Trane Thermo King TriPac EVOLUTION User manual

Revision A
November 2020 TTKK 5555667766--1199--IIMM--EENN
TriPac® EVOLUTION™™
Auxiliary Heating an Cooling Temperature Management
System
Installation Manual

©2020 Trane Technologies TK 55676-19-IM-EN
Introduction
This manual was written to assist with the installation of the TThheerrmmoo KKiinngg TTrriiPPaacc EEVVOOLLUUTTIIOONN Auxiliary Heating an
Cooling System onto a typical semi tractor. While not inten e to be specific to a particular vehicle, the information in
this manual will provi e the installer with etails to correctly an safely install each of the stan ar TriPac APU
components. 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. Thermo King offers numerous options
such as Diesel Particulate Filter (DPF), Power Inverters, Hourmeters, etc. which have separate installation instructions.
These options shoul be installe simultaneously with the APU when possible to help re uce overall installation time.
Before beginning the installation, the installer shoul confirm with the customer the location for each of the TriPac
components by using the TriPac Installation Questionnaire. The customer shoul also be ma e aware of any
mo ifications to existing equipment that may be necessary to complete the installation.
Modifications may include:
• OEM components on the chassis may need to be relocated to
accommodate the installation of the TriPac APU.
• Fuel tank may need to be changed to a smaller size.
• TriPac components will be mounted onto the outside of the
sleeper.
• Existing storage space under the bunk will be utilized by TriPac
components.
• Heating and A/C duct work will be routed and vents will be
installed in existing closets or storage compartments.
Due to its complexity, you should not attempt this installation
unless you are:
• are an experienced mechanic.
• can safely lift 75 lbs. (34 kilos).
• are EPA Section 609 certified and 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 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 .
hermo 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.”
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..
Revision History
Revision A (11/20) New manual format.
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TK 55676-19-IM-EN 3
SSaaffeettyy PPrreeccaauuttiioonnss ............................................................................................................................................................ 77
Danger, Warning, Caution, an Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery Cable Installation an Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Hazar s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Refrigerant Oil Hazar s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FirstAi ........................................................................................ 9
Heater Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn ...... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. 1111
Before Beginning the Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
APU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A/C Con enser Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
A/C Evaporator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
D2/D4 Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A/C Hose Connections an Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine Coolant Hose Connections an Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Close Loop Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Wiring an HMI Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss .... .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... 1144
APU .......................................................................................... 14
Con enser .................................................................................... 16
Evaporator.................................................................................... 17
ControlBox ................................................................................... 18
HMI........................................................................................... 19
Stan ar Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
High Output Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
RReeqquuiirree TToooollss aann AA iittiioonnaall SSuupppplliieess.. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .. 2222
TTyyppiiccaall CCoommppoonneenntt LLooccaattiioonnss ...... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .... .. .. .. .. .... .. .... .. .. .... .. .. 2233
TriPac Evolution Components with Truck Coolant Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
TriPac Evolution Components with Optional Close Loop Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
AAPPUU IInnssttaallllaattiioonn .. .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... .. .. .... .. .. 2266
Stan ar Installation Metho – Mounting Claws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EExxhhaauusstt PPiippee IInnssttaallllaattiioonn .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. 2288
Stan ar Short Exhaust Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table o Contents

4TK 55676-19-IM-EN
Optional Exhaust Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
AA//CC CCoonn eennsseerr IInnssttaallllaattiioonn .... .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... 2299
AA//CC RReecceeiivveerr DDrriieerr IInnssttaallllaattiioonn.... .. .... .. .. .. .... .. .... .. .. .. .. .... .... .. .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .. 3311
AAmmbbiieenntt TTeemmppeerraattuurree SSeennssoorr IInnssttaallllaattiioonn ((OOppttiioonn)) ...... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. 3322
AA//CC EEvvaappoorraattoorr IInnssttaallllaattiioonn .. .. .. .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. 3333
Preferre Location – Flush with Front Bulkhea . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Alternative Location – Centere Un er Bunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn ...... .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... 3377
Heater Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drilling Hole In Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Heater Subassembly an Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Exhaust an Combustion Air Intake Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Exhaust an Combustion Air Intake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DD22//DD44 HHeeaatteerr DDuucctt IInnssttaallllaattiioonn.. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. 4422
Duct Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AA//CC DDuucctt IInnssttaallllaattiioonn .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. 4444
A/C Vent Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
AA//CC HHoossee IInnssttaallllaattiioonn.... .. .... .. .... .. .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. 4466
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Compressor Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
AA//CC SSyysstteemm EEvvaaccuuaattiioonn aann LLeeaakk CChheecckk PPrrooccee uurreess .................................................................................. 4499
Evacuation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Leak Check Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
CCoonnttrrooll BBooxx aann MMaaiinn HHaarrnneessss IInnssttaallllaattiioonn .. .. .. .. .... .. .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... 5511
Control Box Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Main Harness Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
HHMMII IInnssttaallllaattiioonn .... .... .. .... .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... ........ 5533
HMILocation.................................................................................. 53
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DD22//DD44 HHeeaatteerr WWiirriinngg IInnssttaallllaattiioonn .. .. .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... 5555
Remote Temperature Sensor - D4 Heater Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
TTaabbllee ooff CCoonntteennttss

TK 55676-19-IM-EN 5
AA//CC WWiirriinngg IInnssttaallllaattiioonn .... .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .... .. .. 5577
SSttaann bbyy TTrruucckk IInntteeggrraattiioonn HHaarrnneessss wwiitthh SSwwiittcchh ((OOppttiioonn)) ........................................................................ 5599
SSttaann bbyy TTrruucckk IInntteeggrraattiioonn HHaarrnneessss wwiitthhoouutt SSwwiittcchh ((OOppttiioonn)) ................................................................ 6611
FFuueell PPiicckkuupp TTuubbee IInnssttaallllaattiioonn .. .. .. .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. 6633
Preferre Installation – Optional A apter Plate (10–379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Alternative Installation – Drilling Hole In Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
HHeeaatteerr FFuueell PPuummpp aann FFuueell LLiinnee IInnssttaallllaattiioonn.................................................................................................... 6677
L-Bracket Installation Proce ures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fuel Tank Bracket Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Fuel Line Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
AAPPUU FFuueell LLiinnee IInnssttaallllaattiioonn .... .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. 6699
TTrraaccttoorr CCoooollaanntt HHoossee IInnssttaallllaattiioonn .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .... .. .. 7700
Preferre Installation – APU Coolant Hoses Tee’ Directly Into Tractor’s Heater Hoses . . . . . . . . . . . . . . . 70
Coolant Hose Routing an Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Alternative Installation – APU Coolant Hoses Attache Directly To Fittings On Tractor’s Engine. . . . . . . 72
Coolant Hose Routing an Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
AArrccttiicc SSwwiittcchh ((OOppttiioonn)) .... .... .. .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... ........ 7744
Installation Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
HHeeaatteerr FFuueell PPuummpp CCoonnnneeccttiioonnss.. .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... 7766
FFuussee HHooll eerr aann AAPPUU BBaatttteerryy CCoonnnneeccttiioonnss .... .. .... .. .... .. .. .... .. .. .... .. .... .. .. .. .... .. .... .. .. .. .. .... .... .. .. .. .. .... .. .... .. .. .. .... .. .. 7777
PPrriimmiinngg tthhee HHeeaatteerr FFuueell PPuummpp ((HHeeaatt OOppttiioonn)) .................................................................................................. 7799
HHeeaatteerr SSttaarrtt--UUpp PPrrooccee uurreess .. .. .. .. .... .. .... .. .. .... .. .. .... .. .. .... .. .. .. .... .... .. .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .. .... .. .... .. .. .... .. .. 8800
Diagnostic Tool Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CCoonnnneeccttiinngg DDiiaaggnnoossttiicc TTooooll .................................................................. 81
Perform the Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
AA//CC SSyysstteemm CChhaarrggiinngg aann AAPPUU EEnnggiinnee SSttaarrtt--uupp PPrrooccee uurreess .................................................................. 8855
A ing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
APU Engine Start-up Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Blee ing the Coolant System – APU’s Equippe with Tra itional Tractor Coolant Integration. . . . . . . . . 86
Blee ing the Coolant System – APU’s Equippe with Close Loop Cooling Option . . . . . . . . . . . . . . . . . . 86
BBlleeee iinngg tthhee FFuueell LLiinneess ....................................................................... 88
TTaabbllee ooff CCoonntteennttss

6TK 55676-19-IM-EN
Verifying Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Unit Setup Proce ures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Service Run-In Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
TTaabbllee ooff CCoonntteennttss

TK 55676-19-IM-EN 7
Sa ety Precautions
Danger, Warning, Caution, and Notice
Thermo King recommen s that all service be performe by a Thermo King ealer an to be aware of several general
safety practices.
Safety a visories appear throughout this manual as require . Your personal safety an the proper installation of this
unit epen 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.
General Practices
DDAANNGGEERR
AAsspphhyyxxiiaattiioonn HHaazzaarr !!
WWhheenn aa TTrriiPPaacc EEvvoolluuttiioonn AAPPUU iiss iinnssttaallllee uunn eerr tthhee ccaabb,, bbeehhiinn ttrruucckk ffaaiirriinnggss,, sskkiirrttiinngg,, eettcc..,, tthhee iieesseell eexxhhaauusstt
oouuttlleett mmuusstt bbee rroouuttee oouutt ttoo aann ooppeenn aarreeaa ttoo pprreevveenntt eexxhhaauusstt ffuummeess ffrroomm eenntteerriinngg tthhee ppaasssseennggeerr ccoommppaarrttmmeenntt
wwhhiicchh ccoouull rreessuulltt iinn ccaarrbboonn mmoonnooxxii ee ppooiissoonniinngg oorr eeaatthh bbyy aasspphhyyxxiiaattiioonn..
DDAANNGGEERR
HHaazzaarr ooff EExxpplloossiioonn!!
NNeevveerr aappppllyy hheeaatt ttoo aa sseeaallee rreeffrriiggeerraattiioonn ssyysstteemm oorr ccoonnttaaiinneerr.. HHeeaatt iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh mmiigghhtt
ccaauussee aann eexxpplloossiioonn rreessuullttiinngg iinn eeaatthh oorr sseerriioouuss iinnjjuurryy..
DDAANNGGEERR
HHaazzaarr oouuss GGaasseess!!
RReeffrriiggeerraanntt iinn tthhee pprreesseennccee ooff aann ooppeenn ffllaammee,, ssppaarrkk,, oorr eelleeccttrriiccaall sshhoorrtt pprroo uucceess ttooxxiicc ggaasseess tthhaatt aarree sseevveerree
rreessppiirraattoorryy iirrrriittaannttss wwhhiicchh ccaann ccaauussee sseerriioouuss iinnjjuurryy oorr ppoossssiibbllee eeaatthh..
DDAANNGGEERR
RReeffrriiggeerraanntt VVaappoorr HHaazzaarr !!
DDoo nnoott iinnhhaallee rreeffrriiggeerraanntt.. UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg wwiitthh rreeffrriiggeerraanntt oorr aa rreeffrriiggeerraattiioonn ssyysstteemm iinn aannyy ccoonnffiinnee
aarreeaa wwiitthh aa lliimmiittee aaiirr ssuuppppllyy.. RReeffrriiggeerraanntt iissppllaacceess aaiirr aann ccaann ccaauussee ooxxyyggeenn eepplleettiioonn,, rreessuullttiinngg iinn
ssuuffffooccaattiioonn aann ppoossssiibbllee eeaatthh..
DDAANNGGEERR
RRiisskk ooff IInnjjuurryy!!
KKeeeepp yyoouurr hhaann ss,, ccllootthhiinngg,, aann ttoooollss cclleeaarr ooff ffaannss aann //oorr bbeellttss wwhheenn wwoorrkkiinngg oonn aa uunniitt tthhaatt iiss rruunnnniinngg oorr wwhheenn
ooppeenniinngg oorr cclloossiinngg ccoommpprreessssoorr sseerrvviiccee vvaallvveess.. LLoooossee ccllootthhiinngg mmiigghhtt eennttaannggllee mmoovviinngg ppuulllleeyyss oorr bbeellttss,, ccaauussiinngg
sseerriioouuss iinnjjuurryy oorr ppoossssiibbllee eeaatthh..

8TK 55676-19-IM-EN
WWAARRNNIINNGG
HHaazzaarr ooff EExxpplloossiioonn!!
NNeevveerr cclloossee tthhee ccoommpprreessssoorr iisscchhaarrggee sseerrvviiccee vvaallvvee wwhheenn tthhee uunniitt iiss ooppeerraattiinngg.. NNeevveerr ooppeerraattee tthhee uunniitt wwiitthh
tthhee iisscchhaarrggee vvaallvvee cclloossee ((ffrroonntt sseeaattee )).. TThhiiss ccoonn iittiioonn iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh ccaann ccaauussee aann
eexxpplloossiioonn..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirree !!
AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess wwhheenn wwoorrkkiinngg oonn aa uunniitt.. RReeffrriiggeerraanntt lliiqquuii ,, ooiill,, aann bbaatttteerryy aaccii ccaann
ppeerrmmaanneennttllyy aammaaggee yyoouurr eeyyeess.. SSeeee ““FFiirrsstt AAii ””..
WWAARRNNIINNGG
EEqquuiippmmeenntt DDaammaaggee aann RRiisskk ooff IInnjjuurryy!!
NNeevveerr rriillll hhoolleess iinnttoo tthhee uunniitt uunnlleessss iinnssttrruuccttee bbyy TThheerrmmoo KKiinngg.. HHoolleess rriillllee iinnttoo hhiigghh vvoollttaaggee ccaabblleess ccoouull
ccaauussee aann eelleeccttrriiccaall ffiirree,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr eevveenn eeaatthh..
WWAARRNNIINNGG
RRiisskk ooff IInnjjuurryy!!
WWhheenn uussiinngg llaa eerrss ttoo iinnssttaallll oorr sseerrvviiccee rreeffrriiggeerraattiioonn ssyysstteemmss,, aallwwaayyss oobbsseerrvvee tthhee llaa eerr mmaannuuffaaccttuurreerr’’ss
ssaaffeettyy llaabbeellss aann wwaarrnniinnggss.. AA wwoorrkk ppllaattffoorrmm oorr ssccaaffffooll iinngg iiss tthhee rreeccoommmmeenn ee mmeetthhoo ffoorr iinnssttaallllaattiioonnss aann
sseerrvviicciinngg..
NNOOTTIICC
EEqquuiippmmeenntt DDaammaaggee!!
AAllll mmoouunnttiinngg bboollttss mmuusstt bbee tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aapppplliiccaattiioonnss aann ttoorrqquuee ttoo ssppeecciiffiiccaattiioonn.. IInnccoorrrreecctt bboolltt
lleennggtthhss aann iimmpprrooppeerr ttoorrqquuee ssppeecciiffiiccaattiioonnss ccaann aammaaggee eeqquuiippmmeenntt..
Battery Cable Installation and Routing
WWAARRNNIINNGG
HHaazzaarr ooff EExxpplloossiioonn!!
IImmpprrooppeerrllyy iinnssttaallllee bbaatttteerryy ccaabblleess ccoouull rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy ccaabblleess mmuusstt bbee iinnssttaallllee ,,
rroouuttee ,, aann sseeccuurree pprrooppeerrllyy ttoo pprreevveenntt tthheemm ffrroomm rruubbbbiinngg,, cchhaaffffiinngg,, oorr mmaakkiinngg ccoonnttaacctt wwiitthh hhoott,, sshhaarrpp,, oorr
rroottaattiinngg ccoommppoonneennttss..
WWAARRNNIINNGG
FFiirree HHaazzaarr !!
DDoo nnoott aattttaacchh ffuueell lliinneess ttoo bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo ccaauussee aa ffiirree aann
ccoouull ccaauussee sseerriioouuss iinnjjuurryy oorr eeaatthh..
WWAARRNNIINNGG
HHaazzaarr ooff EExxpplloossiioonn!!
AAllwwaayyss ccoovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroomm mmaakkiinngg ccoonnttaacctt wwiitthh mmeettaall ccoommppoonneennttss uurriinngg bbaatttteerryy
iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunn iinngg aaggaaiinnsstt mmeettaall ccoouull ccaauussee tthhee bbaatttteerryy ttoo eexxpplloo ee..
CCAAUUTTIIOONN
HHaazzaarr oouuss SSeerrvviiccee PPrrooccee uurreess!!
SSeett aallll uunniitt eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbeeffoorree ccoonnnneeccttiinngg bbaatttteerryy ccaabblleess ttoo tthhee bbaatttteerryy ttoo pprreevveenntt
uunniitt ffrroomm ssttaarrttiinngg uunneexxppeeccttee llyy aann ccaauussiinngg ppeerrssoonnaall iinnjjuurryy..
SSaaffeettyy PPrreeccaauuttiioonnss

TK 55676-19-IM-EN 9
NNOOTTIICC
EEqquuiippmmeenntt DDaammaaggee!!
DDoo nnoott ccoonnnneecctt ootthheerr mmaannuuffaaccttuurreerr’’ss eeqquuiippmmeenntt oorr aacccceessssoorriieess ttoo tthhee uunniitt uunnlleessss aapppprroovvee bbyy TThheerrmmoo KKiinngg..
FFaaiilluurree ttoo oo ssoo ccaann rreessuulltt iinn sseevveerree aammaaggee ttoo eeqquuiippmmeenntt aann vvooii tthhee wwaarrrraannttyy..
Re rigerant Hazards
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirree !!
RReeffrriiggeerraanntt iinn aa lliiqquuii ssttaattee eevvaappoorraatteess rraappii llyy wwhheenn eexxppoossee ttoo tthhee aattmmoosspphheerree,, ffrreeeezziinngg aannyytthhiinngg iitt ccoonnttaaccttss..
WWeeaarr bbuuttyyll lliinnee gglloovveess aann ootthheerr ccllootthhiinngg aann eeyyee wweeaarr wwhheenn hhaann lliinngg rreeffrriiggeerraanntt ttoo hheellpp pprreevveenntt ffrroossttbbiittee..
Re rigerant Oil Hazards
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirree !!
PPrrootteecctt yyoouurr eeyyeess ffrroomm ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TThhee ooiill ccaann ccaauussee sseerriioouuss eeyyee iinnjjuurriieess.. PPrrootteecctt sskkiinn aann
ccllootthhiinngg ffrroomm pprroolloonnggee oorr rreeppeeaattee ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TToo pprreevveenntt iirrrriittaattiioonn,, wwaasshh yyoouurr hhaann ss aann
ccllootthhiinngg tthhoorroouugghhllyy aafftteerr hhaann lliinngg tthhee ooiill.. RRuubbbbeerr gglloovveess aarree rreeccoommmmeenn ee ..
First Aid
RREEFFRRIIGGEERRAANNTT
•EEyyeess:: For contact with liqui , imme iately flush eyes with large amounts of water an get prompt me ical
attention.
•SSkkiinn:: Flush area with large amounts of warm water. Do not apply heat. Remove contaminate clothing an shoes.
Wrap burns with ry, sterile, bulky ressing to protect from infection. Get prompt me ical attention. Wash
contaminate clothing before reuse.
•IInnhhaallaattiioonn:: Move victim to fresh air an use CPR (car io pulmonary resuscitation) or mouth-to-mouth resuscitation
to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
•FFrroosstt BBiittee:: In the event of frost bite , the objectives of First Ai are to protect the frozen area from further injury,
warm the affecte area rapi ly, an to maintain respiration.
RREEFFRRIIGGEERRAANNTT OOIILL
•EEyyeess:: Imme iately flush with large amounts of water for at least 15 minutes. Get prompt me ical attention.
•SSkkiinn:: Remove contaminate clothing. Wash thoroughly with soap an water. Get me ical attention if irritation
persists.
•IInnhhaallaattiioonn:: Move victim to fresh air an use CPR (car io pulmonary resuscitation) or mouth-to-mouth resuscitation
to restore breathing, if necessary. Stay with victim until emergency personnel arrive.
•IInnggeessttiioonn:: Do not in uce vomiting. Imme iately contact local poison control center or physician.
EENNGGIINNEE CCOOOOLLAANNTT
•EEyyeess:: Imme iately flush with large amounts of water for at least 15 minutes. Get prompt me ical attention.
•SSkkiinn:: Remove contaminate clothing. Wash thoroughly with soap an water. Get me ical attention if irritation
persists.
•IInnggeessttiioonn:: Do not in uce vomiting. Imme iately contact local poison control center or physician.
EELLEECCTTRRIICCAALL SSHHOOCCKK
Take IMMEDIATE action after a person has receive an electrical shock. Get quick me ical assistance, if possible.
The source of the shock must be quickly stoppe , by either shutting off the power or removing the victim. If the power
cannot be shut off, the wire shoul be cut with an non-con uctive tool, such as a woo -han le axe or thickly insulate
SSaaffeettyy PPrreeccaauuttiioonnss

10 TK 55676-19-IM-EN
cable cutters. Rescuers shoul wear insulate gloves an safety glasses, an avoi looking at wires being cut. The
ensuing flash can cause burns an blin ness.
If the victim must be remove from a live circuit, pull the victim away with a non-con uctive material. Use woo , rope,
a belt or coat to pull or push the victim away from the current. DO NOT TOUCH the victim. You will receive a shock from
current flowing through the victim’s bo y. After separating the victim from power source, imme iately check for signs
of a pulse an respiration. If no pulse is present, start CPR (car io pulmonary resuscitation). If a pulse is present,
respiration might be restore by using mouth-to-mouth resuscitation. Call for emergency me ical assistance.
Heater Sa ety Precautions
IImmppoorrttaanntt:: Correct installation of this heater is necessary to ensure safe and proper operation. BB FFOORR installing the
heater, thoroughly read and understand this manual and the heater manufacturer’s manuals included with
the heater.
DDAANNGGEERR
HHaazzaarr ooff EExxpplloossiioonn oorr FFiirree!!
FFaaiilluurree ttoo ffoollllooww tthheessee iinnssttrruuccttiioonn ccoouull ccaauussee aa
eexxpplloossiioonn oorr ffiirree rreessuullttiinngg iinn sseerriioouuss oorr ffaattaall iinnjjuurryy..
• Heater must be turned off while re-fueling.
• Install heater so it will maintain a minimum distance of 2” from
any flammable or heat sensitive material.
• Install the exhaust system so it will maintain a minimum distance
of 2” from any flammable or heat sensitive material.
• Stored items in may shift while vehicle is in operation and should
be secured adequately to prevent contact with the heater.
• Use a protective air intake grille on the air inlet side of the heater
to prevent objects from being sucked in.
• The heater must only be operated when the maintenance flap is
closed and the outlet hood is mounted in position.
• Do not install heater in enclosed areas where combustible fumes
may be present.
• Do not store or transport combustibles (road flares, starting
fluids, fuel containers, oil cans, spray cans, gas cartridges, fire
extinguishers, cleaning rags, clothing, paper, etc.) in the same
compartment as the heater.
• Ensure that the fuel system is intact and there are no leaks.
• Do not route electrical wires, harness or battery cables together
with fuel lines.
DDAANNGGEERR
AAsspphhyyxxiiaattiioonn HHaazzaarr !!
TThhee ccoorrrreecctt iinnssttaallllaattiioonn ooff tthhee eexxhhaauusstt aann
ccoommbbuussttiioonn aaiirr iinnttaakkee hhoosseess iiss eexxttrreemmeellyy iimmppoorrttaanntt
ttoo pprreevveenntt ccaarrbboonn mmoonnooxxii ee ppooiissoonniinngg oorr
aasspphhyyxxiiaattiioonn..
• Route the heater exhaust so that exhaust fumes can not enter
into the passenger compartments.
• Ensure an air tight seal will be maintained between the heater and
mounting surface and at any exhaust connection points.
• Ensure that heating air supply is taken from an area where
poisonous gases will not be present.
• When the heater is installed in a enclosed compartment separate
from the evaporator, a inlet for return air must be installed to
provide the heater with a fresh air supply.
• If running exhaust components through an enclosed
compartment, ensure that it is vented to the outside.
• The enclosed compartment must be free of any holes, cracks or
rusted out areas to prevent fumes from entering into the
passenger compartment.
• The heater must be installed flush with the floor pan (i.e. sheet
metal, fiberglass, etc.) to ensure proper sealing of the mounting
plate and gasket.
• The heater must not be operated in closed areas such as garages,
buildings, warehouses, etc.
• Do not inhale exhaust fumes.
NNOOTTIICC
EEqquuiippmmeenntt DDaammaaggee!!
DDiissccoonnnneecctt tthhee hheeaatteerr hhaarrnneessss aatt tthhee bbaatttteerryy bbeeffoorree wweell iinngg oonn tthhee ttrruucckk cchhaassssiiss ttoo pprreevveenntt aammaaggee ttoo tthhee
eelleeccttrroonniicc HHMMII ccoonnttrroolllleerr..
SSaaffeettyy PPrreeccaauuttiioonnss

TK 55676-19-IM-EN 11
Tips For a Success ul Installation
Be ore Beginning the Installation
IImmppoorrttaanntt:: Proper installation of each component onto the vehicle is critical! Refer to the Thermo King TriPac
Installation Standards Guide (TK 56498) 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.
• Rea this manual to un erstan where components are to be locate an how they are to be installe .
• Thermo King offers numerous options such as Diesel Particulate Filter (DPF), Power Inverters, Hourmeters, etc.
which have separate installation instructions. These options shoul be installe simultaneously with the APU when
possible to help re uce overall installation time.
• Review the TriPac component rawings for important minimum/maximum imensions an clearances that must be
taken into consi eration when installing these components.
• Open all TriPac kits an inspect contents before beginning installation.
• Verify tools an special equipment require for the installation are available an in goo working con ition.
• Review component location iagram an iscuss with the customer where each component will be installe on the
truck.
• 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.
APU Installation
• DO NOT wel on any part of the tractor’s frame or rill holes in the top or bottom flanges. Serious structural
amage coul occur. Consult your chassis manufacturer for further information.
• The APU is esigne to be mounte only to the existing frame rails. NNOO OOTTHHEERR MMOOUUNNTTIINNGG IISS AACCCCEEPPTTAABBLLEE!!
• Determine the best location for installing the APU on the existing chassis frame rail.
• Safely relocate any components on the chassis frame rail that interfere with the installation of the APU.
• Check clearance aroun APU before installing.
• The use of a motorcycle/ATV lift or mo ifie floor jack to raise APU into position is recommen e .
• Only the supplie spacer blocks an mounting claws must be use to install the APU to the chassis frame rail.
• If ifferent mounting bolts are use they must be Gra e 5 an of the correct length. DO NOT cut off excessive length
bolts.
• Verify the upper an lower APU mounting bolts are flush with the chassis frame rail before tightening.
• The mounting har ware securing the APU to the tractor’s frame must be correctly positione an torque using the
four-step tightening sequence escribe in the “APU Installation” section in this manual.
• All APU covers, guar s or removable panels must be in place an installe securely while operating the system.
A/C Condenser Installation
• Always keep A/C system fittings cappe an seale until the installation of the refrigeration hoses.
• Determine the best location to mount the con enser onto the exterior of the sleeper.
• 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 finish to prevent amage uring the installation process.
• Use the stainless steel mounting har ware (supplie in the kit) to mount the con enser coil.
• 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 fumes from entering the sleeper.

12 TK 55676-19-IM-EN
A/C Evaporator Installation
• Always keep A/C system fittings cappe an seale until the installation of the refrigeration hoses.
• Determine the best location for the A/C evaporator insi e the sleeper, typically un er the bunk.
• Verify there is no interference with any OEM electrical wiring, internal supports, etc. before rilling any mounting
holes.
• The evaporator shoul be mounte irectly onto the floor mat insi e the sleeper by using the supplie template to
locate the rain an mounting holes.
• Always install the rain valves (kazoos) onto evaporator rain tubes securely with hose clamps.
• The A/C vents shoul be locate an installe to provi e maximum air circulation in the sleeper such as: LOW (floor
level), MEDIUM (above lower bunk level) or HIGH (above upper bunk level).
• 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 fiberglass
cloth an resin.
D2/D4 Heater Installation
• Determine the best location of the heater insi e the sleeper, typically un er the bunk. Allow clearance for
ismantling for service.
• Install heater so it will maintain a minimum istance of 2.00 inches (50.8 mm) from any heat sensitive or flammable
material.
• Heater must be mounte on a flat horizontal surface.
• Heater must be installe flush with the floor pan (i.e. sheet metal, fiberglass, etc.) to ensure proper sealing of the
mounting plate an gasket.
• All e ges of access holes ma e in fiberglass an woo composite floors must be seale correctly with fiberglass
cloth an resin.
• Outsi e air intake an exhaust hoses must be installe correctly for the heater to operate safely.
• Exhaust hose shoul be mounte slightly ownwar s to help rain off con ensation.
• Install exhaust hose so it will maintain a minimum istance of 2.00 inches (50.8 mm) from any heat sensitive or
flammable material.
• Insi e air inlet an outlet ucts must be installe correctly for the heater to operate safely.
• Pulse fuel pump must be installe at a 15 to 35 egree angle from horizontal to operate correctly.
• Fuel pickup tube must be installe correctly in the fuel tank or the heater will not operate.
• Fuel line from the pickup tube to the fuel pump to the heater shoul be route at a continuous rise.
• Use a hose cutter or sharp knife to cut plastic fuel lines. Do not use a wire cutter as this will pinch the plastic fuel line
close .
• Do not route electrical wires, harness or battery cables together with fuel lines.
• BEFORE operating the heater, the fuel lines must be ble of air using the Heater Priming Harness (204-1144) or
amage to the fuel pump will result.
• The Diagnostic Co e Rea er (204-1143) must be use to setup an operate the heater in the run-in mo e.
A/C Hose Connections and Routing
• Always keep A/C system fittings cappe an seale until the installation of the refrigeration hoses.
• 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 PAG 100 refrigerant oil (2030502) when assembling to refrigeration hoses.
• Always install an lubricate O-rings with PAG 100 refrigerant oil (2030502) when connecting refrigeration hose
fittings to component connection fittings.
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn

TK 55676-19-IM-EN 13
• 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 sleeving (installer supplie ) for the refrigeration hoses may be require epen ing on the
installation.
• Always install the con enser’s receiver rier 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 1.2 to 2.0 bs. ( epen ing on hose lengths) of R134a.
Engine Coolant Hose Connections and Routing
The following steps are for APU’s equippe with Tractor Coolant Integration only.
• Coolant hoses shoul be route from the APU to the tractor’s engine without any sharp ben s or kinks.
• Coolant hoses shoul be installe an route in such a way as to allow for vibration an movement. THEY SHOULD
NEVER BE STRETCHED TIGHT!
• Coolant hoses shoul be protecte with supplie plastic sleeving an a equately secure to the chassis with clamps
an ban wraps.
• Always keep coolant hoses from rubbing or chafing against sharp metal objects, rotating components or hot
objects.
• All coolant pipe fittings installe shoul be of proper material type, (i.e: brass to brass, or copper to copper).
• All coolant fittings shoul be assemble using pipe threa sealer to prevent leaks.
• Ball type shutoff valves (supplie ) shoul be installe to allow the TriPac cooling system to be close off an
isolate from the tractor’s engine cooling system.
• Shutoff valves an fittings must be a equately supporte to prevent cracks or leaks from vibration.
Closed Loop Cooling
Do not start the APU’s engine without first a ing coolant an blee ing all air from the system.
Electrical Wiring and HMI Controller Installation
• Electrical wiring shoul be installe an route in such a way as to allow for vibration an movement of the cab.
THEY SHOULD NEVER BE STRETCHED TIGHT!
• Always keep electrical wiring from rubbing or chafing against sharp metal objects, rotating components or hot
objects.
• All electrical wiring shoul be neatly route an secure with ban wraps or clamps.
• Do not route electrical wires, harness or battery cables together with fuel lines.
• Excess length of battery cables shoul be cut off to re uce voltage rop.
• Superlube (203-524) or equivalent shoul be applie to all electrical connections.
• All main power an groun accessory connections must be installe irectly on top of the tractor’s battery terminal
posts an tightene securely. DO NOT INSTALL UNDER OEM BATTERY CABLES!
• The HMI shoul be visible an mounte away from win ows, air vents, out of irect sunlight an not touching
anything to accurately measure air temperature.
TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn

14 TK 55676-19-IM-EN
TriPac Evolution Component Dimensions
APU
Figure 1. TriPac Evolution APU Dimensions (side and ront)

TK 55676-19-IM-EN 15
Figure 2. TriPac Evolution APU Dimensions (side and rear)
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16 TK 55676-19-IM-EN
Condenser
Figure 3. TriPac Evolution Condenser Dimensions
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TK 55676-19-IM-EN 17
Evaporator
Figure 4. TriPac Evolution Evaporator Dimensions
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18 TK 55676-19-IM-EN
Control Box
Figure 5. TriPac Evolution Control Box Dimensions
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TK 55676-19-IM-EN 19
HMI
Figure 6. TriPac Evolution HMI Controller Dimensions
RCS1660
BACK VIEW
FRONT VIEW
SIDE VIEW
203 mm
(8.00 in.)
29 mm
(1.10 in.)
139.7 mm
(5.50 in.)
50.8 mm
(2.00 in.)
46.6 mm
(1.80 in.)
76.2 mm
(3.00 in.) 98.55 mm
(3.88 in.)
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20 TK 55676-19-IM-EN
Standard Heater
Figure 7. Standard Heater Dimensions
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