Thermo King T-580R, T-800M, T-680S, T-880S, T-1080S Installation Manual

Installation Manual

Truck Edition (TSA, EMEIA and AP)

Single Temperature Systems

T-580R, T-80 0M and T-1000M (with TSR Controller)

T-680S, T-88 0S, T-1080S (with SR-3 Controller)

T-600R, T-680R , T-800R, T-880R, T-1000R & T-1080R (with SR-3 Controller)

T-1200R (EMEIA Only with SR-3 Controller)

TK 55212-1-IM (Rev. 4, 01/15)

Installation Manual

Truck Edition (TSA, EMEIA and AP)

Single Temperature Systems

T-580R, T-800M and T-1000M (with TSR Controller)
T-680S, T-880S, T-1080S (with SR-3 Controller)

T-600R, T-680R, T-800R, T-880R, T-1000R and T-1080R (with SR-3 Controller)
T-1200R (EMEIA Only with SR-3 Controller)

TK 55212-1-IM (Rev. 4, 01/15)

Copyright

©

2011 Thermo King Corp., Minneapolis, MN, U.S.A.

2

Installation Manual for T-Series Systems

Release History

Original (09/11) Released
Rev. 1 (02/13) Pages 20, 21, 23, 27 and 29 - Changed art to show revised lifting bar with forged clevis and pins, forged

connecting links and forged locking hooks used for lifting the unit.
Rev. 2 (03/13) Updated manual to include new Tier IV units.
Rev. 3 (10/14) Page 64: Added connection procedures for adding auxiliary power devices.
Rev. 4 (01/15) Page 46: Added important note about fuel tank air vent.

3

Installation Manual for T-Series Systems

4

Introduction

This manual was written to assist with the installation of Thermo King T-Series Systems onto truck bodies specifically designed and built for these
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 of dies el powered

refrigeration systems.

• Have a basic understanding of electricity and electrical wiring.

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

This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is req uir ed, Thermo King Corporation Service Department should be consulted.

Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the manufacturer’s
judgment, to affect its integrity.”

Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any info rmat i on, recommendations or
descriptions contained herein.

5

Table of Contents

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

Unit Dimensions T-580R, T-600R, T-680R, T-680R, T-680S, T-800M,

T-800R, T-880R, T-880S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Unit Dimensions T-1000M, T-1000R, T-1080R, T-1080S and T-1200R 9
Service Area - T-580R, T-600R, T-680R, T-680R, T-680S, T-800M,

T-800R, T-880R, T-880S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Service Area - T-1000M, T-1000R, T-1080R, T-1080S and T-1200R . 11

Remote Power Receptacle Dimensions (OPTION) . . . . . . . . . . . . . . . . 12

Battery Box Dimensions (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Remote Status Light Dimensions (OPTION) . . . . . . . . . . . . . . . . . . . . .14

HMI Controller Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Truck Body Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Lifting Bar Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Installation Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Uncrating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Installing the Hose Management Caps. . . . . . . . . . . . . . . . . . . . . . . . . . 30

Installing the Hose Management System (OPTION). . . . . . . . . . . . . . . 32

Securing the Oil Drain Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Securing the Evaporator Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank. . . . . . 38

Installing the Fuel Pickup Tube Into a Plastic Tank . . . . . . . . . . . . . . . . 40

Installing the Steel Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Installing the Aluminum Fuel Tank (OPTION) . . . . . . . . . . . . . . . . . . . 44

Installing the Fuel Pump and Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the ServiceWatch™ Remote Download Port (OPTION). . . . 48

Installing the Remote Power Receptacle (OPTION) . . . . . . . . . . . . . . . . 50

Installing the Remote Status Light (OPTION) . . . . . . . . . . . . . . . . . . . .52

Installing the HMI Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Installing the Battery Box (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Installing the Door Switch (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Auxiliary Electrical Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

UNIT CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

6

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: Add resses a c ircumsta nce that, if enco untered ,
might lead to death or serious injury.

CAUTION: Addresses a circumstance that, if enco untered,
may cause damage to eq uipment 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 in jury.

DANGER: Never apply heat to a sealed refriger ation system o r
container because it could explode, causing death or serious
injury

DANGER: Fluorocarbon refrigerants, in the pres ence 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 re s ult in death by suffocation.

WARNING: Always wear goggles or safety glasses.
Refrigerant liquid, refrigeration oil, and battery acid can
permanently damage the eyes (see First Aid un der
Refrigeration Oil).

WARNING: Keep your hands away from fans and belts when
the unit is running. This should also be considered when
opening and closing the compressor service valves.

WARNING: Make sure gauge manifold hoses are in good
condition. Never let them come in contact with a belt, fan
motor pulley, or any hot surface.

WARNING: Make sure all mou nti ng bolts are tight and are of
correct length for their particular application

WARNING: Never drill holes in the unit unless absolutely
necessary. Holes dri ll ed into the unit may weaken structural
components. Holes drilled into electric al wiring can cau se fire
or explosion.

WARNING: When using ladders to install or service
refrigeration systems, always observe the ladder
manufacturer’s safety labels and warn ings. A w ork platform is
the recommended method for installations.

WARNING: Exposed coil fins are very sharp and can cause
painful lacerations.Wea r lea ther w ork gloves to prevent i njur y.

7

Safety Precautions (continued)

Battery Installation and Cable Routing Refrigerant

First Aid

FROST 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 am ounts

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 Oil

First Aid

NOTE: In case of eye contact, immediately flush with plen ty of water
for at least 15 minutes. CALL A PHYSICIAN. Wash skin with soap and
water.

WARNING: Im prop erly i ns talled battery cou ld result in a fire or
explosion! A Thermo King approved battery must be instal led
and properly secured to the battery tray.

WARNING: Improperly installed battery cables could result in
fire or explosion! Battery cables must be installed, routed and
secured properly to prevent them from rubbing, chaffing or
making contact with hot, sharp or rotating components.

WARNING: Do not attach fuel lines or any additional wiring
harnesses to the battery cables as this could caus e an
electrical fire!

CAUTION: Set all unit electrical controls to the OFF positio n
before connecting battery cables to the battery to prevent unit
from starting unexpectedly and causing personal injury.

CAUTION: Always wear protective clothing, gloves and eye
wear when handling and installing batteries. Battery acid can
cause serious burns when exposed to eyes or skin. If battery
acid contacts skin or clothing, wash imme diately with soap
and water. If acid enters your eye, immediately flood it with
running cold water for at least twen ty minutes and g et medi cal
attention immediately.

CAUTION: Always cover battery terminals to prevent them
from making contact with metal components during batter y
installation. Battery ter m inals grounding against metal could
cause the battery to explode.

WARNING: Al though 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: Av oid refrig eration o il contact with the eyes. Avo id
prolonged or repeated contact of refrigeration oil with skin or
clothing. Wash th oroughly after handling refrigeration oil to
prevent irritation.

8

Unit Dimensions - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S

NOTE: The top of the unit to be mounted flush with the top of the cargo box when
possible. The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling.

The dimension from the top of the cargo box to the evaporator cutout will vary
depending on the type of box, truck cab tilt clearance. etc.

T-580 th rough T-880 series units minimum dimension = 107 mm (4.2 5 in.)

9

Unit Dimensions T-1000M, T-1000R, T-1080R, T-1080S and T-1200R

NOTE: The top of the unit to be mounted flush with the top of the cargo box when
possible. The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling.

The dimension from the top of the cargo box to the evaporator cutout will vary
depending on the type of box, truck cab tilt clearance. etc.

T-1000 through T-1200 series minimum dimension = 147 mm (5.75 in.)

10

Service Area - T-580R, T-600R T-680R, T-680R, T-680S, T-800M, T-800R, T-880R, T-880S

11

Service Area - T-1000M, T-1000R, T-1080R, T-1080S and T-1200R

12

Remote Power Receptacle Dimensions (OPTION)

NORTH AMERICAN MODELS

INTERNATIONAL MODELS

13

Battery Box Dimensions (OPTION)

14

Remote Status Light Dimensions (OPTION)

15

HMI Controller Dimensions

HMI Controller (LED Display)

HMI Controller (Graphics Display)

16

Truck Body Opening Dimensions

Installing a New Unit onto a New Truck Box

Important Installation Requirements:

• Gasket sealing surface of 50.8 mm (2.00 in.) wide is required around the unit opening. This surface must be flat within 6.4 mm (0.25 in.) and free of all rivets or head b o
proper gasket sealing.

• The top of the evaporator to be positioned 25.4 mm (1.00 in.) below ceiling.

• Unit mounting location must allow for adequate tilt clearance (see Unit Dimensions ).

NOTE: The top of the unit to be
mounted flush with the top of t he
cargo box when possible. The
top of the evaporator to be
positioned 25.4 mm (1.00 in.)
below ceiling.

The dimension from the top of
the cargo box to the evaporator
cutout will vary dependin g on the
type of box, truck cab tilt
clearance. etc.

T-580 through T-880 series
minimum dimension = 107 mm
(4.25 in.)

17

Truck Body Opening Dimensions

Retrofitting a New Unit onto a Older Truck Box

Important Installation Requirements:

• Gasket sealing surface of 50.8 mm (2.00 in.) wide is required around the unit
opening. This surface must be flat within 6.4 mm (0.25 in.) and free of all rivets or head bolts for proper gasket se aling.

• Evaporator to be positioned 25.4 mm (1.00 in.) below ceiling.

• Unit mounting location must allow for adequate tilt clearance (see Unit Dimensions ).

NOTE:

Existing opening same as

RD-II, TS-500 and TS-600 units

and does not require

modifications.

Opening must only be enlarged

when changing from a TS-200,

TS-300, MD-100, MD-200,

MD-300, MD-II or KD-II

349.3 mm
(13.75 in.)

Enlarge Opening as shown (See

18

Unit Weights

Model 30 Units (approximate weight) Model 50 Units (approximate weight)

CAUTION: The truck wall must be structurally strong enough to support the weight of the refrigeration unit.

T-580R 434 kg (957 lbs.)
T-600R 443 kg (977 lbs.)
T-680R 437 kg (963 lbs.)
T-680S 447 kg (985 lbs.)
T-800R 443 kg (977 lbs.)
T-880R 437 kg (963 lbs.)
T-880S 447 kg (985 lbs.)
T-800M 443 kg (977 lbs.)
T-1000M 476 kg (1029 lbs.)
T-1000R 461 kg (1016 lbs.)
T-1080R 453 kg (999 lbs.)
T-1080S 459 kg (1012 lbs.)
T-1200R 475 kg (1046 lbs.)

T-580R 459 kg (1012 lbs.)
T-600R 468 kg (1032 lbs.)
T-680R 462 kg (1018 lbs.)
T-680S 472 kg (1040 lbs.)
T-800R 468 kg (1032 lbs.)
T-880R 462 kg (1018 lbs.)
T-880S 472 kg (1040 lbs.)
T-800M 468 kg (1032 lbs.)
T-1000M 516 kg (1138 lbs.)
T-1000R 510 kg (1125 lbs.)
T-1080R 502 kg (1108 lbs.)
T-1080S 508 kg (1121 lbs.)
T-1200R 524 kg (1155 lbs.)

19

Lifting Bar Details

IMPORTANT: All T-580 through T-1200 series truck units require a new
lifting bar. This new bar must be used to safely lift and install these series
units. This new lifting bar can also be used to install earlier series truck
units.

WARNING: Thermo King requires a 3 point lifting bar to safely
lift and install units. A lifting bar can be made from the drawings
provided.

WA R NING : All h ard ware us ed to asse mble the li f t ing bar m ust 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: Use forged clevis and pins, forged chain links and
forged locking hooks with strength equal to total lift capacity of
hoist mechanism and that meet all safety standards.