Thermo King Trailer Edition Heat King 450 Series User manual

Revision A
April 2021 TTKK 5566111188--66--IIMM--EENN
Heat King 450 Series
HK450, HK450 HO and HK450 MAX Diesel Heating nits
Installation Manual

©2021 Trane Technologies TK 56118-6-IM-EN
Introduction
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.
This manual is published for informational purposes only and the information furnished herein should not be
considered as all-inclusive or meant to cover all contingencies. If more information is required, consult your Thermo
King Service Directory for the location and telephone number of the local dealer.
TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
oorr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo 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..
There is nothing complicated about operating and maintaining your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a regular basis will minimize operating problems. A regular
maintenance program will also help to keep your unit in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most efficient and dependable temperature control system
available.
All service requirements, major and minor, should be handled by a Thermo King dealer for four very important reasons:
• They are equipped with the factory recommended tools to perform all service functions.
• They have factory trained and certified technicians.
• They have genuine Thermo King replacement parts.
• The warranty on your new unit is valid only when the repair and replacement of component parts is performed by
an authorized Thermo King dealer.
Revision History
Revision A (04/21) Released new manual format.
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TK 56118-6-IM-EN 3
SSaaffeettyy PPrreeccaauuttiioonnss ............................................................................................................................................................ 44
Danger, Warning, Caution and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IImmppoorrttaanntt IInnssttaallllaattiioonn RReeqquuiirreemmeennttss .................................................................................................................... 66
Trailer / Container Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
nitWeight................................................................................. 6
Front Wall Dimensions and Swing Radius. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting Bolt Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CCoommppoonneenntt DDiimmeennssiioonnss .... .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .... 1100
nit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote HMI Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RReeqquuiirreedd TToooollss ...... .... .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ........ 1144
IInnssttaallllaattiioonn KKiitt CCoommppoonneennttss ........ .... .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .......... .... .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ........ 1155
IInnssttaalllliinngg nniitt .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1166
IInnssttaalllliinngg RReemmoottee HHMMII ...... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. 1188
Surface Mount Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Flush Mount Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
IInnssttaalllliinngg FFuueell SSyysstteemm ...... .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .... .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... 2200
nder Chassis Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing Fuel Pump and Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Optional Nose Mounted 65 Gallon Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation Best Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installing Fuel Pump and Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
IInnssttaalllliinngg BBaatttteerryy .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .... .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. 2244
SSeerrvviiccee TTeesstt PPrroocceedduurree .. .... .. .. .. .. .. .. .. .......... .. .... .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .... .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2266
Engine Break-in Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SSyysstteemm CChheecckk LLiisstt .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2277
Table of Contents

4TK 56118-6-IM-EN
Safety Precautions
anger, Warning, Caution and Notice
Thermo King recommends that all service be performed by a Thermo King dealer and to be aware of several general
safety practices.
Safety advisories appear throughout this manual as required. Your personal safety and the proper installation of this
unit depend upon the strict observance of these precautions.
Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury and unsafe
practices.
Indicates a situation that could result in equipment or property-damage only accidents.
DDAANNGGEERR
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
TToo pprreevveenntt sseevveerree eeqquuiippmmeenntt ddaammaaggee,, sseerriioouuss iinnjjuurryy,, oorr ddeeaatthh,, tthhee ffrroonntt wwaallll ooff tthhee ttrraaiilleerr oorr ccoonnttaaiinneerr mmuusstt
bbee ssttrruuccttuurraallllyy ssttrroonngg eennoouugghh ttoo ssuuppppoorrtt tthhee wweeiigghhtt ooff aa HHeeaatt KKiinngg 445500 sseerriieess uunniitt,, oorr wwhheenn uussiinngg tthhee ffrroonntt wwaallll
mmoouunntteedd ffuueell ttaannkk ooppttiioonn,, tthhee ccoommbbiinneedd wweeiigghhtt ooff aa HHeeaatt KKiinngg 445500 sseerriieess uunniitt,, pplluuss tthhee wweeiigghhtt ooff tthhee ffuueell,, tthhee
ffuueell ttaannkk aanndd bbrraacckkeettss..
DDAANNGGEERR
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
FFaaiilluurree ttoo sseeccuurree tthhee HHeeaatt KKiinngg 445500 sseerriieess uunniitt pprrooppeerrllyy ttoo tthhee ttrraaiilleerr oorr ccoonnttaaiinneerr ccaann rreessuulltt iinn sseevveerree
eeqquuiippmmeenntt ddaammaaggee,, sseerriioouuss iinnjjuurryy,, oorr ddeeaatthh..
DDAANNGGEERR
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
CCoonnssuulltt yyoouurr ttrraaiilleerr oorr ccoonnttaaiinneerr mmaannuuffaaccttuurreerr ffoorr ssppeecciiffiicc ddeettaaiillss oonn pprrooppeerr ffuueell ttaannkk iinnssttaallllaattiioonn aanndd
rreeccoommmmeennddaattiioonnss.. AAnn iimmpprrooppeerrllyy iinnssttaalllleedd ffuueell ttaannkk ccoouulldd lleeaadd ttoo sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
AAllll uunniitt mmoouunnttiinngg bboollttss mmuusstt bbee iinnssttaalllleedd,, bbee tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aapppplliiccaattiioonn,, aanndd ttoorrqquueedd ttoo
ssppeecciiffiiccaattiioonnss.. MMiissssiinngg bboollttss,, iinnccoorrrreecctt bboolltt lleennggtthhss aanndd iimmpprrooppeerr ttoorrqquuee ssppeecciiffiiccaattiioonnss ccaann ddaammaaggee
eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..

TK 56118-6-IM-EN 5
Battery Installation and Cable Routing
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAnn iimmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. AA TThheerrmmoo KKiinngg aapppprroovveedd bbaatttteerryy
mmuusstt bbee iinnssttaalllleedd aanndd pprrooppeerrllyy sseeccuurreedd ttoo tthhee bbaatttteerryy ttrraayy..
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
IImmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccaabblleess ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy ccaabblleess mmuusstt bbee iinnssttaalllleedd,,
rroouutteedd,, aanndd sseeccuurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheemm ffrroomm rruubbbbiinngg,, cchhaaffffiinngg,, oorr mmaakkiinngg ccoonnttaacctt wwiitthh hhoott,, sshhaarrpp,, oorr
rroottaattiinngg ccoommppoonneennttss..
WWAARRNNIINNGG
FFiirree HHaazzaarrdd!!
DDoo nnoott aattttaacchh ffuueell lliinneess ttoo bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo ccaauussee aa ffiirree aanndd
ccoouulldd ccaauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
WWAARRNNIINNGG
HHaazzaarrdd ooff EExxpplloossiioonn!!
AAllwwaayyss ccoovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroomm mmaakkiinngg ccoonnttaacctt wwiitthh mmeettaall ccoommppoonneennttss dduurriinngg bbaatttteerryy
iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall ccoouulldd ccaauussee tthhee bbaatttteerryy ttoo eexxppllooddee..
CCAA TTIIOONN
HHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!
SSeett aallll uunniitt eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbeeffoorree ccoonnnneeccttiinngg bbaatttteerryy ccaabblleess ttoo tthhee bbaatttteerryy ttoo pprreevveenntt
uunniitt ffrroomm ssttaarrttiinngg uunneexxppeecctteeddllyy aanndd ccaauussiinngg ppeerrssoonnaall iinnjjuurryy..
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott ccoonnnneecctt ootthheerr mmaannuuffaaccttuurreerr’’ss eeqquuiippmmeenntt oorr aacccceessssoorriieess ttoo tthhee uunniitt oorr ttoo tthhee TTKK BBaatttteerriieess uunnlleessss
aapppprroovveedd bbyy TThheerrmmoo KKiinngg.. FFaaiilluurree ttoo ddoo ssoo ccaann rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..
SSaaffeettyy PPrreeccaauuttiioonnss

6TK 56118-6-IM-EN
Important Installation Requirements
Trailer / Container Requirements
DDAANNGGEERR
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
TToo pprreevveenntt sseevveerree eeqquuiippmmeenntt ddaammaaggee,, sseerriioouuss iinnjjuurryy,, oorr ddeeaatthh,, tthhee ffrroonntt wwaallll ooff tthhee ttrraaiilleerr oorr ccoonnttaaiinneerr mmuusstt
bbee ssttrruuccttuurraallllyy ssttrroonngg eennoouugghh ttoo ssuuppppoorrtt tthhee wweeiigghhtt ooff aa HHeeaatt KKiinngg 445500 sseerriieess uunniitt,, oorr wwhheenn uussiinngg tthhee ffrroonntt wwaallll
mmoouunntteedd ffuueell ttaannkk ooppttiioonn,, tthhee ccoommbbiinneedd wweeiigghhtt ooff aa HHeeaatt KKiinngg 445500 sseerriieess uunniitt,, pplluuss tthhee wweeiigghhtt ooff tthhee ffuueell,, tthhee
ffuueell ttaannkk aanndd bbrraacckkeettss..
DDAANNGGEERR
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
FFaaiilluurree ttoo sseeccuurree tthhee HHeeaatt KKiinngg 445500 sseerriieess uunniitt pprrooppeerrllyy ttoo tthhee ttrraaiilleerr oorr ccoonnttaaiinneerr ccaann rreessuulltt iinn sseevveerree
eeqquuiippmmeenntt ddaammaaggee,, sseerriioouuss iinnjjuurryy,, oorr ddeeaatthh..
DDAANNGGEERR
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
CCoonnssuulltt yyoouurr ttrraaiilleerr oorr ccoonnttaaiinneerr mmaannuuffaaccttuurreerr ffoorr ssppeecciiffiicc ddeettaaiillss oonn pprrooppeerr ffuueell ttaannkk iinnssttaallllaattiioonn aanndd
rreeccoommmmeennddaattiioonnss.. AAnn iimmpprrooppeerrllyy iinnssttaalllleedd ffuueell ttaannkk ccoouulldd lleeaadd ttoo sseerriioouuss iinnjjuurryy oorr ddeeaatthh..
Unit Weight
UNIT WEIGHT*
Heat King 450 series unit with EON battery
installed.
HK450/HK450 HO
220 kg (484 lbs.)
HK450 MAX
231 kg (510 lbs)
*Does not include the weight of the fuel, the fuel tank and brackets.

TK 56118-6-IM-EN 7
Front Wall imensions and Swing Radius
Figure 1. Front Wall imensions and Swing Radius Shown
AAA665-1
914.4 mm (36.00 in.)
B
C
D
517.7 mm
(20.38 in.
939.8 mm
(37.00 in.
984.2 mm
(38.75 in.
711.3 mm
(28.00 in.
152.4 mm
(6.00 in.) 492.1 mm
(19.38 in.
469.9 mm
(18.50 in.
212.9 mm
(8.38 in.)
A
C
C
L
L
A. Trailer opening must be square.
Diagonal dimension must be +/- .12 in.
B. King Pin Setting
C. Swing Radius
D. 407.2 mm (55.40) Radius for Standard HK installation
464.3 mm (57.65) Radius for Zero Cube HK installation
IImmppoorrttaanntt IInnssttaallllaattiioonn RReeqquuiirreemmeennttss

8TK 56118-6-IM-EN
Mounting Bolt Specifications
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
AAllll uunniitt mmoouunnttiinngg bboollttss mmuusstt bbee iinnssttaalllleedd,, bbee tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aapppplliiccaattiioonn,, aanndd ttoorrqquueedd ttoo
ssppeecciiffiiccaattiioonnss.. MMiissssiinngg bboollttss,, iinnccoorrrreecctt bboolltt lleennggtthhss aanndd iimmpprrooppeerr ttoorrqquuee ssppeecciiffiiccaattiioonnss ccaann ddaammaaggee
eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..
DDAANNGGEERR
RRiisskk ooff IInnjjuurryy!!
TThhee uussee ooff mmoouunnttiinngg bboollttss ootthheerr tthhaann tthhoossee ssppeecciiffiieedd ccoouulldd rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt,, vvooiidd tthhee
wwaarrrraannttyy,, oorr ccaauussee ppeerrssoonnaall iinnjjuurryy oorr ddeeaatthh..
NNoottee:: Mounting hardware to be supplied by installer.
• Metric M12 x 1.75 pitch class 8.8 (or 1/2 in.-13 NC - 2B Rolled thread grade 5), medium carbon steel bolts and
locking nuts
• All hardware must be zinc plated with dichromate finish.
NNoottee:: The location of the unit mounting bolts in the trailer front wall is critical to proper unit installation.
• A gasket sealing surface of 76.2 mm (3.00 in.) wide all around the trailer/container wall opening must be free from
rivets or bolt heads and flat within 6.5 mm (.25 in.)
• All mounting bolts must be square with the front wall and securely fastened to the trailer/container wall in such a
manner to allow the mounting nuts be torqued to 82 N•m (60 ft. lbs.) from outside the trailer/container.
• Mounting bolts are to extend 57.2 mm (2.25 in.) beyond the front wall ((SSeeee FFiigg.. 22)).
• Surface of all mounting bolts are to be flat within 2.5 mm (0.10 in.).
IImmppoorrttaanntt IInnssttaallllaattiioonn RReeqquuiirreemmeennttss

TK 56118-6-IM-EN 9
Figure 2. Mounting Bolt Specifications Shown
AAA668-1
57.2 mm
(2.25 in.)
IImmppoorrttaanntt IInnssttaallllaattiioonn RReeqquuiirreemmeennttss

10 TK 56118-6-IM-EN
Component imensions
Unit imensions
Figure 3. HK Unit imensions Shown
87.88 mm
(3.46 in.) 833.12 m
(32.8 in.)
1117.60 mm
(44.00 in. 86.61 mm
(3.41 in.)
847.85 m
(33.38 in.
920.75 m
(36.25 in.
AAA670-1

TK 56118-6-IM-EN 11
Remote HMI imensions
Figure 4. Remote HMI imensions Shown
ABA420-1
247.7 mm
(9.75 in.)
111.3 mm
(4.38 in.)
81.3 mm
(3.20 in.)
215.9 mm
(8.50 in.) 16.0 mm
(0.63 in.)
14.9 mm
(0.59 in.)
4X 5.84 mm
(0.23 in.)
172.5 mm
(6.79 in.)
60.5 mm
(2.38 in.)
CCoommppoonneenntt DDiimmeennssiioonnss

12 TK 56118-6-IM-EN
Battery Selection Guide
NN TTIICCEE
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott ccoonnnneecctt ootthheerr mmaannuuffaaccttuurreerr’’ss eeqquuiippmmeenntt oorr aacccceessssoorriieess ttoo tthhee uunniitt oorr ttoo tthhee TTKK BBaatttteerriieess uunnlleessss
aapppprroovveedd bbyy TThheerrmmoo KKiinngg.. FFaaiilluurree ttoo ddoo ssoo ccaann rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..
IImmppoorrttaanntt:: The specified battery, electrical wiring and electronic controls were designed to operate and maintain only
the Thermo King Heat King unit and factory authorized Thermo King options. 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!
Heat King units:
• are designed for one 12 volt, Group 31 battery supplied by the installer.
• must use a battery suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr.
NNoottee:: See following table for Thermo King approved batteries. Refer to Service Bulletin T&T 446 for more information
regarding Battery Selection and Maintenance.
BATTERY APPLICATION TABLE
750 CCA Wet Cell
Thermo King ReliaMax 750S
P/N 203-731 Threaded Stud
P/N 203-730 SAE Post
925 CCA Wet Cell
Thermo King ReliaMax 925N
P/N 203-733 Threaded Stud
P/N 203-732 SAE Post
1150 CCA Dry Cell (AGM)
Thermo King EON
P/N 203-550 Threaded Stud
P/N 203-551 SAE Post
• Wet Cell Technology
• Better suited for warmer climates
• Less cranking power at low ambient
temperatures
• 18-24 month expected life *see note
below
• Choose for southern climates
• Wet Cell Technology
• Better suited for colder climates
• High cranking power at low ambient
temperatures
• 18-24 month expected life *see note
below
• Choose for northern climates
• Dry Cell Technology
• Better suited for all applications
• High cranking power at low ambient
temperatures
• Suited for extreme temperatures
• Best for high cycling applications (Cycle-
Sentry use)
• 5–7 year expected life
NOTE: Wet cell battery life and maintenance requirements are determined by the operating environment and the charge/discharge rate
(cycles) while the battery is in service. Higher ambient temperatures and frequent discharges will shorten a wet cell battery’s overall life
expectancy and increase maintenance requirements.
CCoommppoonneenntt DDiimmeennssiioonnss

TK 56118-6-IM-EN 13
Battery imensions
Figure 5. Group 31 Battery imensions Shown
CCoommppoonneenntt DDiimmeennssiioonnss

14 TK 56118-6-IM-EN
Required Tools
1. Safety Glasses
2. Drill
3. Drill Bits
4. Tape Measure
5. Mechanics Tools
6. Lifting Device
7. Two Forged Eyebolts (1/2–13 NC)
8. Work Platform (Recommended)
9. Torque Wrench
NNoottee:: Equipment such as torque wrenches should be in good working condition and routinely calibrated to assure
accurate readings.

TK 56118-6-IM-EN 15
Installation Kit Components
HARDWARE KIT FUEL LINE KIT FUEL PUMP KIT
Clamps 1/4” OD x 40 ft. Fuel Hose Fuel Pump
Band wraps 3/8” OD x 40 ft. Fuel Hose 3/8 Hose Fiting
1/4–20 SS Screw 1/4” Eyelet Fitting Fuel Pump Bracket
1/4–20 SS Nut 3/8” Eyelet Fitting Harness
1/2–13 Nut 1/4” Sleeve Fitting Nameplate
1/2 SAE Washer 3/8” Sleeve Fitting
1/4–SS Washer 1/4” Nut Fitting
1.25 OD Washer 3/8” Nut Fitting
#10 Screw 1/4” Connector
1/4–20 Screw Fuel Line Connector
T-25 Torx Screw 4” Long Hose

16 TK 56118-6-IM-EN
Installing Unit
WWAARRNNIINNGG
EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
DDoo nnoott uussee aa ffoorrkklliifftt ttoo iinnssttaallll tthhee uunniitt.. TThhiiss ccoouulldd rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt,, vvooiidd tthhee wwaarrrraannttyy,, oorr
ccaauussee ppeerrssoonnaall iinnjjuurryy oorr ddeeaatthh..
WWAARRNNIINNGG
RRiisskk ooff IInnjjuurryy!!
ssee oonnllyy lloocckkiinngg hhooookkss ttoo ssaaffeellyy lliifftt tthhee uunniitt.. FFaaiilluurree ttoo uussee lloocckkiinngg hhooookkss ccoouulldd rreessuulltt iinn sseevveerree ddaammaaggee ttoo tthhee
eeqquuiippmmeenntt,, vvooiidd tthhee wwaarrrraannttyy,, oorr ccaauussee ppeerrssoonnaall iinnjjuurryy oorr ddeeaatthh..
To avoid unnecessary damage to your unit, place the crated unit near the trailer/container prior to its removal. Carefully
remove top boards of the crate, the installation kit boxes, and any other loose components from rear of unit.
1. Attach two forged lifting eyebolts (1/2-13 NC) into the thread holes located on top of unit (Detail I).
a. Attach lifting device to eyebolts and slightly raise unit and remove hardware holding unit to crate.
NNoottee:: For Zero–Cube installations, refer to Zero-Cube installation instructions (TK 56142) available at Thermo King
iService or Thermoking.com.
2. Lift the unit and position it in the trailer/container opening.
a. With the unit access door open, align the four unit mounting holes with the trailer/container mounting bolts.
3. Attach supplied 1-1/4'' washers and locking nuts.
a. Torque mounting hardware to 82 N•m (60 ft. lbs.).
4. SSeeee ““IInnssttaalllliinngg RReemmoottee HHMMII”” oonn ppaaggee 1188..
5. HHKK445500 MMAAXX NNIITTSS OONNLLYY – From inside the unit, place the supplied hose clamp over the end of the copper
exhaust drain tube and slide it up the tube a few inches.
a. From under the unit, insert the drain hose up through the two grommets located in the frame and over the
copper exhaust drain tube. Slide the hose clamp down onto the drain hose and tighten clamp securely.
b. Route the drain hose straight down past the bottom of the trailer and secure with supplied clamps and screws.
Be sure not to pinch the drain hose closed when routing and installing clamps.
NNoottee:: When installing an optional exhaust extension kit 701181 or 701182, follow the instructions that are included with
the kit.

TK 56118-6-IM-EN 17
Figure 6. Standard HK Unit Installation Shown
RCS156-1
5
4
2
3
1
IInnssttaalllliinngg nniitt

18 TK 56118-6-IM-EN
Installing Remote HMI
Surface Mount Installation
NNoottee:: The installation views shown are for reference only. The actual locations chosen for installing the remote HMI
may vary per your specific application and should not interfere with the operation of the trailer or container.
1. Position the HMI onto the surface of the front wall while providing a drip loop as shown.
2. Open the front cover to access the four mounting holes.
a. Secure to the trailer wall with the supplied T-25 Torx head self tapping screws.
IImmppoorrttaanntt:: Do not overtighten the screws or the plastic enclosure will be damaged.
3. Secure the harness to the trailer wall with the supplied clamps and self tapping screws.
Figure 7. Surface Mount Installation Shown
1
2
3
ABA422-1

TK 56118-6-IM-EN 19
Flush Mount Installation
NNoottee:: N TE: Installer to provide a recessed pocket in the trailer wall to accommodate the remote HMI. This recessed
pocket must be deep enough to help protect the HMI from damage and allow for water drainage.
1. Position the HMI into the recessed pocket while providing a drip loop as shown.
2. Open the front cover to access the four mounting holes.
a. Secure to the recessed pocket with the supplied T-25 Torx head self tapping screws.
NNoottee:: Do not overtighten the screws or the plastic enclosure will be damaged.
3. Secure the harness to the trailer wall with the supplied clamps and self tapping screws.
Figure 8. Flush Mount Installation Shown
1
RCS1761
2
3
IInnssttaalllliinngg RReemmoottee HHMMII

20 TK 56118-6-IM-EN
Installing Fuel System
Under Chassis Fuel Tank
Installation Best Practices
DDAANNGGEERR
FFiirree HHaazzaarrdd!!
LLeeaakkiinngg ffuueell lliinneess ccoouulldd ccaauussee aa ffiirree rreessuullttiinngg iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy.. AAllll ffuueell lliinnee ffiittttiinnggss mmuusstt bbee ttiigghhtt aanndd
lleeaakk ffrreeee..
DDAANNGGEERR
FFiirree HHaazzaarrdd!!
DDoo nnoott rroouuttee ffuueell lliinneess wwiitthh bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall wwiirreess,, aass tthhiiss ccoouulldd ccaauussee aa ffiirree..
• All fuel lines should be routed in a protective housing with no kinks and sharp bends.
• Rubber grommets must be used when routing fuel lines through holes in metal.
• Secure all fuel lines with provided clamps.
• Remove plastic cap from the fuel vent and point the outlet towards the rear of the trailer.
IImmppoorrttaanntt:: The factory installed fuel tank air vent must be in place and functional for the Thermo King unit’s fuel
system to operate correctly and for the fuel tank to remain in compliance with Federal Motor Carrier Safety
Administration specifications (title 49, paragraph 393.67). A plugged or restricted fuel tank air vent can
result in premature damage to the fuel pump and could also cause severe damage to the fuel tank. NEVER
remove or install any other component in place of the fuel tank air vent.
Installing Fuel Pump and Fuel Lines
1. Install fuel pump and bracket as low as possible and near fuel tank to provide rapid pump priming.
2. Route a fuel ssuuppppllyy line from:
a. IInnlleett fitting on fuel filter to the oouuttlleett fitting on top of fuel pump and tighten all fuel lines securely.
b. Route another fuel ssuuppppllyy line from iinnlleett fitting on bottom of fuel pump to the oouuttlleett fitting on fuel tank.
c. Cut fuel supply line at 45 degree angle and install sleeve and nut provided in installation kit.
d. Insert fuel supply line into fuel tank oouuttlleett fitting until it bottoms out, then pull line up 25.4 mm (1.00 in.) and
tighten nut securely.
3. Route a fuel rreettuurrnn line from:
a. RReettuurrnn fitting from the fuel filter to the fuel tank iinnlleett fitting.
b. Cut fuel line at 45 degree angle and install sleeve and nut provided in installation kit.
c. Insert fuel line into fuel tank iinnlleett fitting until it bottoms out, then pull line up 25.4 mm (1.00 in.) and tighten nut
securely.
4. Route the electrical harness from the unit to the fuel pump and attach to the fuel pump connector. The connector
must be installed out of road spray area.
NNoottee:: It is important not to allow the unit to run out of fuel during the engine beak-in period. Add a sufficient amount of
fuel (approximately 20 gallons) to allow the unit to run for 8 to 12 hours during engine break-in and pre-delivery
procedures.
IImmppoorrttaanntt:: Factory installed fuel tank air vent must be in place and functional for Thermo King unit’s fuel system to
operate correctly and for the fuel tank to remain in compliance with Federal Motor Carrier Safety
Administration specifications (title 49, paragraph 393.67). A plugged or restricted fuel tank air vent can
result in premature damage to the fuel pump and could also cause severe damage to the fuel tank. NEVER
remove or install any other component in place of the fuel tank air vent.