support straps to the lower mounting holes of each mounting bracket with the supplied 1/2-13 x 1.50'' long bolts, flat washers and 1. Install the tank mounting brackets with six, (installer supplied) 1/2-13 locking nuts.
  • Page 32 Installing the Fuel Tank - Aluminum, L-Shaped, 65 Gallon - (Option) Mounting Strap with T-bolts and Rubber Pad Mounting Bracket with 711 mm (28.00'') Rubber Pad Support Strap with 635 mm (25.00'') Rubber Pad...

  • Page 33: Installing The Fuel Tank - Steel, Rectangle, 65 Gallon - (Option)

    HK heating unit. to, the installation of the 65 gallon steel fuel tank, positioned directly under a Thermo King HK heating unit, and mounted onto the front B. TANK STRAP POSITION wall of a trailer or intermodal container designed specifically for this •...
  • Page 34 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option)
  • Page 35 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) Fuel Tank Installation 4. Install the T-bolts on the support straps into the upper and lower holes of the L-brackets with the supplied 1/2'' washers and locking nuts. 1. Install the L-brackets with six, (installer supplied) 1/2-13 screws, Verify the rubber pads and strips are properly positioned on the L- washers and locking nuts onto the front wall of the container or trailer.
  • Page 36 Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option)

  • Page 37: Installing The Fuel Pump And Fuel Lines

    Installing the Fuel Pump and Fuel Lines FOR UNDER CHASSIS FUEL TANKS Installation Recommendations Installing the Fuel Pump and Fuel Lines 1. Install the fuel pump and bracket as low as possible to provide rapid DANGER: Leaking fuel lines could cause a fire resulting in pump priming.
  • Page 38 Installing the Fuel Pump and Fuel Lines FOR UNDER CHASSIS FUEL TANKS FUEL FILTER LOCATED INSIDE UNIT FUEL PUMP LOCATED OUTSIDE TRAILER...
  • Page 39 Installing the Fuel Pump and Fuel Lines FOR NOSE MOUNTED L-SHAPED and RECTANGLE SHAPED 65 GALLON FUEL TANKS Fuel Pump Installation Fuel Line Installation 3. Remove the protective plugs from each of the fuel fittings and install DANGER: Leaking fuel lines could cause a fire resulting in the fuel line supply and return line fittings securely.
  • Page 40 Installing the Fuel Pump and Fuel Lines FOR NOSE MOUNTED L-SHAPED and RECTANGLE SHAPED 65 GALLON FUEL TANKS FUEL PUMP LOCATED INSIDE HK UNIT FUEL FILTER LOCATED INSIDE UNIT Return Supply...

  • Page 41: Installing The Remote Status Light - (Option)

    Installing the Remote Status Light - (Option) Installation NOTE: Corner mounted light shown. Flush mounted light installs into recessed opening (See “Flush Mount Status Light Opening Dimensions (Option)” on page 17. 1. Mount the Status Light in a location that is visible in the tractor mirror to the driver.
  • Page 42 Installing the Remote Status Light - (Option)

  • Page 43: Installing The Battery

    Installing the Battery Installing the Battery 1. Open unit door to access battery tray. 2. Install battery into tray and secure with hold down bracket, bolts, lock CAUTION: Set all electrical controls to the OFF position before washers and flat washers. connecting the battery to prevent the unit from starting! •...
  • Page 44 Installing the Battery...

  • Page 45: System Check List

    SYSTEM CHECK LIST All unit mounting hardware torqued to specifications. Battery secured correctly and all connections clean and tight. No air gaps between unit and trailer wall. Remote HMI mounted securely. Drain hose properly routed and secured. Run Pre-Trip Inspection (refer to Operator’s Manual). Fuel tank properly installed.
  • Page 46 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.

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