Ingersoll-Rand Thermo King T-500R User manual

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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Installation Manual for T-Series Systems
Release History
Original (8/16) Released

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Installation Manual for T-Series Systems

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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.
• Can safely lift 34 kilos (75 lbs.).
• Are certified or trained in the repair and maintenance of diesel powered
refrigeration systems.
• Have a basic understanding of electricity and electrical wiring.
• Have the necessary tools and equipment to complete the installation.
This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s
judgment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or
descriptions contained herein.

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Table of Contents
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Unit Dimensions – T-500R/T-Dairy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit Dimensions – T-570R, T-600, T-600R, T-800, T-800R, T-800M . .9
Unit Dimensions T-1000, T-1000R, T-1000M and T-1200R . . . . . . . . .10
Service Area – T-500R/T-Dairy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Service Area – T-570R, T-600, T-600R, T-800, T-800R and T-800M . .12
Service Area – T-1000, T-1000R, T-1000M and T-1200R . . . . . . . . . . .13
Remote Power Receptacle Dimensions (OPTION) . . . . . . . . . . . . . . . . 14
Battery Box Dimensions (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
HMI Controller Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HMI T-1200R Inter-modal Controller Dimensions . . . . . . . . . . . . . . . . .17
Truck Body Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Lifting Bar Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Uncrating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Installing the Hose Management Caps . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installing the Hose Management System (OPTION) . . . . . . . . . . . . . . .36
Securing the Oil Drain Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Securing the Evaporator Drain Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank . . . . . .42
Installing the Fuel Pickup Tube Into a Plastic Tank. . . . . . . . . . . . . . . . 44
Installing the Steel Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Installing the Aluminum Fuel Tank (OPTION) . . . . . . . . . . . . . . . . . . .48
Installing the Fuel Pump and Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . 50
Installing the Fuel Pump and Fuel Lines (T-1200R Inter-modal) . . . . . .52
Installing the HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Installing the ServiceWatch™ Download Port (Option EMEIA) . . . . . .56
CARGOWATCH Sensor Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installing the Remote Power Receptacle (OPTION) . . . . . . . . . . . . . . . .59
Installing the Battery Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Installing the Door Switch (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . 65
UNIT CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

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Safety Precautions
The 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.
DANGER: Never operate the unit with the discharge valve
closed because it could cause the compressor to explode,
causing death or serious injury.
DANGER: Never apply heat to a sealed refrigeration system or
container because it could explode, causing death or serious
injury
DANGER: Fluorocarbon refrigerants, in the presence of an
open flame or electrical short, produce toxic gases that are
severe respiratory irritants capable of causing death.
DANGER: Be careful when working with a refrigerant or
refrigeration system in any enclosed or confined area with a
limited air supply (i.e., a trailer, container or the hold of a
ship). Refrigerant tends to displace air and can cause oxygen
depletion which may result in death by suffocation.
WARNING: Always wear goggles or safety glasses.
Refrigerant liquid, refrigeration oil, and battery acid can
permanently damage the eyes (see First Aid under
Refrigeration Oil).
WARNING: Keep your hands away from fans and belts when
the unit is running. This should also be considered when
opening and closing the compressor service valves.
WARNING: Make sure gauge manifold hoses are in good
condition. Never let them come in contact with a belt, fan
motor pulley, or any hot surface.
WARNING: Make sure all mounting bolts are tight and are of
correct length for their particular application
WARNING: Never drill holes in the unit unless absolutely
necessary. Holes drilled into the unit may weaken structural
components. Holes drilled into electrical wiring can cause fire
or explosion.
WARNING: When using ladders to install or service
refrigeration systems, always observe the ladder
manufacturer’s safety labels and warnings. A work platform is
the recommended method for installations.
WARNING: Exposed coil fins are very sharp and can cause
painful lacerations.Wear leather work gloves to prevent injury.

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Safety Precautions (continued)
Battery Installation and Cable Routing Refrigerant
First Aid
FROST BITE: In the event of frost bite, the objectives of First Aid are to
protect the frozen area from further injury, to warm the affected area
rapidly and to maintain respiration.
EYES: For contact with liquid, immediately flush eyes with large amounts
of water and get prompt medical attention.
SKIN: Flush area with large amounts of lukewarm water. Do not apply
heat. Remove contaminated clothing and shoes. Wrap burns with dry,
sterile, bulky dressing to protect from infection/injury. Get medical
attention. Wash contaminated clothing before reuse.
INHALATION: Move victim to fresh air and use CPR or mouth-to-mouth
ventilation, if necessary. Stay with victim until arrival of emergency
medical personnel.
Refrigeration Oil
First Aid
NOTE: In case of eye contact, immediately flush with plenty of water
for at least 15 minutes. CALL A PHYSICIAN. Wash skin with soap and
water.
WARNING: Improperly installed battery could result in a fire or
explosion! A Thermo King approved battery must be installed
and properly secured to the battery tray.
WARNING: Improperly installed battery cables could result in
fire or explosion! Battery cables must be installed, routed and
secured properly to prevent them from rubbing, chaffing or
making contact with hot, sharp or rotating components.
WARNING: Do not attach fuel lines or any additional wiring
harnesses to the battery cables as this could cause an
electrical fire!
CAUTION: Do not connect other manufacturer’s equipment or
accessories to the Thermo King unit. This could result in
severe damage to equipment and void the warranty!
CAUTION: Set all unit electrical controls to the OFF position
before connecting battery cables to the battery to prevent unit
from starting unexpectedly and causing personal injury.
CAUTION: Always wear protective clothing, gloves and eye
wear when handling and installing batteries. Battery acid can
cause serious burns when exposed to eyes or skin. If battery
acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with
running cold water for at least twenty minutes and get medical
attention immediately.
CAUTION: Always cover battery terminals to prevent them
from making contact with metal components during battery
installation. Battery terminals grounding against metal could
cause the battery to explode.
WARNING: Although fluorocarbon refrigerants are classified
as safe refrigerants, certain precautions must be observed
when handling them or servicing a unit in which they are
used. When released to the atmosphere in the liquid state,
fluorocarbon refrigerants evaporate rapidly, freezing anything
they contact.
WARNING: Avoid refrigeration oil contact with the eyes. Avoid
prolonged or repeated contact of refrigeration oil with skin or
clothing. Wash thoroughly after handling refrigeration oil to
prevent irritation.

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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. etc.
T-500R/T-Dairy minimum dimension = 107 mm (4.25 in.)

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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. etc.
T-570R, T-600 and T-800 minimum dimension = 107 mm (4.25 in.)

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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. etc.
T-1000 minimum dimension = 147 mm (5.75 in.)

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Service Area – T-500R/T-Dairy

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

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

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

15
Battery Box Dimensions (OPTION)

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

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HMI T-1200R Inter-modal Controller Dimensions

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Truck Body Opening Dimensions
Installing a New Unit onto a New Truck Box T-500R/T-Dairy
Important Installation Requirements:
• Gasket sealing surface of 50.8
mm (2.00 in.) wide is required around the unit opening. This surface must be flat within 6.4 mm (0.25 in.) and free of all rivets or head bolts for proper gasket sealing.
• The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling.
• Unit mounting location must allow for adequate tilt clearance (see Unit Dimensions).
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. etc.
T-500R/T-Dairy minimum
dimension = 107 mm (4.25 in.)

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Truck Body Opening Dimensions
Installing a New Unit onto a New Truck Box (all except T-500R/T-Dairy)
Important Installation Requirements:
• Gasket sealing surface of 50.8 mm (2.00 in.) wide is required around the unit opening. This surface must be flat within 6.4 mm (0.25 in.) and free of all rivets or head bo
proper gasket sealing.
• The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling.
• Unit mounting location must allow for adequate tilt clearance (see Unit Dimensions).
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. etc.
T-570R, T-600, T-600R, T-800,
T-800R and T-800M minimum
dimension = 107 mm (4.25 in.)

20
Truck Body Opening Dimensions
Retrofitting a New Unit onto a Older Truck Box T-500R/T-Dairy
Important Installation
Requirements:
• Gasket sealing
surface of 50.8 mm
(2.00 in.) wide is
required around the unit opening. This surface must be flat within 6.4 mm (0.25 in.) and free of all rivets or head bolts for proper gasket sealing.
NOTE:
Existing opening same as
MD-100, MD-200 units
and does not require modifications.
Cannot be retrofitted from any other
existing Truck body.