Thermo King HK 400 Trailer Edition User manual

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TK 53320-2-IM Nov 2023
Installation Manual
Trailer Edition
HK 400 and HK 400 HO
Diesel Heating Unit
November 2023
Revision 4
TK-53320-2-IM

Installation Manual
Trailer Edition
HK-400 and HK-400 HO
Diesel Heating Units
TK 53320-2-IM (Rev. 4, 11/23)
Copyright©2006 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

2
Release History
Released
Rev. 1
Rev. 2
Rev.3
Rev. 4
(8/06)
(04/09) Updated manual to include the following - Page 14; added new Battery Selection Guide, pages 18-19; added new
Surface Mount Controller instructions, pages 20-21; added new Flush Mount Controller instructions, pages 22-23; added
early (enclosed style) fuel tank mounting bracket, pages 24-27; added late (open style) fuel tank mounting bracket.
(09/11) Updated manual toinclude the following: Page 6; added battery installation and cable routing information to the
Safety Section, pages 34-37; added 65 gallon rectangle fuel tank information.
(02/13) Page 19 - Changed art to show forged connecting links and forged locking hooks used for lifting the unit.
(11/23) Page 37 - Added new fuel return line fitting (133520) to image.

3
Introduction
This installation manual was written to assist with the installation of the Thermo King HK-400 and HK-400 HO diesel heating units onto trailers or
intermodal containers specifically designed and built for these applications.
Due to its complexity, you should not attempt this installation unless you:
• Are an experienced mechanic
• Can safely lift 34 kilos (75 lbs.)
• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems
• Have a basic understanding of electricity and electrical wiring
• Have the necessary tools and equipment to complete the installation.
This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the
manufacturer’s judgment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or
descriptions contained herein.

4
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Trailer / Container Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting Bolt Specifications and Installation Requirements . . . . . . . . . 12
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Group 31 Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Uncrating and Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installing the Surface Mount Controller (Option) . . . . . . . . . . . . . . . . . . 20
Installing the Flush Mount Controller (Option). . . . . . . . . . . . . . . . . . . . 22
Installing the Fuel Tank - Alum., 22'' dia. 30 & 50 Gallon - (Option). . . 24
Installing the Fuel Tank - Alum., L-Shaped, 65 Gallon - (Option) . . . . . 28
Installing the Fuel Tank - Steel, Rectangle, 65 Gallon - (Option) . . . . . 32
Installing the Fuel Pump and Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SYSTEM CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5
Safety Precautions
The symbol appears next to a point that is particularly important:
DANGER: Addresses a circumstance that, if encountered,
will lead to death or serious injury
WARNING: Addresses a circumstance that, if encountered,
might lead to death or serious injury.
CAUTION: Addresses a circumstance that, if encountered,
may cause damage to equipment or minor injury.
WARNING: Keep your hands away from fans and belts when
the unit is running. Set all electrical controls to the OFF
position before servicing the unit.
WARNING: Make sure all mounting bolts are tight and are of
correct length for their particular application
WARNING: Never drill holes in the unit unless absolutely
necessary. Holes drilled into the unit may weaken structural
components. Holes drilled into electrical wiring can cause fire
or explosion.
WARNING: When using ladders to install or service
refrigeration systems, always observe the ladder
manufacturer’s safety labels and warnings. A work platform is
the recommended method for installations.
CAUTION: Exposed coil fins are very sharp and can cause
painful lacerations. Wear leather work gloves to prevent
injury.

6
Safety Precautions (continued)
Battery Installation and Cable Routing
WARNING: Improperly installed battery could result in a fire or
explosion! A Thermo King approved battery must be installed
and properly secured to the battery tray.
WARNING: Improperly installed battery cables could result in
fire or explosion! Battery cables must be installed, routed and
secured properly to prevent them from rubbing, chaffing or
making contact with hot, sharp or rotating components.
WARNING: Do not attach fuel lines or any additional wiring
harnesses to the battery cables as this could cause an
electrical fire!
CAUTION: Do not connect other manufacturer’s equipment or
accessories to the Thermo King unit. This could result in
severe damage to equipment and void the warranty!
CAUTION: Set all unit electrical controls to the OFF position
before connecting battery cables to the battery to prevent unit
from starting unexpectedly and causing personal injury.
CAUTION: Always wear protective clothing, gloves and eye
wear when handling and installing batteries. Battery acid can
cause serious burns when exposed to eyes or skin. If battery
acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with
running cold water for at least twenty minutes and get medical
attention immediately.
CAUTION: Always cover battery terminals to prevent them
from making contact with metal components during battery
installation. Battery terminals grounding against metal could
cause the battery to explode.

7
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 UNC)
8. Work Platform (Recommended)
9. Torque Wrench
NOTE: Equipment such as torque wrenches should be in good
working condition and routinely calibrated to assure accurate
readings.

8
Installation Components
HARDWARE KIT
Clamps
Bandwraps
Screw 1/4-20 SS
Nut 1/4-20 SS
Nut 1/2-13
Washer 1/2- SAE
Washer 1/4 SS
Washer 1.25 OD
Screw #10
Screw 1/4-20
FUEL LINE KIT
Hose 1/4 OD x 40 ft.
Hose 3/8 OD x 40 ft.
Eyelet fitting 1/4''
Eyelet Fitting 3/8''
Sleeve Fitting 1/4''
Sleeve Fitting 3/8''
Nut Fitting 1/4''
Nut Fitting 3/8''
Connector 1/4''
Connector Fuel Line
Hose 4.00 in. long
FUEL PUMP KIT
Fuel Pump
Hose Fitting 3/8''
Pump Bracket
Harness
Nameplate

9
BLANK PAGE

10
Trailer / Container Requirements
HK- 400 and HK-400 HO
IMPORTANT: Thermo King HK-400 and HK-400 HO diesel heating
units should only be installed onto trailers or containers specifically
designed and built for these applications.
* Does not include weight of fuel, fuel tank and brackets.
Front Wall Mounted Fuel Tank
-
IMPORTANT: Thermo King HK-400 and HK-400 HO diesel heating
units should only be installed onto trailers or containers specifically
designed and built for these applications.
DANGER: The front wall of the trailer or container must be
structurally strong enough to support the weight of the
HK-400 or HK-400 HO unit!
APPROXIMATE WEIGHTS
Thermo King HK unit with EON
battery installed. HK-400
203 kg (448 lbs.)
HK-400 HO
221 kg (488 lbs.)
DANGER: The front wall of the trailer or container must be
structurally strong enough to support the weight of the
HK-400 or HK-400 HO unit and the 65 gallon fuel tank!
DANGER: An improperly installed fuel tank could lead to
serious injury or death! Consult your trailer or container
manufacturer for specific details on proper fuel tank
installation and recommendations.

11
Trailer / Container Requirements

12
Mounting Bolt Specifications and Installation Requirements
Mounting Bolts Specifications
NOTE: Mounting hardware to be supplied by installer.
•Use Metric M12 x 1.75 pitch class 8.8 (1/2 in.-13 UNC - 2B Rolled
thread grade 5), medium carbon steel bolts and locking nuts.
•All hardware must be zinc plated with dichromate finish.
Mounting Bolt Installation Requirements
NOTE: 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 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 wall in such a manner to allow the mounting nuts
be torqued to 82 N•m (60 ft. lbs.) from outside the trailer.
• Mounting bolts are to extend 57.2 mm (2.25 in.) beyond the front wall
(Detail I).
• Surface of all mounting bolts are to be flat within 2.5 mm (0.10 in.).
DANGER: The use of mounting bolts other than those
specified could result in severe damage to equipment, void
the warranty or cause personal injury or death!
DANGER: Four mounting bolts must be installed to properly
secure the unit to the trailer front wall! Failure to do so could
result in severe damage to equipment, void the warranty or
cause personal injury or death!

13
Mounting Bolt Specifications and Installation Requirements

14
Unit Dimensions

15
BLANK PAGE

16
Battery Selection Guide
Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance.
IMPORTANT: The specified battery, electrical wiring and electronic
controls were designed to operate and maintain only the Thermo
King refrigeration system and factory authorized Thermo King
options.
Trailer units are designed for one 12 volt, Group 31 battery supplied by the
installer.
The battery must be suitable for deep cycling, heavy duty and rated with a
minimum of 95 amp/hr.
NOTE: See following table for Thermo King approved batteries.
Refer to Service Bulletin T&T 446 for more information regarding
Battery Selection and Maintenance.
CAUTION: Do not connect other manufacturer’s equipment or
accessories to the Thermo King unit! This could result in
severe damage to equipment and void the warranty!
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 (AGM) Technology
• Better suited for all applications
• High cranking power at lower
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.

17
Group 31 Battery Dimensions
Lug Connections Threaded Stud Connections

18
Uncrating and Installing the Unit
Uncrating the Unit
To avoid unnecessary damage to your unit, place the crated unit near the
trailer prior to its removal.
1. Carefully remove top boards of the crate.
2. Remove installation kit boxes and any other loose components from
rear of unit.
3. Attach two forged lifting eyebolts (1/2-13 UNC) into the thread holes
located on top of unit (Detail I).
4. Attach lifting device to eyebolts and slightly raise unit.
5. Remove hardware holding unit to crate.
Installing the Unit
Optional Zero Cube Installation
A zero cube installation kit is available from your Thermo King Dealer.
The kit consists of a insulated collar that positions the HK unit outside the
cargo area of the trailer.
6. Loosen each lifting plate bolt located on the collar, rotate the lifting
plates 180 degrees and retighten bolts.
7. Attach a lifting device to the lifting plates and raise the collar into
position at the rear of the unit with the gasket surface facing the trailer
opening.
8. Secure the collar to the rear of the unit with appropriate hardware and
tighten securely.
9. Unbolt and remove the lifting plates from the collar. Reinstall only the
bolts onto the collar.
10. Continue by following steps #11-15 below.
Standard Unit Installation
11. Lift the HK unit and position it in the trailer opening.
12. With the HK unit access door open, align the four mounting holes with
the mounting bolts.
13. Attach washer and elastic stop nuts (Nylock) and torque to 82 N•m (60
ft. lbs.).
14. Route the drain hose straight down and 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.
15. Install the control box in a easily accessible location on the front of the
trailer wall without interfering with the operation of the trailer.
DANGER: Do not use a forklift to install the unit! This could
result in severe damage to the equipment, void the warranty
or cause personal injury or death!
WARNING: Use only locking hooks to safely lift the unit!
Failure to use locking hooks could result in severe damage to
the equipment, void the warranty or cause personal injury or
death! (Detail I).

19
Uncrating and Installing the Unit