Trane Thermo King T-590 Series User manual

Revision C
August 2020 TTKK 5566770000--11--IIMM--EENN
Self-Powered Truck Edition
Single Temperature Systems
T-590, T-690, T-890 and T-1090 Series
Installation Manual

©2019 Trane Techn l gies TK 56700-1-IM-EN
Introduction
This manual was written t assist with the installati n f Therm King T-90 Series Systems nt truck b dies
specifically designed and built f r refrigerated applicati ns. Separate installati n instructi ns f r Therm King pti ns
(e.g., d r switches, status light, fuel tanks, etc.) can be f und at www.therm king.c m.
Due t its c mplexity, y u sh uld n t attempt this installati n unless y u:
• Are an experienced mechanic.
• Can safely lift 34 kil s (75 lbs.).
• In the U.S., EPA 608 certified and trained in the repair and maintenance f transp rt refrigerati n systems.
• Have a basic understanding f electricity and electrical wiring.
• Have the necessary t ls and equipment t c mplete the installati n.
• Have a truck b dy designed and built t meet the requirements f this installati n.
• F ll w all safety precauti ns utlined in this manual.
This manual is published f r inf rmati nal purp ses nly. Therm King makes n representati ns warranties express
r implied, with respect t the inf rmati n rec mmendati ns and descripti ns c ntained herein. Inf rmati n pr vided
sh uld n t be regarded as all-inclusive r c vering all c ntingencies. If further inf rmati n is required, Therm King
C rp rati n Service Department sh uld be c nsulted.
TThheerrmm KKiinngg’’ss wwaarrrraannttyy sshhaallll nn tt aappppllyy tt aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ss iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreedd
rr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, tt aaffffeecctt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
Revision History
Revision A (09/19) New manual.
Revision B (02/20) Add information on installing unit without nut plates.
Revision C (08/20) Added information for EPA conformance regarding attaching label near fuel tank stating “ULTRA-LOW–SULFUR FUEL
ONLY”
Customer Satisfaction Survey
Let y ur v ice be heard!
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Scan the Quick Resp nse (QR) c de r click r type the web address https://tranetechn l gies.iad1.qualtrics.c m/jfe/
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TK 56700-1-IM-EN 3
SSaaffeettyy PPrreeccaauuttii nnss ............................................................................................................................................................ 55
Danger, Warning, Cauti n, and N tice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FirstAid........................................................................................ 6
Unit Installati n Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel System C mp nent Installati n Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Installati n and Cable R uting Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
RReettuurrnnaabbllee SStteeeell CCrraattee IInnff rrmmaattii nn .......................................................... .. ............ .. .. .. .......... .. .. .......... .. .. .. .......... 1100
Overview...................................................................................... 10
Crate Breakd wn Pr cedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Imp rtant St ring and Return Shipping Inf rmati n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DDiimmeennssii nnss.................................................................. .. .. .. ........ .. .. .. .......... .. .. .. ........ .. .. .......... .. .. .. .......... .. .. .. ........ .. .. .. .......... 1133
Unit Dimensi ns and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unit Service Area Dimensi ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Truck B dy Opening Dimensi ns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Unit Lifting Bar Dimensi ns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HMI C ntr ller Dimensi ns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Standby P wer Receptacle Dimensi ns (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
RReeqquuiirreedd TT llss .. .. ...... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. ...... .. .. 2277
CC nnddeennssiinngg UUnniitt IInnssttaallllaattii nn CC mmpp nneennttss .................................................................... .. .. .. .. .. ...... .. .. .. .. .. .. .. .... 2288
IInnssttaalllliinngg UUnniitt .......................... .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. .. .. ........ .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. 3300
Unit M unting B lt Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Uncrating Pr cedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installati n Pr cedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SSeeccuurriinngg OOiill DDrraaiinn HH ssee .............................................................................. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .... 3355
SSeeccuurriinngg EEvvaapp rraatt rr DDrraaiinn HH sseess ............................................ .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. 3366
IInnssttaalllliinngg UUSSBB DD wwnnll aadd PP rrtt ((OOPPTTIIOONN)).................................. .......... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. 3377
SSeeccuurriinngg SSttaannddbbyy PP wweerr RReecceeppttaaccllee ((OOPPTTIIOONN)).............................. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .... .. .. 3388
IInnssttaalllliinngg HHMMII CC nnttrr lllleerr.... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. ...... .. .. 3399
SStteeeell rr AAlluummiinnuumm TTaannkk .................................. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. 4400
PPllaassttiicc TTaannkk................................ .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .... 4411
Table of Contents

4TK 56700-1-IM-EN
IInnssttaalllliinngg FFuueell PPuummpp aanndd FFuueell LLiinneess...................................................................................................................... 4422
BBaatttteerryy CC nnnneeccttii nnss .......................................... .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .. .. 4433
AAuuxxiilliiaarryy EElleeccttrriiccaall AAcccceessss rriieess .............................................................. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. .. ........ .. .. .. .. .. .. .. .. .. 4455
TracKing (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CC mmmmiissssii nniinngg aanndd PPDDII FF rrmmss.................................... .. .. .. .. .. .... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. .. .. ...... .. .. .. .. .. .. .. .... .. .. .. .. .. .. .. .. 4466
C mmissi ning F rm Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pre-Delivery Inspecti n (PDI) F rm Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
TTaabbllee ff CC nntteennttss

TK 56700-1-IM-EN 5
Safety Precautions
anger, Warning, Caution, and Notice
Safety advis ries appear thr ugh ut this manual as required. Y ur pers nal safety and the pr per installati n f this
unit depend up n the strict bservance f these precauti ns.
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.
General Practices
DDAANNGGEERR
HHaazzaarrdd uuss GGaasseess!!
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..
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..
DDAANNGGEERR
RRiisskk ff IInnjjuurryy!!
KKeeeepp yy uurr hhaannddss,, ccll tthhiinngg,, aanndd tt llss cclleeaarr ff ffaannss aanndd// rr bbeellttss wwhheenn ww rrkkiinngg nn aa uunniitt tthhaatt iiss rruunnnniinngg rr wwhheenn
ppeenniinngg rr ccll ssiinngg cc mmpprreessss rr sseerrvviiccee vvaallvveess.. LL ssee ccll tthhiinngg mmiigghhtt eennttaannggllee mm vviinngg ppuulllleeyyss rr bbeellttss,, ccaauussiinngg
sseerrii uuss iinnjjuurryy rr pp ssssiibbllee ddeeaatthh..
WWAARRNNIINNGG
HHaazzaarrdd ff EExxppll ssii nn!!
NNeevveerr ccll ssee tthhee cc mmpprreessss rr ddiisscchhaarrggee sseerrvviiccee vvaallvvee wwhheenn tthhee uunniitt iiss ppeerraattiinngg.. NNeevveerr ppeerraattee tthhee uunniitt wwiitthh
tthhee ddiisscchhaarrggee vvaallvvee ccll sseedd ((ffrr nntt sseeaatteedd)).. TThhiiss cc nnddiittii nn iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh ccaann ccaauussee aann
eexxppll ssii nn..
WWAARRNNIINNGG
PPeerrss nnaall PPrr tteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AAllwwaayyss wweeaarr gg gggglleess rr ssaaffeettyy ggllaasssseess wwhheenn ww rrkkiinngg nn aa uunniitt.. RReeffrriiggeerraanntt lliiqquuiidd,, iill,, aanndd bbaatttteerryy aacciidd ccaann
ppeerrmmaanneennttllyy ddaammaaggee yy uurr eeyyeess.. SSeeee ““FFiirrsstt AAiidd””..