Thermo King Trailer Edition Heat King 450 Series User manual

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TK 56118-6-IM May 2015
Installation Manual
Trailer Edition
Heat King 450 Series
HK450, HK450 HO and HK450 MAX
Diesel Heating Units
May 2015
Revision 1
TK-56118-6-IM

Installation Manual
Trailer Edition
Heat King 450 Series
HK450, HK450 HO and HK450 MAX
Diesel Heating Units
TK 56118-6-IM (Rev. 1, 05/15)
Copyright©2015 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

2
Release History
Released 05/15
Rev. 1 05/15 Page10: Updated unit weights, pages 18-19: Added drain hose installation instructions (HK450 MAX only).

3
Introduction
This installation manual was written to assist with the installation of the Thermo King Heat King 450 Series transport heaters onto trailers or intermodal
containers specifically designed and built for these applications. Separate installation instructions for the various fuel tanks and factory options available for
the HK unit are located at Thermo King iService or Thermoking.com.
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
HMI Remote Mount Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Selection Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Group 31 Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installing the Unit - Standard Installation . . . . . . . . . . . . . . . . . . . . . . . . 18
Installing the Remote HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing the Fuel Pump and Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SYSTEM CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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
Screw Torx T-25
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
Heat King 450 Series Units
IMPORTANT: Heat King 450 series 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.
Optional Front Wall Mounted Fuel Tank
-
IMPORTANT: Heat King 450 series 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 a Heat
King 450 series unit!
UNIT WEIGHTS*
Heat King 450 series unit with EON
battery installed. HK450 HK450 HO
220 kg (484lbs.)
HK450 MAX
231 kg (510 lbs.)
DANGER: The front wall of the trailer or container must be
structurally strong enough to support the weight of the
Heat King 450 series unit, the 65 gallon fuel tank and fuel!
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
HK450, HK450 HO and HK450 MAX Units

15
HMI Remote Mount Dimensions

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
Installing the Unit - Standard Installation
Uncrating the Unit
To avoid unnecessary damage to your unit, place the crated unit near the
trailer 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 UNC) into the thread holes
located on top of unit (Detail I).
• Attach lifting device to eyebolts and slightly raise unit and remove
hardware holding unit to crate.
Standard Installation
2. Lift the unit and position it in the trailer opening.With the unit access
door open, align the four unit mounting holes with the trailer mounting
bolts.
3. Attach supplied 1-1/4'' washers and locking nuts. Torque to 82 N•m
(60 ft. lbs.).
4. See “Installing the Remote HMI” on page 20.
Exhaust Drain Tube (HK450 MAX Units Only)
5. 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.
•Fromunder 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.
• 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.
Zero-Cube Option
Zero-Cube installation instructions (TK 56142) are available at Thermo
King iService or Thermoking.com.
Exhaust Extension Option
When installing an optional exhaust extension kit 701181 or 701182,
follow the instructions that are included with the kit.
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).