Thermo King E-200 User manual

Revision B
July 2021 TTKK 5566888811--1188--IIMM--EENN
Vehicle Powered Truck Edition
E-200 Series
Single Temperature Systems
Installation Manual

©2020 Trane Techn l gies TK 56881-18-IM-EN
Introduction
This manual was written t assist with the general installati n f Therm King®c mp nents nt trucks designed and
built f r refrigerated applicati ns. The TThheerrmm KKiinngg IInnssttaallllaattii nn SSttaannddaarrddss aanndd PPrr cceedduurreess GGuuiiddee (TK 56430)
pr vides m re detailed inf rmati n that must be f ll wed t safely and pr perly c mplete the entire installati n.
Due t its c mplexity, y u sh uld n t attempt this installati n unless y u:
• Are an experienced mechanic.
• Can safely lift 34 kil s (75 lbs.).
• In the U.S., EPA 608 certified and trained in the repair and maintenance f transp rt refrigerati n systems.
• Have a basic understanding f electricity and electrical wiring.
• Have the necessary t ls and equipment t c mplete the installati n.
• Have a truck b dy designed and built t meet the requirements f this installati n.
• F ll w all safety precauti ns utlined in the Therm King Installati n Standards and Pr cedures Guide (TK 56430).
This manual is published f r inf rmati nal purp ses nly. Therm King makes n representati ns warranties express
r implied, with respect t the inf rmati n rec mmendati ns and descripti ns c ntained herein. Inf rmati n pr vided
sh uld n t be regarded as all-inclusive r c vering all c ntingencies. If further inf rmati n is required, Therm King
C rp rati n Service Department sh uld be c nsulted.
TThheerrmm KKiinngg’’ss wwaarrrraannttyy sshhaallll nn tt aappppllyy tt aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ss iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
rr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, tt aaffffeecctt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
Revision History
Revision A (02/21) Released new manual.
Revision B (07/21) Page 45 - Corrected 115V/1PH electrical plug number.
Custo er Satisfaction Survey
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TK 56881-18-IM-EN 3
SSaaffeettyy PPrreeccaauuttii nnss ............................................................................................................................................................ 55
Danger, Warning, Cauti n, and N tice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rec ver Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RReeqquuiirreedd TT llss .................................................................................................................................................................... 66
Overview....................................................................................... 6
Required Supp rt Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AAlltteerrnnaatt rr AAmmppeerraaggee TTeesstt ............................................................................................................................................ 88
Rec mmended Best Practice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
UUnnppaacckkiinngg aanndd IInnssppeeccttiinngg tthhee UUnniitt.......................................................................................................................... 99
Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Aut Start Hard St p / Disable C nnect r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PPrreeppaarriinngg CC nnddeennsseerr ff rr IInnssttaallllaattii nn.. .......... .. .. .. .. .......... .. .. .. .......... .. .. .. .... ...... .. .. .. .. .. .. ........ .. .. .. .. .......... .. .. .. .. ........ 1111
C ver and Fan H using Rem val (All M dels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fan H using M dificati ns (N sem unt Installati ns Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
IInnssttaalllliinngg tthhee CC nnddeennsseerr .......... .. .. .. .......... .. .. .. .......... .. .. .. .. .. ........ .. .. .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .......... .. .. .. ...... 1133
C ndenser Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
R fM unted................................................................................. 14
Fr nt M unted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EEvvaapp rraatt rr IInnssttaallllaattii nn ...... .. .. .. .......... .. .. .. .. .......... .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .. .. ...... .... .. .. .. .. ........ .. .. .. .. .......... 1166
Installing the Evap rat r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RReeffrriiggeerraanntt HH ssee CC nnnneeccttii nnss........ .. .. .. .. ........ .. .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .. .. ...... .... .. .. .. .. ........ .. .. .. .. .......... 1177
IInnssttaalllliinngg tthhee FFiilltteerr DDrriieerr aanndd SSiigghhtt GGllaassss .......................................................................................................... 1188
WWiirriinngg CC nnnneeccttii nnss .... .. .. .. .. ........ .. .. .. .. .... ...... .. .. .. .. .. ........ .. .. .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .... ...... .. .. .. .. .. 1199
IInnssttaalllliinngg tthhee IInn--CCaabb CC nnttrr lllleerr.......... .. .. .. .......... .. .. .. .......... .. .. .. .. .......... .. .. .. .. .. ...... .... .. .. .. .......... .. .. .. .. ........ .. .. .. .. ........ 2200
Opti nal Internal DIN Adapt r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BBaatttteerryy CC nnnneeccttii nnss .... .. .. .. .. .......... .. .. .. .. .. ...... .... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .... ...... .. .. .. .. .. .. ........ .. .. 2222
CC nnnneeccttiinngg tt TThhiirrdd PPaarrttyy HH lldd vveerr BBaatttteerryy OOppttii nn .................................................................................... 2233
H ld- ver Opti n Installati n Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
C ntr ller Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installati n Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
........................................................................................... 25
SSttaarrtt//SStt pp FFuunnccttii nnaalliittyy .. .. .. .. .. .......... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .. .. ...... .... .. .. .. .. ........ .. .. .. .. .......... 2266
Table of Contents

4TK 56881-18-IM-EN
C ncept....................................................................................... 26
Parts Required bef re Starting Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installati n Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
IInnccrreeaasseedd IIddllee SSppeeeedd SSeettuupp.. ...... .. .. .. .. .. .. .......... .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .... ...... .. .. .. .. .. ........ .. .. .. .. .. .......... .. 3300
C ncept....................................................................................... 30
Parts Required bef re Starting Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installati n Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SSttaannddbbyy RReecceeppttaaccllee BB xx IInnssttaallllaattii nn ((MM ddeellss 2200 aanndd 5500 OOnnllyy)).............................................................. 3344
EEvvaapp rraatt rr DDrraaiinn HH ssee IInnssttaallllaattii nn...... .. .. .. .. .. .. ...... .... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .. ........ .. .. .. .. .. .. ...... .... .. .. 3355
ES-100N/ES150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CC mmpplleettiinngg tthhee IInnssttaallllaattii nn.. .. ...... .... .. .. .. .......... .. .. .. .......... .. .. .. .. .......... .. .. .. .......... .. .. .. .... ...... .. .. .. .. .. .. ...... .... .. .. .. .......... .. 3377
SSuuccttii nn PPrreessssuurree RReegguullaatt rr ((SSPPRR)) AAddjjuussttmmeenntt PPrr cceedduurreess -- MMAAXX ...... .. .. .. .......... .. .. .. .. ........ .. .. .. .. ...... 3388
DDiisscchhaarrggee PPrreessssuurree RReegguullaatt rr ((DDPPRR)) AAddjjuussttmmeenntt PPrr cceedduurreess -- MMAAXX................................................ 3399
CC mmpprreessss rr OOiill AAmm uunnttss aanndd TTyyppee ...... .... .. .. .. .......... .. .. .. .. .......... .. .. .. .......... .. .. .. .......... .. .. .. .. ........ .. .. .. .. .. .. ...... .... .. .. 4400
RReecc mmmmeennddeedd RReeffrriiggeerraanntt CChhaarrggee bbyy MM ddeell.................................................................................................. 4411
CChheecckkiinngg tthhee IInnssttaallllaattii nn .. .......... .. .. .. .. .. ...... .... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .... ...... .. .. .. .. .. .. ........ .. .. 4422
CC nnddeennsseerr aanndd EEvvaapp rraatt rr DDiimmeennssii nnss ............................................................................................................ 4433
SSttaannddbbyy PP wweerr PPlluugg WWiirriinngg ...... .. .. .. .. .. ...... .... .. .. .. .. ........ .. .. .. .. .......... .. .. .. .......... .. .. .. .. .......... .. .. .. .......... .. .. .. .. .. ...... .... .. .. 4455
TTaabbllee ff CC nntteennttss

TK 56881-18-IM-EN 5
Safety Precautions
Danger, Warning, Caution, and Notice
Therm King®rec mmends that all service be perf rmed by a Therm King dealer and t be aware f several general
safety practices.
Safety advis ries appear thr ugh ut this manual as required. Y ur pers nal safety and the pr per perati n f this unit
depend up n the strict bservance f these precauti ns. The f ur types f advis ries are defined as f ll ws:
DDAANNGGEERR
HHaazzaarrdd!!
IInnddiiccaatteess aann iimmmmiinneennttllyy hhaazzaarrdd uuss ssiittuuaattii nn wwhhiicchh,, iiff nn tt aavv iiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh rr sseerrii uuss iinnjjuurryy..
WWAARRNNIINNGG
HHaazzaarrdd!!
IInnddiiccaatteess aa pp tteennttiiaallllyy hhaazzaarrdd uuss ssiittuuaattii nn wwhhiicchh,, iiff nn tt aavv iiddeedd,, cc uulldd rreessuulltt iinn ddeeaatthh rr sseerrii uuss iinnjjuurryy..
CCAAUUTTIIOONN
HHaazzaarrdd!!
IInnddiiccaatteess aa pp tteennttiiaallllyy hhaazzaarrdd uuss ssiittuuaattii nn wwhhiicchh,, iiff nn tt aavv iiddeedd,, cc uulldd rreessuulltt iinn mmiinn rr rr mm ddeerraattee iinnjjuurryy aanndd
uunnssaaffee pprraaccttiicceess..
NN TTIICCEE
HHaazzaarrdd!!
IInnddiiccaatteess aa ssiittuuaattii nn tthhaatt cc uulldd rreessuulltt iinn eeqquuiippmmeenntt rr pprr ppeerrttyy--ddaammaaggee nnllyy aacccciiddeennttss..
Recover Refrigerant
NNoottee:: In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas
Regulations must be observed when working on refrigeration systems.
At Therm King®, we rec gnize the need t preserve the envir nment and limit the p tential harm t the z ne layer
that can result fr m all wing refrigerant t escape int the atm sphere.
We strictly adhere t a p licy that pr m tes the rec very and limits the l ss f refrigerant int the atm sphere.
When w rking n transp rt temperature c ntr l systems, a rec very pr cess that prevents r minimizes refrigerant
l ss t the atm sphere is required by law. In additi n, service pers nnel must be aware f the appr priate Eur pean
Uni n, Nati nal, Federal, State, and/ r L cal regulati ns g verning the use f refrigerants and certificati n f
technicians. F r additi nal inf rmati n n regulati ns and technician pr grams, c ntact y ur l cal THERMO KING
dealer.
SSeerrvviiccee TT llss - Use the pr per service t ls. Gauge manif ld sets sh uld include appr priate shut ff valves r
disc nnects near the end f each service line.
RReecc vveerryy EEqquuiippmmeenntt - Rec very equipment must be used. Pr per rec vering, st ring and recycling f refrigerants is
an imp rtant part f all service w rk.
SSeerrvviiccee PPrr cceedduurreess - Rec mmended pr cedures must be used t minimize refrigerant l ss.
CC mmpp nneennttss mmaayy bbee iiss llaatteedd by cl sing service valves and perf rming system pump-d wns.
CC mmpp nneennttss uunnaabbllee tt bbee iiss llaatteedd f r service must be repaired nly after refrigerant is pr perly rec vered.

6TK 56881-18-IM-EN
Required Tools
Overview
While basic mechanics t ls and refrigerati n service equipment are a necessity, there are als special t ls that are
required when installing Therm King Vehicle P wered Truck Units. Using these t ls will assure the installati n is
d ne c rrectly. Many f these are available fr m Therm King.
*These are included with the Evacuation Station 204-725.

TK 56881-18-IM-EN 7
RCS481-1
t
r
a
n
i
c
W
S
e
o
r
f
a
t
w
WinTrac Software
(latest version must always be used)
Required Support Materials
Please have the f ll wing supp rt material in hand pri r t starting y ur installati n as it is listed as reference
thr ugh ut this manual:
1. Vehicle P wered Truck Installati n Standards and Pr cedures Guide (TK 56430) l cated at www.therm king.c m
RReeqquuiirreedd TT llss

8TK 56881-18-IM-EN
Alternator A perage Test
Reco ended Best Practice
Bef re install f the E-200 it is rec mmended t get a baseline f the amp draw being c nsumed by the vehicle.
Using an amp clamp n the alternat r utput wire measure the amp draw:
1. At idle
2. Radi n
3. AC and fans n high
4. Wipers n high
5. Headlights n
F r the example ab ve we measure 60 amps.
The E-200 requires an additi nal 115 amps excess amperage fr m the alternat r.
F r best results, this sh uld be available even at idle, at which p int the alternat r will have appr ximately 60-75% the
rated amperage.
EExxaammppllee::
• Using the amp draw as defined ab ve the vehicle uses 60 amps.
• P wer requirement f 60A draw fr m the vehicle + 115A draw f the E-200 = 175A.
• Available p wer at idle needs t be 60-75% f the alternat rs rated amperage/150-187 amps available f r an
alternat r rated at 250 amps.
• Kn wing the E-200 and vehicle needs 175 amps we w uld want an alternat r with at least 250 amps r higher.

TK 56881-18-IM-EN 9
Unpacking and Inspecting the Unit
Unpacking the Unit
1. Open the packaging.
2. Find the unit d cumentati n.
3. Verify that the packaging c ntains all the access ries indicated n the list attached with the d cumentati n.
4. Check that the h se length is c rrect bef re starting the installati n. Checking can be carried ut by c nsulting the
“Packing List” included with the unit d cumentati n.
Inspecting the Unit
1. Open the c ndenser unit c ver and ensure the f ll wing:
• Neither the c ver n r the unit sh uld sh w any sh ck damage r imperfecti ns.
• The c ndenser unit sh uld be charged with helium gas.
• The v ltage f all the electrical c mp nents is c rrect (12/24V).
2. Open the evap rat r unit c ver and make the f ll wing checks:
• Neither the c ver n r the unit sh uld sh w any sh ck damage r imperfecti ns.
• The evap rat r unit sh uld be charged with helium gas.
• The v ltage f all the electrical c mp nents is c rrect (12/24V).

10 TK 56881-18-IM-EN
Auto Start Hard Stop / Disable Connector
DDAANNGGEERR
HHaazzaarrdd uuss VV llttaaggee!!
TTaakkee ccaarree tthhaatt tthhiiss cc nnnneecctt rr dd eess nn tt ddiisscc nnnneecctt tthhee AACC vv llttaaggee iinnppuutt.. IIff sseerrvviiccee ff tthhee eelleeccttrriiccaall bb xx iiss
rreeqquuiirreedd,, yy uu MMUUSSTT uunnpplluugg tthhee AACC SShh rree PP wweerr bbeeff rree pprr cceeeeddiinngg..
This c nnect r has the f ll wing tw main functi nalities:
1. HHaarrdd SStt pp - this c nnect r is wired directly t the p wer relays. When y u disc nnect (unplug this c nnect r), the
relays and the circuit pens immediately st pping the unit.
2. DDiissaabbllee AAuutt ssttaarrtt - during unit c mmissi ning r while any maintenance is being carried ut n the unit, and a
p wer ff Is needed, is rec mmended t unplug this c nnect r. In this case, the p wer relays remain pen and the
machine cann t start.
UUnnppaacckkiinngg aanndd IInnssppeeccttiinngg tthhee UUnniitt

TK 56881-18-IM-EN 11
Preparing Condenser for Installation
Cover and Fan Housing Re oval (All Models)
T access the unit m unting h les:
1. Rem ve plastic c ndenser c ver.
2. Rem ve the fan h using assembly. (Rem ve the fan c nnect r).
3. Rem ve “P wer Off Device” C nnect r and Electric B x C ver.
4. M unting h les are n w accessible.

12 TK 56881-18-IM-EN
Fan Housing Modifications (Nose ount Installations Only)
Turn fan h using ver and use a hand saw t trim the area sh wn f r refrigerati n h se clearance.
NNoottee:: The fan housing assembly will be reinstalled later.
1. Access for Hoses and Harnesses
PPrreeppaarriinngg CC nnddeennsseerr ff rr IInnssttaallllaattii nn

TK 56881-18-IM-EN 13
Installing the Condenser
Condenser Installation
IImmppoorrttaanntt:: See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck
Installation Standards and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
NNoottee:: Nose mount and roof top condenser mounting and access hole dimensions can be found at the back of this
manual.
WWAARRNNIINNGG
EEqquuiippmmeenntt DDaammaaggee!!
SSeeaall aallll tthhee hh lleess iinnssiiddee tthhee eelleeccttrriicc bb xx wwhhiicchh aarree nn tt uusseedd ff rr iinnssttaallllaattii nn ((ddeeppeennddiinngg nn ssee mm uunntt//rr ff tt pp))..
OOtthheerrwwiissee wwaatteerr wwiillll ggeett iinntt tthhee eelleeccttrriicc bb xx aanndd ddaammaaggee tthhee cc mmpp nneennttss..
Figure 1. Condenser Mounting Bolts
1. Mounting holes when unit is mounted on the Front of the Truck (6)
2. Mounting holes when unit is mounted on the Roof of the Truck (6)

14 TK 56881-18-IM-EN
Roof Mounted
IImmppoorrttaanntt:: See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck
Installation Standards and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
1. P siti n c ndenser nt r f and install m unting hardware as sh wn.
a. R tate rubber c mpensati n washers until c ndenser is level.
b. Tighten hardware t 7 ft-lbs (10 N•m).
2. Reinstall electric b x c ver and reattach “P wer Off Device” c nnect r.
3. R ute electrical harnesses thr ugh access h le in c ndenser frame and int carg area.
Figure 2. Roof Mounted Condenser Shown
1
2
3
4
5
6
7
8
9
RCS1678
1. Bolt, M10
2. Washer, large metal M10
3. Washer, flat rubber
4. Vehicle roof
5. Washer, large rubber (with incline)
6. Washer, small rubber (compensation)
7. E-100 Condenser frame
8. Washer, split lock M10
9. Nut, M10
IInnssttaalllliinngg tthhee CC nnddeennsseerr

TK 56881-18-IM-EN 15
Front Mounted
IImmppoorrttaanntt:: See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck
Installation Standards and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
1. Attach supplied f am insulati n t rear f c ndenser as sh wn.
2. P siti n c ndenser nt fr nt f carg b x and install m unting hardware as sh wn.
a. Tighten hardware t 26.5 ft-lb. (36 N•m).
3. Reinstall electric b x c ver and reattach “P wer Off Device” c nnect r.
4. R ute electrical harnesses thr ugh access h le in c ndenser frame and int carg area.
Figure 3. Front Mounted Condenser Shown
RCS1679
IInnssttaalllliinngg tthhee CC nnddeennsseerr

16 TK 56881-18-IM-EN
Evaporator Installation
Installing the Evaporator
IImmppoorrttaanntt:: See Section 4 - Unit Installation Standards and Procedures in the Thermo King Vehicle Powered Truck
Installation Standards and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
1. Rem ve screws securing evap rat r c ver t evap rat r frame and rem ve c ver.
NNoottee:: Follow instruction on template to install evaporator on vehicle’s ceiling and to drill access hole for refrigerant
hoses and electrical wiring. Check for interference with vehicle electrical wires, etc. before drilling holes.
2. Drill access h le f r refrigerant h ses and electrical wiring.
3. Mark m unting l cati ns and drill pil t h les in ceiling.
a. L sely install supplied lag b lts and washers int ceiling pil t h les.
b. Tighten b lts until appr ximately 0.50 in. (6 mm) pr trudes fr m ceiling.
4. P siti n the evap rat r’s keyh le m unting h les nt the lag b lts in the ceiling.
a. Slide evap rat r s b lts fit int keyh le sl ts and tighten screws securely.
Figure 4. Typical ceiling ounted evaporator shown
X4
X4
RCS1618

TK 56881-18-IM-EN 17
Refrigerant Hose Connections
IImmppoorrttaanntt:: See Section 6 - Refrigerant Hose and Fittings Standards in the Thermo King Vehicle Powered Truck
Installation Standards and Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
Figure 5. Hose Connections Shown
1. O-Ring (#4, o-ring seal) 8. Fitting, straight (female o-ring seal, #6 fitting to #8 hose)
2. Fitting, straight (female o-ring seal, #4 fitting to #4 hose) 9. O-Ring (#10, o-ring seal)
3. O-Ring (#6, o-ring seal) 10. Fitting, 90 degree (female o-ring seal, #10 fitting to #10 hose)
4. Fitting, 90 degree (female o-ring seal, #6 fitting to #6 hose) 11. Hose, liquid line (#4, 50 ft)
5. O-Ring (#8, o-ring seal) 12. Hose, defrost line (#6, 50 ft)
6. Fitting, 90 degree (female o-ring seal, #8 fitting to #10 hose) 13. Hose, suction line (#10, 50 ft)
7. Fitting, 90 degree (straight, #6 fitting to #4 hose)

18 TK 56881-18-IM-EN
Installing the Filter Drier and Sight Glass
1. L cate the Filter Drier/Sight Glass assembly in y ur installati n kit.
2. Lubricate the -rings pri r t installing them nt each end f the assemblies.
3. Install the assembly with appr priate wrench (hand tighten).
4. Perf rm vacuum pr cedure f air fr m the Filter Drier and Sight Glass via the service valves n either side f this
assembly.
IImmppoorrttaanntt:: See Section 10 - System Evacuation Procedures and Section 12 - System Charging Procedures in the
Thermo King Vehicle Powered Truck Installation Standards and Procedures Guide (TK 56430). THESE
PR CEDURES MUST BE F LL WED!
Figure 6. Installing the Filter Drier and Sight Glass

TK 56881-18-IM-EN 19
Wiring Connections
IImmppoorrttaanntt:: See Section 7 - Electrical Standards in the Thermo King Vehicle Powered Truck Installation Standards and
Procedures Guide (TK 56430). THESE PR CEDURES MUST BE F LL WED!
2
3
7
4
5
6
11
A
C
D
E
8
9
B
1
NBAT
10
+
ACC
BAT
RCS1681
Item Component Description Connections Item Component Description Connections
A. Main Harness Connections 4. Temperature Sensor S1/PNK
B. To Power Receptacle 5. Evaporator Fan 1 CH_B/EF1
C. To Vehicle Ignition Switch ACC. 6. Drain Line Heater 1 HT1/CH_A
D. To Vehicle Battery + BAT+ 7. Defrost Solenoid PS1/CH_Y
E. To Vehicle Battery — BAt- 8. Vehicle Battery Fuse (F25) 5A
1. Door Switch DSW1/CHW 9. Ignition Fuse 5A
2. Defrost Temperature Switch DKI/CHB 10. Main Fuse 150A
3. Liquid Solenoid Valve PS3/CHI 11. HMI In-Cab Controller RXD, TXD, 8XP,
CH_N

20 TK 56881-18-IM-EN
Installing the In-Cab Controller
1. Install the m unting bracket f r the c ntr ller. Its design all ws the m unting bracket t be p siti ned in vari us
places in the cab interi r. Find a l cati n which is accessible and visible fr m the driver’s seat, and which d es n t
restrict the m bility r visibility f either the driver r the vehicle’s instruments and levers.
2. Depending n the l cati n ch sen, the base sh uld be m unted f ll wing either Opti n A r Opti n B.
3. M unt the base f the m unting bracket in the ch sen l cati n. Use screws ((CC)), rubber mat ((DD)) and metal plate ((EE)),
which are supplied by Therm King, as indicated in the drawing.
4. When placing the c ntr ller n the bracket, rest the c ntr ller n the arm ((FF)), and slide it t the right until the arm
tab is pr perly fitted t the c ntr ller frame.
5. The tilt f the c ntr ller’s fr nt face may be altered by l sening screw ((GG)).
6. C nnect the data cable t c nnect r ((HH)).
7. T rem ve the c ntr ller fr m the bracket, press the tab ((II)) and slide t the left.
Figure 7. In-Cab controller shown
RCS1622
1 2 3
45-6 7