Thermo King T-580R Installation Manual
Thermo King T-580R Installation Manual

Thermo King T-580R Installation Manual

Truck edition (tsa, emeia and ap) single temperature systems

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Installation Manual

Truck Edition (TSA, EMEIA and AP)
Single Temperature Systems
T-580R, T-800M and T-1000M (with TSR Controller)
T-680S, T-880S, T-1080S (with SR-3 Controller)
T-600R, T-680R, T-800R, T-880R, T-1000R & T-1080R (with SR-3 Controller)
T-1200R (EMEIA Only with SR-3 Controller)
TK 55212-1-IM (Rev. 4, 01/15)

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Summary of Contents for Thermo King T-580R

  • Page 1: Installation Manual

    Installation Manual Truck Edition (TSA, EMEIA and AP) Single Temperature Systems T-580R, T-800M and T-1000M (with TSR Controller) T-680S, T-880S, T-1080S (with SR-3 Controller) T-600R, T-680R, T-800R, T-880R, T-1000R & T-1080R (with SR-3 Controller) T-1200R (EMEIA Only with SR-3 Controller)
  • Page 3 Installation Manual Truck Edition (TSA, EMEIA and AP) Single Temperature Systems T-580R, T-800M and T-1000M (with TSR Controller) T-680S, T-880S, T-1080S (with SR-3 Controller) T-600R, T-680R, T-800R, T-880R, T-1000R and T-1080R (with SR-3 Controller) T-1200R (EMEIA Only with SR-3 Controller) TK 55212-1-IM (Rev.
  • Page 4 Installation Manual for T-Series Systems Release History Original (09/11) Released Rev. 1 (02/13) Pages 20, 21, 23, 27 and 29 - Changed art to show revised lifting bar with forged clevis and pins, forged connecting links and forged locking hooks used for lifting the unit. Rev.
  • Page 5 Installation Manual for T-Series Systems...
  • Page 6 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 7: Table Of Contents

    Securing the Evaporator Drain Hoses ......36 Service Area - T-580R, T-600R, T-680R, T-680R, T-680S, T-800M, Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank.
  • Page 8: 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 9 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 10: Unit Dimensions T-580R, T-600R, T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S

    Unit Dimensions - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S 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 11: Unit Dimensions T-1000M, T-1000R, T-1080R, T-1080S And T-1200R

    Unit Dimensions T-1000M, T-1000R, T-1080R, T-1080S 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 12: Service Area - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S

    Service Area - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S...
  • Page 13: Service Area - T-1000M, T-1000R, T-1080R, T-1080S And T-1200R

    Service Area - T-1000M, T-1000R, T-1080R, T-1080S 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: Remote Status Light Dimensions (Option)

    Remote Status Light Dimensions (OPTION)
  • Page 17: Hmi Controller Dimensions

    HMI Controller Dimensions HMI Controller (LED Display) HMI Controller (Graphics Display)
  • Page 18: Truck Body Opening Dimensions

    Truck Body Opening Dimensions Installing a New Unit onto a New Truck Box 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 Retrofitting a New Unit onto a Older Truck Box 349.3 mm (13.75 in.) Enlarge Opening as shown (See 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 20: 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-580R 434 kg (957 lbs.) T-580R 459 kg (1012 lbs.) T-600R 443 kg (977 lbs.)
  • Page 21: Lifting Bar Details

    This new lifting bar can also be used to install earlier series truck units. 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.
  • Page 22 DRAWING AND ALL INFORMATION IN IT, WHICH ARE DIMENSIONS ARE IN INCHES. UNLESS OTHERWISE SPECIFIED TOLERANCES PROTECTED BY COPYRIGHT AND OTHER LAWS AND MAY INTERPRET DIM AND TOL PER Thermo King ON DIMENSIONS PER TKS09109 BE SUBJECT TO LAWS REGARDING EXPORTING ASME Y14.5M - 1994 DRAWN DATE INFORMATION OUTSIDE OF THE U.S.
  • Page 23 Lifting Bar Details 54.2 27.1 25.1 2X 58° .50 THICK 2X 58° .534 1.75 .534 .50 THICK 2X 3.4 (30.3) 2X .8 50.20 2X 58° .534 28.70 26.60 23.50 R1.25 11.2 17.2 31.7 1.75 1.75 (1.6) .875 SCALE 0.250 REAR MEMBER 1.75 1.75 1.75...
  • Page 24: 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) with forged clevis and pins, forged connecting links and forged locking hooks. 7. Work Platform (Recommended)
  • Page 25 Required Tools...
  • Page 26: Installation Components

    Installation Components 1. Unit Mounting Washers 1.250 x 0.188 THK 15. Self Tapping Screws #10 HWHSM 2. Locking Nuts 1/2-13 16. In-Line Fuse Holder 3. Torx Head Screws 17. Fuse 60 amp 4. Hose Management Cap s 18. Terminal Connector Splice 5.
  • Page 27 Installation Components...
  • Page 28: Uncrating The Unit

    1. Remove the top covers, top screen (if equipped) and the muffler from the unit. WARNING: Thermo King requires a 3 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings 2. Install two M12 eyebolts and washers into the lifting holes in the rear provided.
  • Page 29 Uncrating the Unit...
  • Page 30: Installing The Unit

    See “Lifting Bar Details” on page 19. opening. WARNING: Thermo King requires a 3 point lifting bar to safely 2. Install four M12 (1/2-13 in. Grade 5) mounting bolts through the wall lift and install units. A lifting bar can be made from the drawings of the truck box.
  • Page 31 Installing the Unit...
  • Page 32: 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 33 Installing the Hose Management Caps Cutout Guide Marks Front Unit...
  • Page 34: Installing The Hose Management System (Option)

    Installing the Hose Management System (OPTION) Hose Management System (OPTION) 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. The hose management system organizes the routing of the drain hoses, electrical cables and fuel lines down the truck wall.
  • Page 35 Installing the Hose Management System (OPTION) Front Unit...
  • Page 36: 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 37 Securing the Oil Drain Hose The cutouts in the hose management cap should be as large as possible with no sharp edges.
  • Page 38: 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 39 Securing the Evaporator Drain Hoses...
  • Page 40: 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 41 Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank...
  • Page 42: 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 43 Installing the Fuel Pickup Tube Into a Plastic Tank...
  • Page 44: 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 45 Installing the Steel Fuel Tank...
  • Page 46: 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 47 Installing the Aluminum Fuel Tank (OPTION)
  • Page 48: Installing The Fuel Pump And Fuel Lines

    IMPORTANT: The factory installed fuel tank air vent must be in place and not more than 762 mm (30.00 in.) above the fuel in the fuel tank. and functional for the Thermo King unit’s fuel system to operate correctly and for the fuel tank to remain in compliance with Federal 2.
  • Page 49 Installing the Fuel Pump and Fuel Lines...
  • Page 50: Installing The Servicewatchâ„¢ Remote Download Port (Option)

    Installing the ServiceWatch™ Remote Download Port (OPTION) 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 51 Installing the ServiceWatch™ Remote Download Port...
  • Page 52: 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 53 Installing the Remote Power Receptacle (OPTION)
  • Page 54: Installing The Remote Status Light (Option)

    Installing the Remote Status Light (OPTION) Installation 1. Mount the Status Light in a location so that is visible to the driver in the truck’s mirror. • Mark and drill the four mounting holes using a 3/16'' drill. • Mount the status light securely with the supplied rivets. 2.
  • Page 55 Installing the Remote Status Light (OPTION)
  • Page 56: 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 57 Installing the HMI Controller NOTE: HMI with LED Display shown, HMI with Graphics Display installs the same.
  • Page 58: Installing The Battery Box (Option)

    Installing the Battery Box (OPTION) 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 59 Installing the Battery Box (OPTION)
  • Page 60: Battery Connections

    Routing” on page 7 for additional information. Negative Cable NOTE: Thermo King units are designed for one 12 volt, group 31 4. At the unit, locate the large black cable marked NEG -. Route this cable battery. The battery must be suitable for deep cycling, heavy duty to the battery, cut to the proper length and add the battery lug from and rated with a minimum of 95 amp/hr.
  • Page 61 Battery Connections...
  • Page 62: 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 are intended as reference guide only to IMPORTANT INSTALLATION NOTES: assist with a typical door switch installation. Your installation may be •...
  • Page 63 Installing the Door Switch (OPTION) Right Angle Mounting Top x Top Mounting Side x Side Mounting...
  • Page 64 Installing the Door Switch (OPTION) NOTE: The Door Switch Harness Connectors are located at the rear of the host unit. 1. Attach the interface harness to matching door switch connector located at the rear of the host unit. 2. Route a 3 wire harness (INSTALLER SUPPLIED) from the interface harness to a door switch.
  • Page 65 Installing the Door Switch (OPTION) Interface Harness Wiring Door Switch Wiring RED = (DSP) POWER RED = (DSP) POWER BLACK = (CH) GROUND BLACK = (CH) GROUND WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT...
  • Page 66: Auxiliary Electrical Accessories

    SR-3 Controllers and Tier 4 Engines. However, if auxiliary accessories are connected to the electrical system, see the following guidelines to ensure emission compliance for the Tier 4 engines. The function and safety of the auxiliary accessory connected to the Thermo King electrical system is the customer’s responsibility.
  • Page 67: Unit Check List

    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 68 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,...
  • Page 70 Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for customers globally. 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.

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