installation manual—a trailer edition super ii single...

Installation Manual—A

Trailer EditionSuper II rature SystemsSuper II perature SystemsTK 50556-2-IM (Rev.6

t© 1999 Ther A.
Copyrigh
Single Tempe TCI Multi-Tem

, 02/06)

mo King Corp., Minneapolis, MN, U.S.

2

ation regarding installing fuel tank under trailer.

Relaese HistoryReleased (09/01/00)

Rev. 1 (01/11/01) Update controller art.

Rev. 2 (01/29/01) Text corrections and updates.



Rev. 5 (05/23/05) Added new door switch installation instructions.

Rev. 6 (02/06) Page 36 - Added DOT/Federal Highway Regulations inform

3

Systems
Trailer Edition
Installation Manual for Super II

AGA803

4

ons warranties express or implied, with respect to ould not be regarded as all-inclusive or covering ent should be consulted.

ined, repaired or altered as, in the manufacturer’s

perty damage or any other direct, indirect, r any information, recommendations or

Introduction

Installation Manual-A was written to assist with the installation of the Thermo King SUPER II and SUPER II TCI refrigeration systems onto trailers specifically designed and built for refrigerated applications.

Due to its complexity, you should not attempt this installation unless you:

• are an experienced mechanic.

• can safely lift 34 kilos (75 lbs.)

• are certified or trained in the repair and maintenance ofdiesel powered refrigeration systems.

• have a basic understanding of electricity and electrical wiring.

• have the necessary tools and equipment to complete the installation.

Installation Manual-B was written to complete the installation of the Multi-Temperature systems with TLE remote evaporators.

This manual is published for informational purposes only. Thermo King makes no representatithe information recommendations and descriptions contained herein. Information provided shall contingencies. If further information is required, Thermo King Corporation Service Departm

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintajudgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, prospecial, or consequential damages whatsoever, arising out of the use of this manual odescriptions contained herein.

5

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Trailer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Evaporator Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Mounting Bolt Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Super II Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Bulkhead Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Rear Remote Controller Dimensions (OPTION) . . . . . . . . . . . . . . . . . . . . . . 24

Status Light Dimensions (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Uncrating the Super II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installing the Super II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Installing the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installing the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installing the Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Installing the Rear Remote Controller (OPTION) . . . . . . . . . . . . . . . . . . . . . 40

Installing the Door Switch (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installing the Status Light (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Installing the Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installing the Bottom Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6

Always wear goggles or safety glasses. Refrigerant ration oil, and battery acid can permanently damage

First Aid under Refrigeration Oil).

Keep your hands away from fans and belts when the g. This should also be considered when opening and mpressor service valves.

Make sure gauge manifold hoses are in good ver let them come in contact with a belt, fan motor hot surface.

Make sure all mounting bolts are tight and are of h for their particular application.

Never drill holes in the unit unless absolutely oles drilled into the unit may weaken structural Holes drilled into electrical wiring can cause fire or

When using ladders to install or service refrigeration ys observe the ladder manufacturer’s safety labels

s. A work platform is the recommended method for

Exposed coil fins are very sharp and can cause ations.

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.

DANGER: Never operate the unit with the discharge valve closed because it could cause the compressor to explode, causing death or serious injury.

DANGER: Never apply heat to a sealed refrigeration system or container because it could explode, causing death or serious injury.

DANGER: Fluorocarbon refrigerants, in the presence of an open flame or electrical short, produce toxic gases that are severe respiratory irritants capable of causing death.

DANGER: Be careful when working with a refrigerant or refrigeration system in any enclosed or confined area with a limited air supply (i.e., a trailer, container or the hold of a ship). Refrigerant tends to displace air and can cause oxygen depletion which may result in death by suffocation.

WARNING: liquid, refrigethe eyes (see

WARNING: unit is runninclosing the co

WARNING: condition. Nepulley, or any

WARNING: correct lengt

WARNING: necessary. Hcomponents.explosion.

WARNING: systems, alwaand warninginstallations.

WARNING: painful lacer

7

ed)

il

immediately flush with plenty of water for at least HYSICIAN. Wash skin with soap and water.

id refrigeration oil contact with the eyes. Avoid peated contact of refrigeration oil with skin or thoroughly after handling refrigeration oil to n.

Safety Precautions (continu

Refrigerant

First AidFROST BITE: In the event of frost bite, the objectives of First Aid are to protect the frozen area from further injury, to warm the affected area rapidly and to maintain respiration.

EYES: For contact with liquid, immediately flush eyes with large amounts of water and get prompt medical attention.

SKIN: Flush area with large amounts of lukewarm water. Do not apply heat. Remove contaminated clothing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection/injury. Get medical attention. Wash contaminated clothing before reuse.

INHALATION: Move victim to fresh air and use CPR or mouth-to-mouth ventilation, if necessary. Stay with victim until arrival of emergency medical personnel.

Refrigeration O

First AidIn case of eye contact, 15 minutes. CALL A P

WARNING: Although fluorocarbon refrigerants are classified as safe refrigerants, certain precautions must be observed when handling them or servicing a unit in which they are used. When released to the atmosphere in the liquid state, fluorocarbon refrigerants evaporate rapidly, freezing anything they contact.

WARNING: Avoprolonged or reclothing. Wash prevent irritatio

8

Required Tools

1. Safety Glasses

2. Drill

3. Drill Bits

4. Tape Measure

5. Mechanics Tools

6. Lifting Bar

7. Work Platform (Recommended)

8. Torque Wrench

9. Forged Eyebolts

NOTE: Equipment such as scales, gauges, refrigerant leak detectors, and torque wrenches should be in good working condition and routinely calibrated to assure accurate readings.

9

N21

Required Tools

8

9

AB

10

ts

ck Valves

ps

er

rt Channel

ting Strap

ting Brackets

plate

ng Plates

n)

Installation Componen

1. Screws, Flatwashers,Lockwashers

1/4 in.

2. Locking Nuts

1/2 in. x 13

3. Washers

1/4 in.

4. Captive Nuts

1/4 in.

5. Grommets

6. Screws-Self Tapping

7. Clamps

8. Cable Ties

9. Fuel Line

1/4 in. OD

3/8 in. OD

10. Fuel Line Fittings

1/4 in.

3/8 in.

11. Fuel Line Connector

12. PVC Hose

13. Drain Hose Che

14. Bottom Panels

15. Vinyl Taper Stri

16. Fuel Tank

17. Fuel Tank Hang

18. Fuel Tank Suppo

19. Fuel Tank Moun

20. Fuel Tank Moun

21. Fuel Tank Name

22. Fuel Tank Backi

23. Bulkhead (optio

11

Installation Components

12

67 lbs.)

efrigeration unit!

mm (36.00 in.) or severe damage to the equipment

in.) or severe damage to the equipment will result.

Trailer Requirements

Approximate WeightSuper II 667 kg (1468 lbs.) to 758 kg (16

DANGER: The front trailer must be structurally strong enough to support the weight of the r

CAUTION: The minimum distance from the king pin to the front of the trailer must be 914.4 will result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

CAUTION: The minimum clearance required for the swing radius must be 1549.4 mm (61.00VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!

13

AGA807

Trailer Requirements

14

sions

ip Installation Instructionsface area of overlap seams above opening.

cking from vinyl taper strip.

r strip to trailer seams, positioning thicker side along etail I).

Evaporator Opening Dimen

Evaporator Opening

The location of the unit mounting bolts and evaporator opening in the front wall is critical. VERIFY ALL DIMENSIONS BEFORE INSTALLING UNIT!

NOTE: It may be necessary to relocate the front corner clearance lights to the corner radius of the trailer to prevent damage.

1. The evaporator opening must be square. The diagonal measurements must be within ± 3.0 mm (0.12 in.).

2. The gasket surface around the opening must be at least 76.2 mm (3.00 in.) wide, be flat ± 3.2 mm (0.05 in.) and free of rivets, seams or bolt heads.

3. Trailers often have overlap vertical seams above the unit opening which cause poor gasket sealing and adversely affect the performance of your Thermo King unit (Detail I).

4. To provide proper sealing surface at these seams, install the vinyl taper strips supplied in the installation kit (Detail I).

Vinyl Taper Str• Clean trailer sur

• Peel off paper ba

• Apply vinyl tapeedge of seam (D

DANGER: The front trailer wall must be structurally strong enough to support the weight of the refrigeration unit!

15

ions

AGA808

Evaporator Opening Dimens

16

ns

Specifications

.75 pitch class 8.8 (1/2 in.-13 UNC - 28 Rolled thread rbon steel bolts and locking nuts. All hardware must ichromate finish.

he use of mounting bolts other than those specified n severe damage to equipment, void the warranty or al injury or death!

Mounting Bolt Dimensio

Mounting Bolts

NOTE: The location of the unit mounting bolts in the trailer front wall is critical to proper unit installation.

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 to be torqued to 82 N•m (60 ft. lbs.) from outside the trailer.

1. Six top mounting bolts are to extend 44.4 mm (1.75 in.) beyond the front wall (Detail I).

2. Two bottom mounting bolts are to extend 57.2 mm (2.25 in.) beyond the front wall (Detail II).

Mounting Bolts

Use Metric M12 x 1grade 5), medium cabe zinc plated with d

DANGER: Eight 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!

DANGER: Tcould result icause person

17

s
Mounting Bolt Dimension

18

Super II Dimensions

I. Front View

II. Side View

III. Top View

IV. Overall area required for servicing the unit.

19

.8 mm5 in.)29.5 mm

(5.10 in.)

693.4(27.3 in.)

914.6 mm(36.01 in.)

Super II Dimensions

215(8.

1

AGA810

20

ulkheado King dealers.

Shown (Dimensions are approximate)

Bulkhead Dimensions

Thermo King Recommends Using A BBulkheads are available from authorized Therm

Return AirflowRestrictions of the return airflow adversely affects the performance of the unit. The area directly behind the evaporator return air inlet must not be restricted.

Bulkhead FunctionA bulkhead is used to keep the return airflow from being restricted if the load shifts. The bulkhead also prevents the load from shifting into the return airflow passageway on the front wall of the trailer.

Typical Bulkhead

I. Front View

II. Side View

21

AGA791

Bulkhead Dimensions

22

ber

SAE Ratings

Cold Crank Amps

30 Seconds @ 0 F

Reserve Capacity

ions)750 180 minutes minimum

@ 25 amps

)750 180 minutes minimum

@ 25 amps

)950

ions)950

ions)700

re available with either lugs or threaded studs.

Battery Dimensions

NOTE: 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.

Units are designed for one 12 volt, Group C31 battery supplied by the installer.

• 750 CCA recommended for ambients above -15 F (-26 C).

• 950 CCA recommended for ambients below -15 F (-26 C).

The battery must be suitable for deep cycling, heavy duty and rated with a minimum of 95 amp/hr.

NOTE: See chart for Thermo King approved batteries.

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!

Thermo KingService Part Num

203-600(3/8-16 NC connect

203-601(lug connections

203-724(lug connections

203-725(3/8-16 NC connect

203-726(3/8-16 NC connect

NOTE: Batteries a

23

Battery Dimensions

24

ensions
Rear Remote Controller Dim(OPTION)
Controller and Mounting Box DimensionsI. Front View

II. End View

III. Side View

25

nsions
Rear Remote Controller Dime(OPTION)

26

s
Status Light Dimension(OPTION)
I. Front View

II. Side View

27

s
Status Light Dimension(OPTION)

28

s

d lifting bar.

in.

nks.

Chain Link.

Lifting Bar Dimension

I. Front View.

II. Side View.

III. Complete welde

1. Forged Clevis P

2. Forged Chain Li

3. Locking Master

WARNING: Do not use a fork lift to install unit!

WARNING: Thermo King requires a 2 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided.

WARNING: All hardware used to assemble the lifting bar must be DIN 931 class 10.9 (SAE grade 8). The use of hardware other than specified may cause personal injury, severe damage to the equipment and void the warranty.

WARNING: The lifting bar and lifting device combined must be able to support minimum weight of 1360.8 kilos (1 1/2 tons).

29

AGA806

Lifting Bar Dimensions

30

I

od Crated crate member.

ebolts and 2 point lifting bar to unit.

re holding unit to crate uprights.

tion kit boxes and any other loose components from

re holding unit to crate base.

te.

y for installation.

Uncrating the Super I

Super II units are shipped in either a disposable wood crate or a returnable steel crate which can be returned for credit. Contact Thermo King for details.

NOTE: To avoid unnecessary damage to your unit, place the crated unit near the trailer prior to its removal.

Returnable Steel Crate• Carefully remove plastic stretch wrap from unit.

• Attach forged eyebolts and 2 point lifting bar to unit.

• Remove installation kit boxes and any other loose components from rear of unit.

• Remove hardware to disassemble crate.

• Remove hardware holding unit to crate uprights.

• Remove hardware holding unit to crate base.

• Remove hardware holding unit to crate.

• Unit is now ready for installation.

NOTE: The crate can be returned for credit. Contact Thermo King for details.

Disposable Wo• Remove top woo

• Attach forged ey

• Remove hardwa

• Remove installarear of unit.

• Remove hardwa

• Disassemble cra

• Unit is now read

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: Thermo King requires a 2 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided (see Lifting Bar Dimensions).

31

AGA813

Uncrating the Super II

32

I

nve overlap seams above the unit opening which cause ing and adversely affect the performance of your it.

er sealing surface at these seams, install the vinyl taper the installation kit.

ip Installation Instructionsface area of overlap seams above opening.

cking from vinyl taper strip.

r strip to trailer seams positioning thicker side along

1 forged lifting eyebolts into threaded holes located on it (Detail I).

ar to lift unit up to the trailer opening.

nd elastic stop nuts provided in the installation kit. m (60 ft. lbs.).

t hold the unit to the trailer should be elastic stop nuts ded in the installation kit.

Installing the Super I

Access to Mounting Holes (Detail II).1. Access mounting hole through the opening on the top of the unit.

2. Access mounting hole by opening the left side door.

3. Access mounting hole by opening the lift side door.

4. Access mounting hole by opening the control box door.

5. Access mounting hole by opening the right side door.



8. Access mounting hole through the opening on the top of the unit.

Unit Installatio9. Trailers often ha

poor gasket sealThermo King un

10. To provide propstrips supplied in

Vinyl Taper Str• Clean trailer sur

• Peel off paper ba

• Apply vinyl tapeedge of seam.

11. Install two 5/8-1the top of the un

12. Use the lifting b

13. Attach washer aTorque to 82 N•

NOTE: All nuts tha(Nylock Type) provi

WARNING: Do not use a forklift to install the unit! This could result in severe damage to 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).

WARNING: Thermo King requires a 2 point lifting bar to safely lift and install units. A lifting bar can be made from the drawings provided (see Lifting Bar Dimensions).

33

AGA811

Installing the Super II

34

es
Installing the Drain Hos
1. Drain Hoses should run straight down the trailer wall from the unit with no kinks or bends.

2. Secure with screws and clamps provided in installation kit.

3. Cut off excess hose and attach drain hose check valves provided in installation kit.

35

s
Installing the Drain Hose
AGA812

36

k

commendations used with every tank installation.

wing shows a typical installation with 12 inch acing. For other crossmember spacing, refer to TK 2.

rdware to 81 - 88 N•m (60 - 65 ft. lb).

rdware to 34 N•m (25 ft. lb).

mping hardware to 48 N•m (35 ft. lb).

from fuel tank, through conduit and connect to unit. .6 mm (24.0 in.).

commends the fuel tank be mounted 203.2 mm of the trailer frame. Otherwise, the OEM or installer is sure the fuel tank position meets or exceeds DOT or

y regulations, when applicable.

228.6 mm (9.00 in.) from center line of trailer.

Installing the Fuel Tan

NOTE: Thermo King supplies the Fuel Tank, Fuel Tank Hangers, Fuel Tank Channels and Fuel Tank Straps. Due to differences in trailer manufacturers, additional support channels may be required to safely support the overall weight of the fuel tank components including the full capacity of diesel fuel. Consult your trailer manufacturer for specific details on proper fuel tank installation and recommendations.

Installation Re1. Channel must be

NOTE: This dracrossmember spdrawing 5937C2

2. Torque 1/2 in. ha

3. Torque 3/8 in. ha

4. Torque band cla

5. Route fuel lines Clamp every 609

6. Thermo King re(8.00 in.) inside responsible to enFederal Highwa

7. Position fuel line

DANGER: An improperly installed fuel tank could lead to serious injury or death! Consult your trailer manufacturer for specific details on proper fuel tank installation and recommendations.

37

Installing the Fuel Tank

38

s

nes with provided clamps (Detail II).

ly line from the bracket to the fuel pickup on the fuel line connector (provided in installation kit), cut end of degree angle and insert into fuel pickup tube until it is n.) from bottom of tank and tighten securely.

n line from the bracket to the fuel tank return fitting. connectors and tighten securely.

cap from the fuel vent and point the outlet to the rear of

ient amount of fuel (1/4 tank) to allow the unit to run ring engine break-in and pre-delivery procedures.

Installing the Fuel Line

1. Install the fuel line bracket to the predrilled holes in the frame or any convenient location on the trailer.

2. Fuel lines should be routed in a protective housing with no kinks or sharp bends (Detail I).

3. Rubber grommets must be used when routing fuel lines through holes in metal (Detail I).

4. Secure all fuel li

5. Route fuel supptank. Install fuelfuel line at a 45 25.4 mm (1.00 i

6. Route fuel returAttach fuel line

7. Remove plastic the trailer.

NOTE: Add a sufficfor 8 to 12 hours du

DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All fuel line fittings must be tight and leak free!

DANGER: Do not route fuel lines with battery cables or electrical wires, as this could cause a fire!

39

AGA815

Installing the Fuel Lines

40

ontroller

ould not protrude more than 6.4 mm (.25 in.) inside

ttom of controller box before foaming trailer wall.

to controller box and install securely into trailer wall.

(or equivalent) to interface harness connector and o back of controller. Route interface harness through ntroller to controller box with screws.

interface harness from controller to host unit. Secure

arness and strip wire ends. Crimp onto existing splice ink covering.

(or equivalent) and secure connect remote interface r to evaporator harness connector.

n.)

in.)

Installing the Rear Remote C(OPTION)

Foamed-In-Place InstallationNOTE: NOTE: Verify mounting location and all dimensions before installing the remote controller.

Preferred Wire Routing (Steps 1,2, 6-10)

NOTE: The preferred routing of the electrical harness chase and interface harness is from the bottom of the controller box.

1. Connect the harness chase to the bottom of controller while providing a drip loop.

2. Install and route a 1/2 in. CPVC drain hose from the bottom of the controller box out of trailer floor.

Alternative Wire Routing (Steps 3-10)

NOTE: The alternative routing of the electrical harness chase and interface harness is from the side of the controller box.

3. Drill an appropriate size hole in the controller box for the harness chase coupling.

4. Install harness chase coupling.

NOTE: Coupling shthe controller box.

5. Install cap in bo

6. Apply chalking

7. Apply Superlubeattach securely tchase. Secure co

8. Route chase andwith clamps.

9. Cut off excess hand use heat shr

10. Apply Superlubeharness connecto

A. 69.8 mm (2.75 i

B. 196.8 mm (7.75

DANGER: Do not route electrical harness together with fuel lines as this could cause a fire resulting in death or serious injury!

CAUTION: Do not drill holes into refrigeration, electrical or mechanical components or severe damage to the equipment will result!

41

ntroller
Installing the Rear Remote Co(OPTION)

42

ontroller

to controller box and install securely in trailer wall.

re the drain hose and harness chase are connected

to remote controller with interface connector harness, wn chase and forward to unit.

nder trailer through chase in floor or I-beam cross s the unit.

trailer, measure and drill an appropriate size hole and up into the trailer towards the unit.

hole is properly sealed after routing harness.

o the backside of the unit with clamps.

th of harness required to connect to host unit ss connector, cut off excess harness and strip wire existing splice and use heat shrink covering.

t the remote interface harness to the evaporator harness

Installing the Rear Remote C (OPTION)

Retro-Fit InstallationNOTE: Verify mounting location and all dimensions before installing the remote controller.

1. Cut opening in trailer wall per dimensions shown.

A. 203 mm (8.0 in.)

B. 107.9 mm (4.25 in.)

C. 38 x 12.7 mm (1.5 x .5 in.)

2. Install and route a 1/2 in. CPVC drain hose and 0.88 O.D. harness chase from the bottom of the controller box out of the trailer.

3. Apply caulking

NOTE: Make suproperly.

4. Apply caulking route harness do

5. Route harness umembers toward

6. From inside the route the harness

NOTE: Ensure

7. Secure harness t

8. Measure the lengevaporator harneends. Crimp into

9. Securely connecconnector.

DANGER: Do not route electrical harness together with fuel lines as this could cause a fire resulting in death or serious injury!


CAUTION: Rubber grommets must be used when routing electrical harnesses through metal holes!

43

ntroller

B

A

C

AAB76

3

1

4

3

Installing the Rear Remote Co (OPTION)

2

6

8

9

5

7

44

installation. Your installation may be different s.

magnet must be installed parallel to each other, ng cross hair aligns to long cross hair.

maximum gap of 19 mm (0.75 in.) is maintained itch and the magnet. Shims may be required and tic material (aluminum, wood, plastic, etc.) or the

operate properly.

unted lush with the top edge of the door and secure with

ount the switch to the door sill parallel with the e “cross hairs” are aligned and that the maximum

in.) is maintained.

ted lush with the bottom edge of the door and secure are.

ount the switch to the floor parallel with the e “cross hairs” are aligned and that the maximum

in.) is maintained.

or Installation

lush with the top edge of the door and secure with

ount the switch to the door sill parallel with the e “cross hairs” are aligned and that the maximum

in.) is maintained

Installing the Door Switch(OPTION)

NOTE: These instructions are intended as reference guide only to assist with a typical door switchdepending on the trailer, the amount and types of doors and the customers particular requirement

Door Switch ComponentsThe door switch consists of a magnet, a switch, non-magnetic mounting hardware and a interface harness to connect to the host unit.

• The magnet is always mounted on the door.

• The switch (with harness) is always mounted to a stationary location.

• Two short interface harnesses are available depending on your particular kit. One allows a single door switch in a single zone to activate a unit shutdown. The other allows two door switches in the same zone to each activate a unit shutdown.

Non-magnetic mounting hardware is included to install the switches. If alternate hardware is used it must also be non-magnetic or the door switch will not operate properly.

Installer is to supply and fabricate the harness connecting the interface harness to the door switch per the table below. The harness should be 18 AWG or better, 3 wires, color coded RED, BLACK and WHITE.

Mounting LocationsThe door switch can be mounted on the inside or outside of either swing out or roll-up doors and can be mounted in various positions to accommodate particular applications.

IMPORTANT INSTALLATION NOTES:• The door switch must be installed away from traffic (i.e. forklifts) or

protected from it.

• The door switch andnot perpendicular. Lo

• It is important that a between the door swmust be a non-magnedoor switch will not

(Detail A) Ceiling Mo1. Mount the magnet f

supplied hardware.

2. Close the door and mmagnet, being sure thgap of 19 mm (0.75

(Detail B) Floor Moun1. Mount the magnet f

with supplied hardw


(Detail C) Outside Do

1. Mount the magnet fsupplied hardware.


Interface Harness Wiring Door Switch Wiring

RED = (12 Vdc) POWER RED = (12 Vdc) POWER

BLACK = (CH) GROUND BLACK = (CH) GROUND

WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT

45

h
Installing the Door Switc(OPTION)
Right Angle Mounting

Top x Top Mounting

Side x Side Mounting

46

ch

ear of the host unit.

itch Activation / Single Zone (Detail B)

ace harness (1E30238) to matching door switch 1, 2 or 3) located at the rear of the host unit.

arness (Installer Supplied) from the interface harness itch in that zone - Maximum Two Doors. Connect er the table below (RED/RED, WHITE/WHITE,

K) to each door switch using splice connectors. Crimp s securely and apply heat with a heat gun.

ould be installed, routed and properly secured to age.

verify door switch operation.

rness Wiring Door Switch Wiring

2 Vdc) POWER RED = (12 Vdc) POWER

H) GROUND BLACK = (CH) GROUND

S) OUTPUT WHITE = (DS) OUTPUT

Installing the Door Swit(OPTION)

NOTE: The Door Switch Harness Connectors are located at the r

Single Door Switch Activation / Single Zone (Detail A)

1. Attach the interface harness (1E29281) to matching door switch connector (Zone 1, 2 or 3) located at the rear of the host unit.

2. Route a 3 wire harness (INSTALLER SUPPLIED) from the interface harness to a single door switch. Connect matching wires per the table below (RED/RED, WHITE/WHITE, BLACK/BLACK) to each door switch using splice connectors. Crimp splice connectors securely and apply heat with a heat gun.

3. All harnesses should be installed, routed and properly secured to protect from damage.

Multiple Door Sw

4. Attach the interfconnector (Zone

5. Route a 3 wire hto each door swmatching wires pBLACK/BLACsplice connector

6. All harnesses shprotect from dam

7. Operate unit and





Interface Ha

RED = (1

BLACK = (C

WHITE = (D

47

h
Installing the Door Switc(OPTION)








48

ht
Installing the Status Lig(OPTION)
1. Mount the Status Light in a location so that is visible in the tractor mirror to the driver. Mount securely with the provided screws.

2. Route harness as shown allowing a “drip-loop” to prevent water from migrating into the Status Light.

3. Secure harness with clamps.

4. Connect to matching connector located under control box.

49

t
Installing the Status Ligh(OPTION)
AGA817

50

d

ulkheado King dealers.

ad Shownhead manufacturer specific details for proper

ommendations.

Installing the Bulkhea

Thermo King Recommends Using A BBulkheads are available from authorized Therm

Return AirflowRestrictions of the return airflow adversely affects the performance of the unit. The area directly behind the evaporator return air inlet must not be restricted.

Bulkhead FunctionA bulkhead is used to keep the return airflow from being restricted if the load shifts. The bulkhead also prevents the load from shifting into the return airflow passageway on the front wall of the trailer.

Typical BulkheNOTE: Follow bulkinstallation and rec


51

Installing the Bulkhead

AGA795

52

is on the curbside of the Super II.

to tray.

bracket onto battery.

s to hold down bracket and tighten nuts. DO NOT over ay crack or distort the battery!

prevent movement of battery.

battery cable on the positive battery post first to ntal electrical shorting.

- battery cable on negative battery post second to ntal electrical shorting.

Installing the Battery

The battery location

1. Install battery on

2. Place hold down

3. Assemble J-bolttighten as this m

4. Adjust item 4 to

5. Install positive +minimize accide

6. Install negative minimize accide

CAUTION: Set all electrical controls to the OFF position before connecting the battery to prevent the unit from starting!

CAUTION: Always wear protective clothing, gloves and eye wear when handling and installing batteries!

CAUTION: Cover battery terminals to prevent accidental shorting during battery installation!

CAUTION: Do not route battery cables together with fuel lines as this could cause a fire!

CAUTION: All battery connections must be clean and tightly secured.

53

816

Installing the Battery

AGA

54

nels
Installing the Bottom Pa
1. Install bottom panels and tighten hardware securely.

55

els
Installing the Bottom Pan
AGA818

56

E

TE THIS INSTALLATION

STOP!

SUPER II

SINGLE TEMPERATUR

SYSTEMS ONLY!

REFER TO SYSTEM CHECK LIST BELOW TO COMPLE

57

System Check List

All unit mounting hardware torqued to specifications.

No air gaps between unit and trailer wall.

Drain hoses properly routed and secured.

Fuel tank properly installed.

Fuel lines properly routed and fuel fittings tightened securely.

Bulkhead properly designed and installed.

Battery secured correctly and all connections clean and tight.

Doors, covers and guards installed securely.

Run Pre-Trip test (refer to Host Unit Operating Manual).

Run unit under load for eight hours to properly break-in engine.

Release to customer.

58

E

his installation refer to:

ystems

STOP!

SUPER II

MULTI-TEMPERATUR

SYSTEMS ONLY!

To install the TLE remote evaporators and complete tInstallation Manual-B

Trailer Edition Multi-Temperature TLE STK-50279-2-IM

59

i) holding charge of erant must be recovered.

gine before completing the overing the host unit soldering the refrigeration ing the system. (SEE

nt and limit the potential escape into the

the loss of refrigerant into

STOP

Caution

Thermo King Multi-Temp host units are shipped with a 35 kPa (5 psR-404A. This holding charge of approximately 1 kg (2 lbs.) of refrig

SEVERE COMPRESSOR DAMAGE will result from operating the ensystem installation which includes: installing the components, recholding charge, releasing the remote unit holding nitrogen charge,lines, leak testing the system, evacuation and clean-up, and chargINSTALLATION MANUAL-B)

Recover Refrigerant

At Thermo King, we recognize the need to preserve the environmeharm to the ozone layer that can result from allowing refrigerant toatmosphere.

We strictly adhere to a policy that promotes the recovery and limitsthe atmosphere.

60

e

nit has problems after installation, check the items

CURE

Turn unit switch “ON”Clean and tighten connectionsRecharge or replace battery

Add fuel to tankCheck fuel line routingCheck connectionsBleed air from fuel lines

Bleed air from fuel linesCheck fuel lines for kinks

Secure doorsSecure grillesSecure guards and covers

Check for bulkhead blocking air return inletCheck for pinched or kinked drain hosesCheck installation of sill gasket

Troubleshooting Guid

NOTE: All Thermo King refrigeration units are pre-tested at the factory prior to shipping. If your ulisted below first. If further assistance is required, consult your Thermo King dealer.

SYMPTOM CAUSE

No display on control panel No power to unitBad battery connectionLow voltage

Diesel engine cranks overbut will not start

No fuelKinked/pinched fuel linesFuel lines connected wrong at tank or unitAir in fuel lines

Diesel engine starts but lacks power Air in fuel linesLow fuel pressure

Rattling noise from unit when running Loose component

Ice buildup on evaporator coil Evaporator coil restriction

Air leakage into trailer

installation manual—a trailer edition super ii single...

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