Trane Thermo King TriPac Envidia User manual

Revision B
November 2020 TTKK 5566445599--1199--IIMM--EENN
Auxiliary Power Unit Edition
TriPac® Envidia™™
Auxiliary Heating an Cooling Temperature Management
System
Installation Manual

©2018 Trane Technologies TK 56459-19-IM-EN
Introduction
This manual was written only to assist with the installation of the TThheerrmmoo KKiinngg TTrriiPPaacc EEnnvvii iiaa AAuuxxiilliiaarryy HHeeaattiinngg aann
CCoooolliinngg SSyysstteemmss onto a typical Class 8 semi truck with sleeper. The TThheerrmmoo KKiinngg TTrriiPPaacc IInnssttaallllaattiioonn SSttaann aarr ss
GGuuii ee (TK 56430) provi es more etaile information that must be followe to safely an properly complete the entire
installation.
Before beginning the installation, the installer shoul confirm with the customer the location for each of the APU’s
components by using the AAPPUU IInnssttaallllaattiioonn QQuueessttiioonnnnaaiirree. The customer shoul also be ma e aware that
mo ifications to existing equipment might be necessary to complete the installation.
MMoo iiffiiccaattiioonnss mmaayy iinncclluu ee::
• Truck’s engine must be fitte with an upgra e alternator of 270 amps or more an with upgra e alternator wiring
of OEM approve esign.
• APU con enser may be irectly mounte to the outsi e of the sleeper.
• APU evaporator, power inverter an /or converter may be installe in existing storage spaces un er the bunk or in
the toolbox areas.
• APU heating an A/C uct work may to be route with vents installe in existing closets or storage compartments.
• OEM components on the chassis may nee to be relocate to accommo ate the installation of the APU battery box.
• OEM fuel tank may nee to be change to a smaller size to accommo ate the installation of the APU battery box.
• For base level performance - truck battery box must have four 12V c batteries connecte to provi e 12V c output.
• For optimum level performance - truck batteries may be upgra e to Thermo King NXT 1150 CCA absorbe glass
mat (AGM) batteries.
DDuuee ttoo iittss ccoommpplleexxiittyy,, yyoouu sshhoouull nnoott aatttteemmpptt tthhiiss iinnssttaallllaattiioonn uunnlleessss yyoouu::
• Are an experience mechanic.
• Can safely lift 34 kilos (75 lbs.)
• Are EPA Section 609 certifie an traine in the repair an maintenance of mobile air con itioning systems (in the
Unite States).
• Have a basic un erstan ing of electricity an electrical wiring.
• Have the necessary tools an equipment to complete the installation.
• Follow the safety precautions outline in the Thermo King TriPac Installation Stan ar s Gui e (TK 56498).
This manual is publishe for informational purposes only. Thermo King makes no representations warranties express
or implie , with respect to the information recommen ations an escriptions containe herein. Information provi e
shoul not be regar e as all-inclusive or covering all contingencies. If further information is require , Thermo King
Corporation Service Department shoul be consulte . Thermo King’s warranty shall not apply to any equipment which
has been “so installe , maintaine , repaire or altere as, in the manufacturer’s ju gment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, property amage or any other irect,
in irect, special, or consequential amages whatsoever, arising out of the use of this manual or any information,
recommen ations or escriptions containe herein.
Revision History
Revision A (02/20) New manual format.
Revision B (11/20) Added new HMI Controller.

TK 56459-19-IM-EN 3
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IInnttrroo uuccttiioonn

4TK 56459-19-IM-EN
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn ............................................................................................................................ 77
Before Beginning the Installation Recommen ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Truck’s Alternator Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Truck’s Battery Recommen ations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
APU Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery Box Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A/C Con enser Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A/C Evaporator / Control Box Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A/C Hose Connections an Routing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Wiring an HMI Controller Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
D2 / D4 Heater Installation Requirements (Units with Heat Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Auxiliary Power Accessories Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
RReeqquuiirree TToooollss aann AA iittiioonnaall SSuupppplliieess.................................. .................... ........................ .................... .......... 1133
TTrriiPPaacc EEnnvvii iiaa CCoommppoonneenntt DDiimmeennssiioonnss.. .... .............. .............................. .............. .............................. ................ 1155
Battery Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Con enser Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Evaporator/Control Box Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HMI Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Stan ar Heater Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Output Heater Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
AC/DC Shore Power Converter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1000 Watt Power Inverter Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TTyyppiiccaall EEnnvvii iiaa CCoommppoonneenntt LLooccaattiioonnss .. ...... .............................. .............. .............................. .............. ................ 2255
BBaatttteerryy BBooxx IInnssttaallllaattiioonn ................................................................................................................................................ 2266
Stan ar Installation Metho – Mounting Claws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Optional Installation Metho – Direct Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RReecceeiivveerr DDrriieerr IInnssttaallllaattiioonn .................. ................ .............................. .............. .............................. .............. ................ 3300
A/C Con enser Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AA//CC EEvvaappoorraattoorr // CCoonnttrrooll BBooxx IInnssttaallllaattiioonn .. .. ............................ .............. .............................. .............. ................ 3333
AA//CC HHoossee IInnssttaallllaattiioonn.. .. ................ .. ................ .. .................... .. ................ .. ........................................ .. ................ .. .......... 3366
AA//CC SSyysstteemm EEvvaaccuuaattiioonn aann LLeeaakk CChheecckk PPrrooccee uurreess .................................................................................. 3377
DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn ((HHeeaatt OOppttiioonn)).............. .. .... .............................. .. ................ .. ................ .. ...... ................ 3388
Heater Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Heater Subassembly an Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ta le of Contents

TK 56459-19-IM-EN 5
Exhaust an Combustion Air Intake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Return an Discharge Ducts an Vents Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
AA//CC DDuucctt IInnssttaallllaattiioonn ...... .. ................ .. .... .................. .. ................ .. .................... .. ................ .. .......................................... 4422
Discharge Air Outlet Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Discharge Air Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Discharge Air Vent Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Backflow Damper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
BBaatttteerryy BBooxx HHaarrnneessss IInnssttaallllaattiioonn ............................................................................................................................ 4466
CCoonn eennsseerr FFaann aann SSeennssoorr HHaarrnneessss IInnssttaallllaattiioonn .......................................................................................... 4499
IIggnniittiioonn SSwwiittcchh aann HHaarrnneessss IInnssttaallllaattiioonn.................... .. ................ .. ................ .. .... ................ .. ................ .. .......... 5500
HHMMII IInnssttaallllaattiioonn ............ .. ........................................ .. ................ .. ................ .. ................ .. .... ................ .. ................ .. .......... 5511
UUSSBB SSeerrvviiccee CCoommmmuunniiccaattiioonn CCaabbllee IInnssttaallllaattiioonn............................................................................................ 5522
DD22//DD44 HHeeaatteerr HHaarrnneessss IInnssttaallllaattiioonn ((HHeeaatt OOppttiioonn)) ...... .. ...................................... .. ................ .. ................ .. ...... 5533
HHeeaatteerr FFuueell PPiicckkuupp TTuubbee IInnssttaallllaattiioonn ((HHeeaatt OOppttiioonn)) ................ .. .................... .. ................ .. ................ .. ........ 5544
Direct Tank Installation – with OEM Fuel Tank Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alternative Installation – Drilling Hole in Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
FFuueell PPuummpp aann FFuueell LLiinnee IInnssttaallllaattiioonn ((HHeeaatt OOppttiioonn)) .. ...................... .. ................ .. ................ .. ...... ................ 5588
Tank Mounte Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Remote Mounte Fuel Pump with L-Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
HHeeaatteerr FFuueell PPuummpp CCoonnnneeccttiioonnss ((HHeeaatt OOppttiioonn)) ............ .. ...................................... .. ................ .. ................ .. ...... 6600
AAuuxxiilliiaarryy AACC PPoowweerr AAcccceessssoorriieess ((OOppttiioonn)).................. .. ................ .. ................ .. .... ........ .. ...... .................. .. .......... 6611
DC/AC Power Inverter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AC/DC Shore Power Converter Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dual System – DC/AC Power Inverter an AC/DC Shore Power Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
BBaatttteerryy CCaabbllee IInnssttaallllaattiioonn ............................................................................................................................................ 6644
PPrriimmiinngg tthhee HHeeaatteerr FFuueell PPuummpp ((HHeeaatt OOppttiioonn)) .................................................................................................. 6666
HHeeaatteerr SSttaarrtt--UUpp PPrrooccee uurreess ((HHeeaatt OOppttiioonn)) .. .......................... .. ................ .. ................ .. ...... .............................. 6677
Diagnostic Tool Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Perform the Start-Up Proce ure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Heater Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
QuitStart-Up.................................................................................. 70
Unable to Perform the Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
TTaabbllee ooff CCoonntteennttss

6TK 56459-19-IM-EN
AA//CC SSyysstteemm CChhaarrggiinngg PPrrooccee uurreess .......................... .. .... ........ .. .................... .. ................ .. ................ .. ...... ................ 7711
OOppeerraattiioonn CChheecckkoouutt PPrrooccee uurreess.............. .. .................... .. ................ .. ........................................ .. ................ .. .......... 7722
Step 1 – Basic Operation Checkout Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Step 2 - Detaile Operation Checkout Proce ures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Unit Setup Proce ures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Envi ia HVAC Function Check Proce ures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
HeatSystemCheck ........................................................................ 74
FanOnlyCheck............................................................................ 74
Envi ia Battery Check Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Envi ia HVAC Function Check Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
TTaabbllee ooff CCoonntteennttss

TK 56459-19-IM-EN 7
Tips For a Successful Installation
Before Beginning the Installation Recommendations
IImmppoorrttaanntt:: Proper installation of each component onto the vehicle is critical! Refer to the Thermo King TriPac
Installation Standards Guide (TK 564 8) before beginning the installation. Adhering to the installation
standards will help assure the components are installed correctly and the system operates as designed. It is
the responsibility of the installer to follow these standards.
• Review component location iagram an iscuss with the customer where each component will be installe on the
truck.
• Verify tools an special equipment require for the installation are available an in goo working con ition.
• Open all installation kits an inspect the contents before beginning installation.
• It is recommen e that one person performs the installation of all the components oouuttssii ee the sleeper while a
secon person installs all the components iinnssii ee the sleeper. This will help minimize any amage to the sleeper’s
interior from grease, irt, etc.
Truck’s Alternator Requirements
• The truck’s engine must be fitte with an upgra e alternator of 270 amps or more an with upgra e alternator
wiring of OEM approve esign.
Truck’s Battery Recommendations
• It is important not to allow the truck’s batteries to become ischarge uring the APU installation process. A battery
charger shoul be connecte to the batteries while the installation is in process or shut the truck’s battery power
supply completely off using the OEM main battery isconnect switch if available.
• An alternative metho is to shut the truck’s battery power completely off using the OEM main battery isconnect
switch if available.
• For TriPac Envi ia bbaassee lleevveell ppeerrffoorrmmaannccee::The truck’s battery box must have four 12V c batteries connecte in
parallel to provi e 12V c output.
• For TriPac Envi ia ooppttiimmuumm lleevveell ppeerrffoorrmmaannccee::Thermo King recommen s the truck’s batteries be upgra e to
Thermo King NXT 1150 CCA absorbe glass mat (AGM) batteries.
APU Battery Requirements
TriPac Envi ia units are shippe with Thermo King NXT AGM batteries fully charge an rea y to use. Batteries that are
kept in stock shoul not require charging for 2 years if kept below 77 F (25 C). Batteries shoul be charge when the
open circuit voltage (OCV) falls below 12.50 volts.
To charge the NXT AGM battery, use the following gui elines:
1. Verify the output voltage of your battery charger is capable of maintaining 14.1 to 14.7 charging voltage. The
recommen e charging voltage range for the NXT AGM battery is 14.1 to 14.7 volts. Voltages are to be measure at
the battery terminals with the battery connecte to the charger.
IImmppoorrttaanntt:: Never exceed 15 volts when charging the NXT AGM battery. Exceeding 15 volts will cause pressure
relief valves to open and out-gas hydrogen and oxygen from inside the battery. This will shorten the life
of the battery and could lead to premature battery failure.
2. Battery chargers with the battery type output setting shoul be set to AGM type battery.
DDOO NNOOTT set the output type to gel cell or maintenance free settings.
3. Determine if your battery charger is an automatic or manual charger. Manual battery chargers must be closely
monitore uring the charge perio an for this reason an automatic battery charger is preferre over a manual
charger.
a. Automatic battery chargers either charge up to a preset voltage an shut off, or charge to a present voltage an
then switch to a trickle charge mo e. Either one of these battery chargers is acceptable: however, the automatic
charger that shuts off may not fully charge the battery.
b. Manual battery chargers will have manual controls for setting the charge amperage rate. The charge amperage
rate will remain the same until the battery charger is manually shut off.

8TK 56459-19-IM-EN
IImmppoorrttaanntt:: When using a manual battery charger, set the charger to charge at 10 or 20 amps and limit the
charging time based on the batteries state of charge (SOC). Use the chart below as a general guide
to determine the amount of time necessary to charge the battery. DDOO NNOOTT oovveerrcchhaarrggee tthhee
bbaatttteerriieess!! See warning below.
Determining Maximum Charge Time Using a Manual Charger
Voltmeter Reading State of Charge Time @ 10 Amps Time @ 20 Amps
12.84 Volts 100% 0 Hours 0 Hours
12.50 Volts 75% 2 Hours 1 Hour
12.20 Volts 50% 4 Hours 2 Hours
11.88 Volts 25% 6 Hours 3 Hours
WWAARRNNIINNGG
RRiisskk ooff IInnjjuurryy!!
OOvveerrcchhaarrggiinngg aa bbaatttteerryy ccaann ccaauussee aammaaggee ttoo tthhee bbaatttteerryy aann ppoossssiibbllyy ccaauussee aa ffiirree oorr eexxpplloossiioonn.. FFoollllooww tthhee
bbaatttteerryy cchhaarrggeerr’’ss rreeccoommmmeenn aattiioonnss ffoorr mmoonniittoorriinngg bbaatttteerriieess wwhhiillee cchhaarrggiinngg.. BBaatttteerriieess sshhoouull bbee
mmoonniittoorree wwhhiillee cchhaarrggiinngg ffoorr ssiiggnnss ooff iinntteerrnnaall pprroobblleemmss.. SSiiggnnss ooff iinntteerrnnaall pprroobblleemmss iinncclluu ee bbuullggiinngg ccaasseess,,
eexxttrreemmee ggaassssiinngg,, ppuunnggeenntt ssmmeellll,, aann eexxttrreemmee hheeaatt.. IIff yyoouu nnoottiiccee aannyy ooff tthheessee ssiiggnnss ttuurrnn tthhee cchhaarrggeerr ooffff aann
aallllooww tthhee bbaatttteerryy ttoo ssttaabbiilliizzee bbeeffoorree hhaann lliinngg oorr tteessttiinngg..
CClleeaanniinngg aa BBaatttteerryy
Use a amp cloth to clean the top of the battery to eliminate con uctive paths create by irt an rie or wet
electrolyte, an to prevent corrosion. Use a battery terminal-cleaning tool that has noncon ucting (plastic or rubber)
cover to clean the battery terminals when corrosion is present. Replace any battery cables (or cable terminals) that
are fraye , corro e , swelle , or amage to the extent that they cannot be cleane .
BBaatttteerryy HHooll DDoowwnn HHaarr wwaarree
Batteries are subjecte to extreme shock loa s an vibration. It is very important to make sure each battery is
secure by the proper mounting har ware. Failure to secure each battery correctly can result in premature battery
failure. Using a torque wrench, torque the hol own nuts in two step increments:
• STEP 1 - Torque each hol own nut to 60 in-lbs. (6.8 Nm)
• STEP 2 - Torque each hol own nut to 120 to 144 in-lbs. (13.5 to 16.3 Nm)
BBaatttteerryy CCaabbllee MMoouunnttiinngg
• On threa e stu type batteries, use only stainless steel nuts to fasten the cable to the battery. Torque the nut to
150 to 200 in-lbs. (17 to 22.5 Nm).
• On SAE post type batteries, use only stainless steel battery clamp bolts. Torque the nut to 60 in-lbs. (7 Nm).
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn

TK 56459-19-IM-EN 9
Battery Box Installation Requirements
IImmppoorrttaanntt:: See “Battery Box Installation Standards” in Section 6 of the Thermo King TriPac Installation Standards
Guide (TK 564 8). THESE STANDARDS MUST BE FOLLOWED!
• The battery box is esigne to be mounte oonnllyy to the existing truck frame rails. NNOO OOTTHHEERR MMOOUUNNTTIINNGG
LLOOCCAATTIIOONN IISS AACCCCEEPPTTAABBLLEE!!
• Safely relocate components on the chassis that interfere with the installation of the battery box.
• Check clearance aroun battery box before beginning the installation.
• Lifting eyebolts (installer supplie ) must be forge steel, 1/2"(12mm) iameter.
• Use only forge clevises an pins to attach to the lifting eyebolts.
• The use of a motorcycle/ATV lift or mo ifie floor jack to raise battery box into position is recommen e .
• Only the supplie spacer blocks an mounting claws must be use to install the battery box to the chassis frame
rail.
• If ifferent mounting bolts are use , they must be Gra e 5 an of the correct length. DDOO NNOOTT cut off excessive
length bolts an DDOO NNOOTT oil the bolt threa s!
• Verify the upper an lower battery box mounting bolts are square an flat with the chassis frame rail before
tightening.
• The mounting har ware securing the battery box to the truck’s frame must be correctly positione an torque
using the four-step tightening sequence escribe in this manual.
A/C Condenser Installation Requirements
IImmppoorrttaanntt:: See “Condenser Installation Standards” in Section 6 of the Thermo King TriPac Installation and Standards
Guide (TK 564 8). THESE STANDARDS MUST BE FOLLOWED!
• Keep all A/C fittings cappe an seale until installation of the refrigeration hoses. Refrigerant oil is extremely
hygroscopic an a system left open for more than 5 minutes may require extensive evacuation/ ehy ration time to
remove moisture.
• Verify all measurements before rilling any mounting holes.
• Verify there is no interference with any OEM electrical wiring, internal supports, etc. before rilling mounting holes.
• Confirm the con enser location oes not interfere with the service or operation of existing tractor components.
• Provi e protection to the tractor’s interior an or exterior finish to prevent amage uring the installation process.
• Use the stainless steel mounting har ware (supplie in the kit) to mount the con enser.
• Use the large fen er washers (supplie in kit) insi e the sleeper to provi e a itional support.
• All mounting holes must be seale with silicone caulking to prevent moisture or exhaust fumes from entering the
sleeper.
A/C Evaporator / Control Box Installation Requirements
IImmppoorrttaanntt:: See “Evaporator / Control Box Installation Standards” in Section 6 of the Thermo King TriPac Installation
and Standards Guide (TK 564 8). THESE STANDARDS MUST BE FOLLOWED!
• This installation requires a two-person or mechanically assiste lift.
• Keep all A/C fittings cappe an seale until installation of the refrigeration hoses. Refrigerant oil is extremely
hygroscopic an a system left open for more than 5 minutes may require extensive evacuation/ ehy ration time to
remove moisture.
• Determine the best location for the A/C Evaporator/Control Box insi e the sleeper, typically un er the bunk an flush
to the front bulkhea .
• Allow a equate clearance for attaching the two air outlet tubes.
• Verify there is no interference with any OEM electrical wiring, internal floor supports, etc. before rilling any
mounting holes in the truck.
• The Evaporator/Control Box shoul be mounte irectly onto the floor mat insi e the sleeper. Use the supplie
template to properly locate the rain an mounting holes.
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn

10 TK 56459-19-IM-EN
• Always install the rain valves (kazoos) into rain holes locate on the bottom pan of the evaporator.
• The A/C vents shoul be locate an installe to provi e maximum air circulation in the sleeper such as: MEDIUM
(above lower bunk level) an HIGH (above upper bunk level). NOTE: Locating a vent LOW (floor level) is not
recommen e . It will significantly re uce river comfort an re uce maximum system run time.
• All mounting holes must be seale with silicone caulk to prevent moisture or exhaust fumes from entering the
sleeper.
• All e ges of access holes ma e in fiberglass an woo composite floors must be seale correctly with (installer
supplie ) fiberglass cloth an resin.
A/C Hose Connections and Routing Requirements
IImmppoorrttaanntt:: See “Refrigerant Hose and Fittings Standards” in Section 8 of the Thermo King TriPac Installation and
Standards Guide (TK 564 8). THESE STANDARDS MUST BE FOLLOWED!
• Keep all the A/C fittings cappe an seale until the installation of the refrigeration hoses. Refrigerant oil is
extremely hygroscopic an a system left open for more than 5 minutes may require extensive evacuation/
ehy ration time to remove moisture.
• Only cut refrigerant hoses with the correct hose cutting tool (204-677). NEVER USE A SAW!
• Always use the correct hose fitting tool (204-1045) when assembling refrigeration hoses.
• Always lubricate hose fittings with Alkyl Benzene Refrigerant Oil (670404TKA) when assembling to refrigeration
hoses.
• Always install an lubricate O-rings with Alkyl Benzene Refrigerant Oil (670404TKA) when connecting refrigeration
hose fittings to component connection fittings.
• Refrigeration hoses shoul be installe onto components in such a way as to allow for vibration an movement of
the cab. THEY SHOULD NEVER BE STRETCHED TIGHT!
• All refrigeration connections shoul be tightene securely using two wrenches.
• Always keep refrigeration hoses from rubbing or chafing against sharp metal objects, rotating components or hot
components.
• Protective covers or sleeves (installer supplie ) for the refrigeration hoses may be require epen ing on the
installation.
• Always install the con enser’s receiver rier so refrigerant flow is in the irection in icate by the arrow.
• Thermo King Evacuation Station (204-725) an Evacuation Station Operation an Fiel Application Instructions (TK-
40612) are recommen e .
• The oil in the evacuation station vacuum pump shoul be change after each use.
• The A/C system must be leak free. Check for leaks by using an electronic leak etector.
• The A/C system will be charge with 2.0 lbs. of R134a refrigerant. NNOOTTEE:: AAccccuurraaccyy iiss iimmppoorrttaanntt.. OOvveerr oorr uunn eerr
cchhaarrggee bbyy 33 oouunncceess wwiillll rree uuccee ccoooolliinngg ccaappaacciittyy..
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn