Thermo King V220 Series User manual

Revision B
June 2022 TTKK 5566443300--1188--IIPP--EENN
Installation Standards and Procedures Guide
V220 and V320 Series Units
User Guide

©2018 Trane Techn l gies TK 56430-18-IP-EN
Introduction
This guide 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 (03/18) New manual format.
Revision B (06/22) Changed the clutch air gap specifications
Customer Satisfaction Survey
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TK 56430-18-IP-EN 3
How To Use This Guide
Please take a few minutes t read this page. It explains the c ntent and structure f this guide. This will make it easier
f r y u t find the inf rmati n y u need. Reading and understanding each secti n pri r t installing a Therm King
Vehicle P wered Truck Refrigerati n System will help make f r a successful installati n.
SSeeccttii nn 11 -- IInnttrr dduuccttii nn
Explains the bjective f this guide.
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss
C ntains general safety inf rmati n t f ll w when installing and servicing a Therm King Vehicle P wered Truck unit.
SSeeccttii nn 33 -- RReeqquuiirreedd TT llss
C ntains a list f t ls required t pr perly install Therm King Vehicle P wered Truck units.
SSeeccttii nn 44 -- UUnniitt IInnssttaallllaattii nn SSttaannddaarrddss aanndd PPrr cceedduurreess
C ntains unit m unting standards and pr cedures al ng with carg b x requirements, unit m unting hardware,
grades, and t rque specificati ns.
SSeeccttii nn 55 -- CC mmpprreessss rr SSeelleeccttii nn aanndd IInnssttaallllaattii nn SSttaannddaarrddss
Describes h w t select the c rrect c mpress r f r y ur applicati n. It als c vers; speed calculati ns, il requirements,
pulley and belt selecti n, belt alignment c mpress r installati n and t rque specificati ns.
SSeeccttii nn 66 -- RReeffrriiggeerraattii nn HH ssee aanndd FFiittttiinnggss SSttaannddaarrddss
Describes h w t pr perly fabricate, r ute and secure h ses. It als c vers h w t ch se and install fittings and h w t
tighten them t the pr per t rque specificati ns.
SSeeccttii nn 77 -- EElleeccttrriiccaall SSttaannddaarrddss
Describes h w t pr perly c nnect the harnesses t the unit’s individual c mp nents and the vehicle’s electrical
system. It als c vers main fuse installati n, harness r uting, harness securing and gr und c nnecti ns.
SSeeccttii nn 88 -- EEvvaapp rraatt rr DDrraaiinn HH ssee SSttaannddaarrddss
Describes the standards f r installing evap rat r drain h ses and heater resistance wires.
SSeeccttii nn 99 -- CC nnffiigguurriinngg SS ffttwwaarree aanndd CC nnttrr lllleerr PPrr cceedduurreess
Describes the pr cedures f r c ntr ller installati n, Firmware installati n, upl ading c nfigurati n files, and m difying
cust mer specific settings.
SSeeccttii nn 1100 -- SSyysstteemm EEvvaaccuuaattii nn PPrr cceedduurreess
Describes the c rrect pr cedures f r evacuating the refrigerati n system using either a 2-p int, 3-p int r 4-p int gauge
and manif ld c nnecti ns.
SSeeccttii nn 1111 -- SSyysstteemm LLeeaakk CChheecckk PPrr cceedduurreess
Describes the c rrect pr cedures f r checking the refrigerati n system f r leaks pri r t charging with refrigerant.
SSeeccttii nn 1122 -- SSyysstteemm CChhaarrggiinngg PPrr cceedduurreess
Describes the c rrect pr cedures f r charging the refrigerati n system.
SSeeccttii nn 1133 -- UUnniitt PPeerrff rrmmaannccee AAddjjuussttmmeennttss
Describes which units are equipped with SPR and CPR valves, definiti ns f the valves, and why they must be adjusted
f r ptimum unit perf rmance.
SSeeccttii nn 1144 -- CC mmmmiissssii nniinngg aanndd PPrree--DDeelliivveerryy IInnssppeeccttii nn ((PPDDII)) FF rrmmss
Describes h w the C mmissi ning and PDI f rms helps assure Therm King equipment is installed with the highest
degree f quality, reliability and durability t meet r exceed the expectati ns f ur cust mers resulting in t tal
cust mer satisfacti n.
IInnttrr dduuccttii nn

4TK 56430-18-IP-EN
SSeeccttii nn 11 -- IInnttrr dduuccttii nn .................................................................................................................................................. 88
Objective....................................................................................... 8
Defining Standards and Pr cedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Imp rtant Inf rmati n Ab ut This Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss.................................................................................................................................... 99
Overview....................................................................................... 9
Danger, Warning, Cauti n, and N tice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Precauti ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Aut Start Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigerant Oil Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Rem val Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Welding Precauti ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Micr pr cess r Precauti ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FirstAid....................................................................................... 14
SafetyDecals.................................................................................. 14
SSeeccttii nn 33 -- RReeqquuiirreedd TT llss .......................................................................................................................................... 1166
Overview...................................................................................... 16
SSeeccttii nn 44 -- UUnniitt IInnssttaallllaattii nn SSttaannddaarrddss aanndd PPrr cceedduurreess ............................................................................1188
Overview...................................................................................... 18
Carg B x Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installati n Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installati n Templates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Unpacking and Inspecting C mp nents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DrillingH les.................................................................................. 20
SealingH les.................................................................................. 22
Sealing Meth ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Sealing Refrigerant Lines and Electrical Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
M unting Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Threads, Grade and Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hardware Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Nuts and Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tightening M unting Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Vehicle P wered Truck Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
N sem unted Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
R ft p M unted Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of Contents

TK 56430-18-IP-EN 5
N sem unt and R ft p M unt Similarities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installati n Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
N sem unt C ndenser Installati n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
R ft p M unted C ndenser Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rem te Evap rat r Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Evap rat r Installati n with Pre-Installed Supp rt Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Evap rat r Installati n with ut Supp rt Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SSeeccttii nn 55 -- CC mmpprreessss rr SSeelleeccttii nn aanndd IInnssttaallllaattii nn SSttaannddaarrddss ..............................................................3344
Overview...................................................................................... 34
C mpress r Selecti n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Understand C mpress r Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Ch se the Best C mpress r Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Calculate the C mpress r Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
C mpress r Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
AddingOil................................................................................. 36
T rque Specificati ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Gr und Strap Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Changing C mpress r Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rem val................................................................................... 41
Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Setting Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Liquid Injecti n Temperature Sens r Installati n Pr cedures(Max Units Only) . . . . . . . . . . . . . . . . . . . . . . 45
SSeeccttii nn 66 -- RReeffrriiggeerraanntt HH ssee aanndd FFiittttiinnggss SSttaannddaarrddss ..................................................................................4477
Overview...................................................................................... 47
H se Lay ut and Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
All wing f r M vement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Examples f H se Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Minimum H se Bend Radius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Securing Refrigerati n H ses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Supp rting H ses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Abrasi n Pr tecti n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pr tective C vers and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pr tective Heat Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Refrigerati n Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Determining Fitting Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Determining Fitting Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Refrigerant H ses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Determining H se Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
O-Rings....................................................................................... 54
TTaabbllee ff CC nntteennttss

6TK 56430-18-IP-EN
Tightening Refrigerati n H se Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Sucti n Line Splice C nnect r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Splice C nnect r Service P rts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Units with Oil Return H se . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Units with Jet C l (Liquid Injecti n System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Sucti n Line R uting and P-Trap F rmati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TK 2000+ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assembly Materials Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
H se Fabricati n Pr cedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SSeeccttii nn 77 -- EElleeccttrriiccaall SSttaannddaarrddss .................................................... .. ............ .. .. .......... .. .. .. .......... .. .. .......... .. .. .. .......... 6611
Overview...................................................................................... 61
Dielectric Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
DC L w V ltage Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Sealed C nnect rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Unsealed C nnect rs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Sealed Splice C nnect rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Heat Shrink Sealed Butt Splice C nnect rs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Parallel Crimp C nnect rs with Heat Shrink Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Unit Gr und Wire t 12 Vdc Negative Battery C nnecti n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Unit Main P wer C nnecti ns t 12 Vdc P sitive Battery C nnecti n . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
12 Vdc P sitive Igniti n C nnecti n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
AC High V ltage P wer Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Receptacle B x Installati n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Standby P wer Cable Wiring C nnecti ns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Electrical Harness Pr tecti n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Abrasi n Pr tecti n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Pr tective C vers and Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
R uting and Securing Electrical Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
R uting Harnesses thr ugh Metal H les . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Pr tective Heat Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
SSeeccttii nn 88 -- EEvvaapp rraatt rr DDrraaiinn HH ssee SSttaannddaarrddss.................................................................................................. 7755
Overview...................................................................................... 75
Drain H se Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Drain Heater Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Heater Resistance Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SSeeccttii nn 99 -- CC nnffiigguurriinngg SS ffttwwaarree aanndd CC nnttrr lllleerr PPrr cceedduurreess ................................................................7799
C ntr ller Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
HMIOverview................................................................................. 80
C ntr ller Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
MainMenu................................................................................ 81
TTaabbllee ff CC nntteennttss

TK 56430-18-IP-EN 7
H urMeter ................................................................................ 81
Inf rmati n Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installati n Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
C nfigurati n Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Flash L ading C nfigurati n Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
SSeeccttii nn 1100 -- SSyysstteemm EEvvaaccuuaattii nn PPrr cceedduurreess ....................................................................................................8877
Overview...................................................................................... 87
Evacuati n Pr cedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DSR lll Equipped Units with 544.xx Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
SSeeccttii nn 1111 -- SSyysstteemm LLeeaakk CChheecckk PPrr cceedduurreess .. .. .. .. .. .. .. .. .. ........ .. .. .. ........ .. .. .......... .. .. .. .......... .. .. .......... .. .. .. .......... 9977
Overview...................................................................................... 97
Testing System f r Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Using Pressurized Nitr gen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Safety Precauti ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Pr cedures ................................................................................ 99
SSeeccttii nn 1122 -- SSyysstteemm CChhaarrggiinngg PPrr cceedduurreess ......................................................................................................110000
Overview.....................................................................................100
Refrigerant Charging Pr cedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Discharge (High Side) Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Sucti n (L w Side) Bump Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
SSeeccttii nn 1133 -- UUnniitt PPeerrff rrmmaannccee AAddjjuussttmmeennttss ..................................................................................................110022
Overview.....................................................................................102
SSeeccttii nn 1144 -- CC mmmmiissssii nniinngg aanndd PPDDII FF rrmmss ..................................................................................................110033
C mmissi ning F rm Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Pre-Delivery Inspecti n (PDI) F rm Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
TTaabbllee ff CC nntteennttss

8TK 56430-18-IP-EN
Section 1 - Introduction
bjective
The bjective f this guide is t pr vide Therm King Dealers, Original Equipment Manufacturers (OEMs), and 3rd Party
Installers with installati n standards and pr cedures t assure Therm King equipment is installed with the highest
degree f quality, reliability, and durability t meet r exceed the expectati ns f ur cust mers resulting in t tal
cust mer satisfacti n.
Defining Standards and Procedures
SSTTAANNDDAARRDDSS mmuusstt ccccuurr dduurriinngg iinnssttaallllaattii nn:: Standards explain what is required by Therm King. The standards in
this guide are based n d cumented engineering principles and a phil s phy f c ntinu us impr vement. Adhering t
these standards will help assure the system is installed c rrectly and perates as designed.
PPRROOCCEEDDUURREESS aarree rreecc mmmmeennddeedd,, bbuutt nn tt rreeqquuiirreedd:: Pr cedures explain the pr per steps t take t c mplete a task.
F ll wing the pr cedures will help assure the installati n is c mpleted in a timely manner.
It is als rec mmended that installers f Therm King equipment n t nly bec me familiar with this manual, but als
any ther referenced publicati ns listed herein bef re beginning the installati n pr cess.
While this manual emphasizes safety, quality, reliability and durability, each installer als has the resp nsibility t :
• Ensure vehicle m dificati ns d n t reduce the vehicle’s integrity.
• Verify vehicle safety is maintained.
• C mply with all Federal, State, and l cal regulati ns.
• C mplete the entire installati n using the best w rkmanship standards.
• Meet r exceed the requirements and expectati ns f the cust mer.
Important Information About This Guide
This guide is intended f r installers wh are aware f the appr priate Nati nal, Federal, State, and/ r L cal regulati ns
g verning the use f refrigerants and certificati n f technicians. EPA Secti n 608 is required t w rk n refrigerati n
systems in the United States. It is n t intended t be a c mplete “h w-t ” auth rity, r a substitute f r s und
engineering and ther judgment. M dificati ns t vehicles t accept Therm King equipment requires skills and
kn wledge n t c vered in this guide.
If further inf rmati n is required, Therm King C rp rati n Service Department sh uld be c nsulted at 612-887-2200.

TK 56430-18-IP-EN 9
Section 2 - Safety Precautions
verview
This secti n includes general safety precauti ns, specific cauti ns, and first aid inf rmati n. Read this material carefully
bef re installing r w rking n any Therm King vehicle p wered truck refrigerati n unit. In the U.S., all technicians
wh maintain, service, repair, r disp se f equipment that c uld release refrigerants int the atm sphere must be EPA
608 certified.
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..
Safety Precautions
DDAANNGGEERR
HHaazzaarrdd ff EExxppll ssii nn!!
NNeevveerr aappppllyy hheeaatt tt aa sseeaalleedd rreeffrriiggeerraattii nn ssyysstteemm rr cc nnttaaiinneerr.. HHeeaatt iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh mmiigghhtt
ccaauussee aann eexxppll ssii nn rreessuullttiinngg iinn ddeeaatthh rr sseerrii uuss iinnjjuurryy..
DDAANNGGEERR
HHaazzaarrdd uuss GGaasseess -- PPeerrss nnaall PPrr tteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
RReeffrriiggeerraanntt iinn tthhee pprreesseennccee ff aann ppeenn ffllaammee,, ssppaarrkk,, rr eelleeccttrriiccaall sshh rrtt pprr dduucceess tt xxiicc ggaasseess tthhaatt aarree sseevveerree
rreessppiirraatt rryy iirrrriittaannttss wwhhiicchh ccaann ccaauussee sseerrii uuss iinnjjuurryy rr pp ssssiibbllee ddeeaatthh.. WWhheenn ww rrkkiinngg wwiitthh rr aarr uunndd hhaazzaarrdd uuss
cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr tt aapppprr pprriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGll bbaall
HHaarrmm nniizzeedd SSyysstteemm ff CCllaassssiiffiiccaattii nn aanndd LLaabbeelllliinngg ff CChheemmiiccaallss)) gguuiiddeelliinneess ff rr iinnff rrmmaattii nn nn aallll wwaabbllee
ppeerrss nnaall eexxpp ssuurree lleevveellss,, pprr ppeerr rreessppiirraatt rryy pprr tteeccttii nn,, aanndd hhaannddlliinngg iinnssttrruuccttii nnss..

10 TK 56430-18-IP-EN
DDAANNGGEERR
RRiisskk ff IInnjjuurryy!!
KKeeeepp yy uurr hhaannddss,, ccll tthhiinngg,, aanndd tt llss cclleeaarr ff mm vviinngg ppaarrttss wwhheenn tthhee uunniitt iiss ppeerraattiinngg rr vveehhiiccllee’’ss eennggiinnee iiss
rruunnnniinngg.. LL ssee ccll tthhiinngg ccaann bbeecc mmee eennttaanngglleedd iinn mm vviinngg ppaarrttss,, ccaauussiinngg sseerrii uuss iinnjjuurryy rr pp ssssiibbllee ddeeaatthh..
DDAANNGGEERR
RReeffrriiggeerraanntt VVaapp rr HHaazzaarrdd!!
DD nn tt iinnhhaallee rreeffrriiggeerraanntt.. UUssee ccaauuttii nn wwhheenn ww rrkkiinngg wwiitthh rreeffrriiggeerraanntt rr aa rreeffrriiggeerraattii nn ssyysstteemm iinn aannyy cc nnffiinneedd
aarreeaa wwiitthh aa lliimmiitteedd aaiirr ssuuppppllyy.. RReeffrriiggeerraanntt ddiissppllaacceess aaiirr aanndd ccaann ccaauussee xxyyggeenn ddeepplleettii nn,, rreessuullttiinngg iinn
ssuuffff ccaattii nn aanndd pp ssssiibbllee ddeeaatthh.. WWhheenn ww rrkkiinngg wwiitthh rr aarr uunndd hhaazzaarrdd uuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr tt
aapppprr pprriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGll bbaall HHaarrmm nniizzeedd SSyysstteemm ff CCllaassssiiffiiccaattii nn
aanndd LLaabbeelllliinngg ff CChheemmiiccaallss)) gguuiiddeelliinneess ff rr iinnff rrmmaattii nn nn aallll wwaabbllee ppeerrss nnaall eexxpp ssuurree lleevveellss,, pprr ppeerr
rreessppiirraatt rryy pprr tteeccttii nn,, aanndd hhaannddlliinngg iinnssttrruuccttii nnss..
WWAARRNNIINNGG
PPeerrss nnaall PPrr tteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AAllwwaayyss wweeaarr gg gggglleess rr ssaaffeettyy ggllaasssseess aanndd pprr ppeerr PPPPEE wwhheenn ww rrkkiinngg nn aa uunniitt.. RReeffrriiggeerraanntt lliiqquuiidd,, iill,, aanndd
bbaatttteerryy aacciidd ccaann ppeerrmmaanneennttllyy ddaammaaggee yy uurr eeyyeess.. WWhheenn ww rrkkiinngg wwiitthh rr aarr uunndd hhaazzaarrdd uuss cchheemmiiccaallss,,
AALLWWAAYYSS rreeffeerr tt aapppprr pprriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGll bbaall HHaarrmm nniizzeedd SSyysstteemm
ff CCllaassssiiffiiccaattii nn aanndd LLaabbeelllliinngg ff CChheemmiiccaallss)) gguuiiddeelliinneess ff rr iinnff rrmmaattii nn nn aallll wwaabbllee ppeerrss nnaall eexxpp ssuurree
lleevveellss,, pprr ppeerr rreessppiirraatt rryy pprr tteeccttii nn,, aanndd hhaannddlliinngg iinnssttrruuccttii nnss..
WWAARRNNIINNGG
PPrr ppeerr EEqquuiippmmeenntt CC nnddiittii nn!!
GGaauuggee mmaanniiff lldd hh sseess mmuusstt bbee iinn gg dd cc nnddiittii nn bbeeff rree uussiinngg tthheemm.. NNeevveerr lleett tthheemm cc mmee iinn cc nnttaacctt wwiitthh
mm vviinngg bbeellttss,, ffaannss,, ppuulllleeyyss rr hh tt ssuurrffaacceess.. DDeeffeeccttiivvee ggaauuggee eeqquuiippmmeenntt ccaann ddaammaaggee cc mmpp nneennttss rr ccaauussee
sseerrii uuss iinnjjuurryy..
WWAARRNNIINNGG
RRiisskk ff IInnjjuurryy!!
WWhheenn uussiinngg llaaddddeerrss tt iinnssttaallll rr sseerrvviiccee rreeffrriiggeerraattii nn ssyysstteemmss,, aallwwaayyss bbsseerrvvee tthhee llaaddddeerr mmaannuuffaaccttuurreerr’’ss
ssaaffeettyy llaabbeellss aanndd wwaarrnniinnggss.. AA ww rrkk ppllaattff rrmm rr ssccaaffff llddiinngg iiss tthhee rreecc mmmmeennddeedd mmeetthh dd ff rr iinnssttaallllaattii nnss aanndd
sseerrvviicciinngg..
CCAAUUTTIIOONN
RRiisskk ff IInnjjuurryy!!
EE--SSeerriieess aanndd VV--SSeerriieess cc nnddeennssiinngg uunniittss aanndd EESS SSeerriieess rreemm ttee eevvaapp rraatt rrss aarree sshhiippppeedd wwiitthh aa 55--1100 ppssii ((3355--6699
kkPPaa)) hh llddiinngg cchhaarrggee ff nniittrr ggeenn.. WWhhiillee tthhiiss hh llddiinngg cchhaarrggee mmaayy bbee ssaaffeellyy vveenntteedd iinntt tthhee aattmm sspphheerree,, eeyyee
pprr tteeccttii nn sshh uulldd bbee ww rrnn wwhheenn rreemm vviinngg ffiittttiinngg ccaappss..
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
AAllll uunniitt mm uunnttiinngg bb llttss mmuusstt bbee iinnssttaalllleedd,, bbee tthhee cc rrrreecctt lleennggtthh ff rr tthheeiirr aapppplliiccaattii nn,, aanndd tt rrqquueedd tt
ssppeecciiffiiccaattii nnss.. MMiissssiinngg bb llttss,, iinncc rrrreecctt bb lltt lleennggtthhss aanndd iimmpprr ppeerr tt rrqquuee ssppeecciiffiiccaattii nnss ccaann ddaammaaggee
eeqquuiippmmeenntt aanndd vv iidd tthhee wwaarrrraannttyy..
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss

TK 56430-18-IP-EN 11
Auto Start Hazards
CCAAUUTTIIOONN
RRiisskk ff IInnjjuurryy!!
TThheerrmm KKiinngg uunniittss ccaann ssttaarrtt aanndd rruunn aauutt mmaattiiccaallllyy aannyy ttiimmee tthhee uunniitt’’ss HHMMII cc nnttrr lllleerr iiss nn.. BBeeff rree rreemm vviinngg
cc vveerrss,, rr ww rrkkiinngg nn aannyy ppaarrtt ff tthhee uunniitt,, aallwwaayyss ttuurrnn ffff tthhee HHMMII MMaaiinn PP wweerr OOnn//OOffff sswwiittcchh..
CCAAUUTTIIOONN
RRiisskk ff IInnjjuurryy!!
SS mmee vveehhiicclleess mmaayy bbee eeqquuiippppeedd wwiitthh AAuutt SSttaarrtt--SStt pp ffeeaattuurree aallll wwiinngg tthhee eennggiinnee tt rreessttaarrtt aauutt mmaattiiccaallllyy iiff
rreeqquuiirreedd bbyy tthhee ssyysstteemm.. SSwwiittcchh tthhee iiggnniittii nn ffff bbeeff rree ppeenniinngg tthhee hh dd rr ppeerrff rrmmiinngg aannyy mmaaiinntteennaannccee..
FFaaiilluurree tt dd ss mmaayy rreessuulltt iinn sseerrii uuss iinnjjuurriieess dduuee tt aauutt mmaattiicc eennggiinnee rreessttaarrtt.. AAllwwaayyss sswwiittcchh tthhee iiggnniittii nn ffff
bbeeff rree lleeaavviinngg vveehhiiccllee,, aass tthhee ssyysstteemm mmaayy hhaavvee ttuurrnneedd tthhee eennggiinnee ffff,, bbuutt tthhee iiggnniittii nn wwiillll ssttiillll bbee nn aanndd
aauutt mmaattiicc rreessttaarrtt mmaayy ccccuurr.. RReeffeerr tt yy uurr vveehhiiccllee wwnneerrss mmaannuuaall ff rr ffuurrtthheerr iinnff rrmmaattii nn..
Refrigerant Hazards
DDAANNGGEERR
HHaazzaarrdd uuss PPrreessssuurreess!!
AAllwwaayyss sstt rree rreeffrriiggeerraanntt iinn pprr ppeerr cc nnttaaiinneerrss,, uutt ff ddiirreecctt ssuunnlliigghhtt aanndd aawwaayy ffrr mm iinntteennssee hheeaatt.. HHeeaatt
iinnccrreeaasseess pprreessssuurree iinnssiiddee sstt rraaggee cc nnttaaiinneerrss,, wwhhiicchh ccaann ccaauussee tthheemm tt bbuurrsstt aanndd cc uulldd rreessuulltt iinn sseevveerree
ppeerrss nnaall iinnjjuurryy..
DDAANNGGEERR
CC mmbbuussttiibbllee HHaazzaarrdd!!
DD nn tt uussee xxyyggeenn ((OO22 )) rr cc mmpprreesssseedd aaiirr ff rr lleeaakk tteessttiinngg.. OOxxyyggeenn mmiixxeedd wwiitthh rreeffrriiggeerraanntt iiss cc mmbbuussttiibbllee..
WWAARRNNIINNGG
HHaazzaarrdd uuss GGaasseess!!
DD nn tt uussee aa HHaalliiddee tt rrcchh.. WWhheenn aa ffllaammee cc mmeess iinn cc nnttaacctt wwiitthh rreeffrriiggeerraanntt,, tt xxiicc ggaasseess aarree pprr dduucceedd.. TThheessee
ggaasseess ccaann ccaauussee ssuuffff ccaattii nn,, eevveenn ddeeaatthh..
WWAARRNNIINNGG
PPeerrss nnaall PPrr tteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
RReeffrriiggeerraanntt iinn aa lliiqquuiidd ssttaattee eevvaapp rraatteess rraappiiddllyy wwhheenn eexxpp sseedd tt tthhee aattmm sspphheerree,, ffrreeeezziinngg aannyytthhiinngg iitt cc nnttaaccttss..
WWeeaarr bbuuttyyll lliinneedd ggll vveess aanndd tthheerr ccll tthhiinngg aanndd eeyyee wweeaarr wwhheenn hhaannddlliinngg rreeffrriiggeerraanntt tt hheellpp pprreevveenntt ffrr ssttbbiittee..
WWhheenn ww rrkkiinngg wwiitthh rr aarr uunndd hhaazzaarrdd uuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr tt aapppprr pprriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss
((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGll bbaall HHaarrmm nniizzeedd SSyysstteemm ff CCllaassssiiffiiccaattii nn aanndd LLaabbeelllliinngg ff CChheemmiiccaallss)) gguuiiddeelliinneess
ff rr iinnff rrmmaattii nn nn aallll wwaabbllee ppeerrss nnaall eexxpp ssuurree lleevveellss,, pprr ppeerr rreessppiirraatt rryy pprr tteeccttii nn,, aanndd hhaannddlliinngg
iinnssttrruuccttii nnss..
Refrigerant il Hazards
WWAARRNNIINNGG
PPeerrss nnaall PPrr tteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
PPrr tteecctt yy uurr eeyyeess ffrr mm cc nnttaacctt wwiitthh rreeffrriiggeerraanntt iill.. TThhee iill ccaann ccaauussee sseerrii uuss eeyyee iinnjjuurriieess.. PPrr tteecctt sskkiinn aanndd
ccll tthhiinngg ffrr mm pprr ll nnggeedd rr rreeppeeaatteedd cc nnttaacctt wwiitthh rreeffrriiggeerraanntt iill.. TT pprreevveenntt iirrrriittaattii nn,, wwaasshh yy uurr hhaannddss aanndd
ccll tthhiinngg tthh rr uugghhllyy aafftteerr hhaannddlliinngg tthhee iill.. RRuubbbbeerr ggll vveess aarree rreecc mmmmeennddeedd.. WWhheenn ww rrkkiinngg wwiitthh rr aarr uunndd
hhaazzaarrdd uuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr tt aapppprr pprriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS
((GGll bbaall HHaarrmm nniizzeedd SSyysstteemm ff CCllaassssiiffiiccaattii nn aanndd LLaabbeelllliinngg ff CChheemmiiccaallss)) gguuiiddeelliinneess ff rr iinnff rrmmaattii nn nn
aallll wwaabbllee ppeerrss nnaall eexxpp ssuurree lleevveellss,, pprr ppeerr rreessppiirraatt rryy pprr tteeccttii nn,, aanndd hhaannddlliinngg iinnssttrruuccttii nnss..
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss

12 TK 56430-18-IP-EN
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee tthhee cc rrrreecctt iill iinn TThheerrmm KKiinngg ssyysstteemmss tt aavv iidd ddaammaaggiinngg eeqquuiippmmeenntt aanndd nnuulllliiffyyiinngg iittss wwaarrrraannttyy..
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DD nn tt mmiixx rreeffrriiggeerraanntt iillss.. MMiixxiinngg iinncc mmppaattiibbllee iillss wwiillll ddaammaaggee tthhee ssyysstteemm..
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
UUssee ddeeddiiccaatteedd rreeffrriiggeerraattii nn eeqquuiippmmeenntt tt pprreevveenntt cc nnttaammiinnaattiinngg rreeffrriiggeerraattii nn ssyysstteemmss wwiitthh tthhee wwrr nngg ttyyppee ff
iill rr rreeffrriiggeerraanntt..
NN TTIICCEE
SSyysstteemm CC nnttaammiinnaattii nn!!
DD nn tt eexxpp ssee tthhee rreeffrriiggeerraanntt iill tt tthhee aaiirr aannyy ll nnggeerr tthhaann nneecceessssaarryy.. SStt rree rreeffrriiggeerraanntt iill iinn aann aapppprr vveedd
sseeaalleedd cc nnttaaiinneerr tt aavv iidd mm iissttuurree cc nnttaammiinnaattii nn.. TThhee iill wwiillll aabbss rrbb mm iissttuurree,, wwhhiicchh rreessuullttss iinn mmuucchh ll nnggeerr
eevvaaccuuaattii nn ttiimmeess aanndd pp ssssiibbllee ssyysstteemm cc nnttaammiinnaattii nn..
NN TTIICCEE
MMaatteerriiaall DDaammaaggee!!
WWiippee uupp ssppiillllss iimmmmeeddiiaatteellyy.. RReeffrriiggeerraanntt iill ccaann ddaammaaggee ppaaiinnttss aanndd rruubbbbeerr mmaatteerriiaallss..
Electrical Hazards
DDAANNGGEERR
HHaazzaarrdd uuss VV llttaaggee!!
UUnniittss eeqquuiippppeedd wwiitthh EElleeccttrriicc SSttaannddbbyy ppttii nn ppeerraattee nn 111155 rr 223300 vv llttss aacc.. TThhiiss vv llttaaggee iiss pp tteennttiiaall
ddaannggeerr uuss,, ccaauussiinngg sseerrii uuss iinnjjuurryy rr ddeeaatthh..
WWAARRNNIINNGG
LLiivvee EElleeccttrriiccaall CC mmpp nneennttss!!
CC nnttrr ll cciirrccuuiittss aarree ll ww vv llttaaggee ((2244 VVaacc aanndd 1122 VVddcc)).. TThhiiss vv llttaaggee pp tteennttiiaall iiss nn tt cc nnssiiddeerreedd ddaannggeerr uuss.. LLaarrggee
aamm uunntt ff ccuurrrreenntt aavvaaiillaabbllee (( vveerr 3300 aammppeerreess)) ccaann ccaauussee sseevveerree bbuurrnnss iiff sshh rrtteedd tt ggrr uunndd.. DD nn tt wweeaarr
jjeewweellrryy,, wwaattcchh rr rriinnggss.. TThheessee iitteemmss ccaann sshh rrttccuutt eelleeccttrriiccaall cciirrccuuiittss aanndd ccaauussee sseevveerree bbuurrnnss tt tthhee wweeaarreerr..
Battery Removal Hazards
WWAARRNNIINNGG
HHaazzaarrdd ff EExxppll ssii nn!!
WWhheenn rreemm vviinngg bbaatttteerryy ccaabblleess,, AALLWWAAYYSS ddiisscc nnnneecctt tthhee nneeggaattiivvee bbaatttteerryy tteerrmmiinnaall ffiirrsstt.. TThheenn rreemm vvee tthhee
pp ssiittiivvee tteerrmmiinnaall.. WWhheenn rreecc nnnneeccttiinngg tthhee bbaatttteerryy tteerrmmiinnaallss,, cc nnnneecctt tthhee pp ssiittiivvee tteerrmmiinnaall ((++)) ffiirrsstt,, aanndd
cc nnnneecctt tthhee nneeggaattiivvee ((--)) tteerrmmiinnaall llaasstt..
Welding Precautions
Take precauti ns bef re perf rming electric welding n any p rti n f the unit r vehicle t which the unit is attached.
Verify welding currents are n t all wed t fl w thr ugh the electr nic circuits f the Therm King unit.
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss

TK 56430-18-IP-EN 13
Microprocessor Precautions
The f ll wing pr cedures must be f ll wed when w rking n micr pr cess r based c ntr l systems:
• Never use testers c nsisting f a battery and a light bulb t test circuits n any micr pr cess r based equipment.
• Always turn the unit ff by pressing the HMI Main P wer On/Off key bef re c nnecting r disc nnecting the truck
batteries. Read and f ll w all truck instructi ns f r rem ving batteries.
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss

14 TK 56430-18-IP-EN
First Aid
RREEFFRRIIGGEERRAANNTT
•EEyyeess:: F r c ntact with liquid, immediately flush eyes with large am unts f water and get pr mpt medical
attenti n.
•SSkkiinn:: Flush area with large am unts f warm water. D n t apply heat. Rem ve c ntaminated cl thing and sh es.
Wrap burns with dry, sterile, bulky dressing t pr tect fr m infecti n. Get pr mpt medical attenti n. Wash
c ntaminated cl thing bef re reuse.
•IInnhhaallaattii nn:: M ve victim t fresh air and use Cardi Pulm nary Resuscitati n (CPR) r m uth-t -m uth
resuscitati n t rest re breathing, if necessary. Stay with victim until emergency pers nnel arrive.
•FFrr sstt BBiittee:: In the event f fr st bite , the bjectives f First Aid are t pr tect the fr zen area fr m further injury,
warm the affected area rapidly, and t maintain respirati n.
RREEFFRRIIGGEERRAANNTT OOIILL
•EEyyeess:: Immediately flush with large am unts f water f r at least 15 minutes. Get pr mpt medical attenti n.
•SSkkiinn:: Rem ve c ntaminated cl thing. Wash th r ughly with s ap and water. Get medical attenti n if irritati n
persists.
•IInnhhaallaattii nn:: M ve victim t fresh air and use Cardi Pulm nary Resuscitati n (CPR) r m uth-t -m uth
resuscitati n t rest re breathing, if necessary. Stay with victim until emergency pers nnel arrive.
•IInnggeessttii nn:: D n t induce v miting. Immediately c ntact l cal p is n c ntr l center r physician.
EENNGGIINNEE CCOOOOLLAANNTT
•EEyyeess:: Immediately flush with large am unts f water f r at least 15 minutes. Get pr mpt medical attenti n.
•SSkkiinn:: Rem ve c ntaminated cl thing. Wash th r ughly with s ap and water. Get medical attenti n if irritati n
persists.
•IInnggeessttii nn:: D n t induce v miting. Immediately c ntact l cal p is n c ntr l center r physician.
BBAATTTTEERRYY AACCIIDD
•EEyyeess:: Immediately flush with large am unts f water f r at least 15 minutes. Get pr mpt medical attenti n. Wash
skin with s ap and water.
•SSkkiinn:: Immediately rem ve c ntaminated cl thing. Wash skin with large v lumes f water, f r at least 15 minutes.
Wash skin with s ap and water. D n t apply fatty c mp unds. Seek immediate medical assistance.
•IInnhhaallaattii nn:: Pr vide fresh air. Rinse m uth and n se with water. Seek immediate medical assistance.
•IInnggeessttii nn:: If the injured pers n is fully c nsci us: make the pers n drink extensive am unts f milk. D n t induce
v miting. Take the injured pers n immediately t a h spital.
EELLEECCTTRRIICCAALL SSHHOOCCKK
Take IMMEDIATE acti n after a pers n has received an electrical sh ck. Get quick medical assistance, if p ssible.
The s urce f the sh ck must be quickly st pped, by either shutting ff the p wer r rem ving the victim. If the p wer
cann t be shut ff, the wire sh uld be cut with an n n-c nductive t l, such as a w d-handle axe r thickly insulated
cable cutters. Rescuers sh uld wear insulated gl ves and safety glasses, and av id l king at wires being cut. The
ensuing flash can cause burns and blindness.
If the victim must be rem ved fr m a live circuit, pull the victim away with a n n-c nductive material. Use w d, r pe,
a belt r c at t pull r push the victim away fr m the current. DO NOT TOUCH the victim. Y u will receive a sh ck fr m
current fl wing thr ugh the victim’s b dy. After separating the victim fr m p wer s urce, immediately check f r signs
f a pulse and respirati n. If n pulse is present, start Cardi Pulm nary Resuscitati n (CPR). If a pulse is present,
respirati n might be rest red by using m uth-t -m uth resuscitati n. Call f r emergency medical assistance.
AASSPPHHYYXXIIAATTIIOONN
M ve victim t fresh air and use Cardi Pulm nary Resuscitati n (CPR) r m uth-t -m uth resuscitati n t rest re
breathing, if necessary. Stay with victim until emergency pers nnel arrive.
Safety Decals
Observe all safety decals placed in vari us l cati ns n the unit.
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss

TK 56430-18-IP-EN 15
Figure 1. Typical Safety Decals
SSeeccttii nn 22 -- SSaaffeettyy PPrreeccaauuttii nnss

16 TK 56430-18-IP-EN
Section 3 - Required Tools
verview
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 56430-18-IP-EN 17
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)
SSeeccttii nn 33 -- RReeqquuiirreedd TT llss

18 TK 56430-18-IP-EN
Section 4 - Unit Installation Standards and Procedures
verview
This secti n defines Therm King unit installati n standards t c rrectly and safely install the individual c mp nents
that make up the c mplete refrigerati n system. Pr per installati n f each c mp nent nt the vehicle is critical.
Impr per installati n can n t nly result in p r system perf rmance, but it can als bec me a safety c ncern. It is the
resp nsibility f the installer t f ll w these standards t assure the c mp nents are installed c rrectly and the unit
perates as designed.
Cargo Box Requirements
The carg b x size, insulati n thickness, d r penings per delivery day and temperature requirements must be
matched t the Therm King refrigerati n system being installed. The wr ng size unit n the wr ng size carg b x may
n t perf rm as designed. The interactive Unit Selecti n Guide sh uld be used t verify the c rrect unit is selected.
Additi nal Requirements:
• The carg b x must be designed and built f r refrigerati n applicati ns with insulated walls, ceilings and fl rs. All
carg b x d rs must cl se and seal tightly.
• Carg b xes that fail t meet these requirements are n t suited f r refrigerated applicati ns and the Therm King
equipment will not maintain temperature.
• Additi nally, the carg b x fr nt wall, r f and ceiling must be able t supp rt the weight f the c ndenser and
rem te evap rat r. Additi nal supp rts may be required and are the resp nsibility f the installer t supply.
•
NNoottee:: Unit weights can be found in the product brochures.
Installation Manuals
Unit installati n manuals are available nline at therm king.c m r thr ugh the Asset Library and ReqDirect rdering
system. . These manuals pr vide unit specific inf rmati n t assist with the installati n such as il am unts, refrigerant
capacity, and valve settings. They als explain in detail the c rrect refrigerati n h se and fitting l cati ns and the
electrical harnesses c nnecti ns. Bef re beginning the installati n, y u sh uld review the unit installati n manual t
familiarize y urself with the vari us c mp nents that make up y ur particular system.

TK 56430-18-IP-EN 19
Installation Templates
Paper templates are available t assist with the installati n f the c ndenser and evap rat r. These templates pr vide
the installer with a “f tprint” f the c mp nent and pr vide the c rrect m unting and access h le l cati ns. Therm
King Dealers can access templates thr ugh Inf Central r rder them thr ugh the ReqDirect system.
• Using templates saves time and err rs by eliminating the time required t measure and mark the l cati ns f the
individual h les.
• When installing multiple units, paper templates sh uld be transferred t a m re durable material such as aluminum.
This will all w y u t reuse the templates as needed.
Unpacking and Inspecting Components
C mp nents are carefully packaged at the fact ry t prevent damage during shipment. H wever, if c mp nents are
f und t be damaged, c ntact the shipping c mpany immediately. C ntact Therm King if c mp nents are missing.
Bef re beginning the installati n, check the f ll wing against the sales rder:
Confirm all components are accounted
for including the kits and any options.
SSeeccttii nn 44 -- UUnniitt IInnssttaallllaattii nn SSttaannddaarrddss aanndd PPrr cceedduurreess

20 TK 56430-18-IP-EN
Confirm condenser model and voltages
shown on the condenser serial plate
matches the sales order.
Confirm evaporator model matches the
sales order.
Drilling Holes
All installati ns will require h les be drilled int the vehicle r carg b x. Spending a few minutes reviewing y ur
particular vehicle bef re drilling any h les can help prevent pr blems later.
IImmppoorrttaanntt:: Never drill holes into the condenser unit or evaporator. Doing so will weaken the structure and void your
warranty.
NNoottee:: Verify there is no interference with EM electrical wiring, internal supports, etc. before drilling holes in vehicle.
• C nsult y ur vehicle’s manufacturer/b x builder bef re drilling any h les in the chassis, carg b x r structural
supp rts.
• Use the unit specific installati n manual t determine h w many refrigerant lines and electrical harnesses need t
pass thr ugh the carg b x wall r r f.
• Select the appr priate size h le saw t cut a h le that is large en ugh t acc mm date all the h ses and electrical
harnesses.
• H les drilled f r m unting c mp nents must be the c rrect size f r the m unting hardware. H les larger than the
diameter f the m unting b lts will result in water/air leakage, damage t the vehicle and t the refrigerati n
c mp nents.
• H les must be drilled straight – n t at an angle.
SSeeccttii nn 44 -- UUnniitt IInnssttaallllaattii nn SSttaannddaarrddss aanndd PPrr cceedduurreess