Trane Thermo King TriPac EVOLUTION Installation Manual

Revision A

November 2020

TTKK 5555667766--1199--IIMM--EENN

TriPac® EVOLUTION™™

Auxiliary Heating and Cooling Temperature Management
System

Installation Manual

Introduction

This manual was written to assist with the installation of the TThheerrmmoo KKiinngg TTrriiPPaacc EEVVOOLLUUTTIIOONN Auxiliary Heating and
Cooling System onto a typical semi tractor. While not intended to be specific to a particular vehicle, the information in
this manual will provide the installer with details to correctly and safely install each of the standard TriPac APU
components. The TThheerrmmoo KKiinngg TTrriiPPaacc IInnssttaallllaattiioonn SSttaannddaarrddss GGuuiiddee (TK 56430) provides more detailed information
that must be followed to safely and 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 should be installed simultaneously with the APU when possible to help reduce overall installation time.

Before beginning the installation, the installer should confirm with the customer the location for each of the TriPac
components by using the TriPac Installation Questionnaire. The customer should also be made aware of any
modifications 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 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 required, Thermo King
Corporation Service Department should be consulted.

hermo 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.”

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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©2020 Trane Technologies

TK 55676-19-IM-EN

Table of Contents

SSaaffeettyy PPrreeccaauuttiioonnss ........ .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .. 77

Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Battery Cable Installation and Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Refrigerant Oil Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Heater Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... 1111

Before Beginning the Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

APU Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A/C Condenser Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A/C Evaporator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

D2/D4 Heater Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

A/C Hose Connections and Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Engine Coolant Hose Connections and Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Closed Loop Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electrical Wiring and HMI Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss .. .. .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... ..1144

APU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Standard Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

High Output Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

RReeqquuiirreedd TToooollss aanndd AAddddiittiioonnaall SSuupppplliieess...... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... 2222

TTyyppiiccaall CCoommppoonneenntt LLooccaattiioonnss ...... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... 2233

TriPac Evolution Components with Truck Coolant Integration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

TriPac Evolution Components with Optional Closed Loop Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

AAPPUU IInnssttaallllaattiioonn ...... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... 2266

Standard Installation Method – Mounting Claws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

EExxhhaauusstt PPiippee IInnssttaallllaattiioonn .. .. .... .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... ..2288

Standard Short Exhaust Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

TK 55676-19-IM-EN

3

TTaabbllee ooff CCoonntteennttss

Optional Exhaust Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

AA//CC CCoonnddeennsseerr IInnssttaallllaattiioonn .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... 2299

AA//CC RReecceeiivveerr DDrriieerr IInnssttaallllaattiioonn...... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... ..3311

AAmmbbiieenntt TTeemmppeerraattuurree SSeennssoorr IInnssttaallllaattiioonn ((OOppttiioonn)) ...... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... 3322

AA//CC EEvvaappoorraattoorr IInnssttaallllaattiioonn .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... 3333

Preferred Location – Flush with Front Bulkhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Alternative Location – Centered Under Bunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... 3377

Heater Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Drilling Hole In Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Heater Subassembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Exhaust and Combustion Air Intake Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Exhaust and Combustion Air Intake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

DD22//DD44 HHeeaatteerr DDuucctt IInnssttaallllaattiioonn.. .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... 4422

Duct Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

AA//CC DDuucctt IInnssttaallllaattiioonn .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... 4444

A/C Vent Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

AA//CC HHoossee IInnssttaallllaattiioonn .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... ..4466

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Compressor Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

AA//CC SSyysstteemm EEvvaaccuuaattiioonn aanndd LLeeaakk CChheecckk PPrroocceedduurreess .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... ..4499

Evacuation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Leak Check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

CCoonnttrrooll BBooxx aanndd MMaaiinn HHaarrnneessss IInnssttaallllaattiioonn .. .. .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... ..5511

Control Box Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Main Harness Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

HHMMII IInnssttaallllaattiioonn .. .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... ..5533

HMI Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

DD22//DD44 HHeeaatteerr WWiirriinngg IInnssttaallllaattiioonn .. .. .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... ..5555

Remote Temperature Sensor - D4 Heater Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4

TK 55676-19-IM-EN

TTaabbllee ooff CCoonntteennttss

AA//CC WWiirriinngg IInnssttaallllaattiioonn ...... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... 5577

SSttaannddbbyy TTrruucckk IInntteeggrraattiioonn HHaarrnneessss wwiitthh SSwwiittcchh ((OOppttiioonn))...... .... .... .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... ..5599

SSttaannddbbyy TTrruucckk IInntteeggrraattiioonn HHaarrnneessss wwiitthhoouutt SSwwiittcchh ((OOppttiioonn)) .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... ..6611

FFuueell PPiicckkuupp TTuubbee IInnssttaallllaattiioonn .... .. .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... ..6633

Preferred Installation – Optional Adapter Plate (10–379) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Alternative Installation – Drilling Hole In Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

HHeeaatteerr FFuueell PPuummpp aanndd FFuueell LLiinnee IInnssttaallllaattiioonn.. .. .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... 6677

L-Bracket Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fuel Tank Bracket Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Fuel Line Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

AAPPUU FFuueell LLiinnee IInnssttaallllaattiioonn .. .. .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... 6699

TTrraaccttoorr CCoooollaanntt HHoossee IInnssttaallllaattiioonn .. .. .. .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... 7700

Preferred Installation – APU Coolant Hoses Tee’d Directly Into Tractor’s Heater Hoses . . . . . . . . . . . . . . . 70

Coolant Hose Routing and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Alternative Installation – APU Coolant Hoses Attached Directly To Fittings On Tractor’s Engine. . . . . . . 72

Coolant Hose Routing and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

AArrccttiicc SSwwiittcchh ((OOppttiioonn)) .... ...... .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... 7744

Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

HHeeaatteerr FFuueell PPuummpp CCoonnnneeccttiioonnss .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... 7766

FFuussee HHoollddeerr aanndd AAPPUU BBaatttteerryy CCoonnnneeccttiioonnss .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... 7777

PPrriimmiinngg tthhee HHeeaatteerr FFuueell PPuummpp ((HHeeaatt OOppttiioonn)) .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... 7799

HHeeaatteerr SSttaarrtt--UUpp PPrroocceedduurreess .... .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... .... .... .. .... .... .... .... .... .... .... .... .... ..8800

Diagnostic Tool Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

CCoonnnneeccttiinngg DDiiaaggnnoossttiicc TTooooll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Perform the Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

AA//CC SSyysstteemm CChhaarrggiinngg aanndd AAPPUU EEnnggiinnee SSttaarrtt--uupp PPrroocceedduurreess...... .... .... .. .... .... .... .... .... .... .... .... .... .... .. .... .... 8855

Adding Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

APU Engine Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Bleeding the Coolant System – APU’s Equipped with Traditional Tractor Coolant Integration . . . . . . . . . 86

Bleeding the Coolant System – APU’s Equipped with Closed Loop Cooling Option . . . . . . . . . . . . . . . . . . 86

BBlleeeeddiinngg tthhee FFuueell LLiinneess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

TK 55676-19-IM-EN

5

TTaabbllee ooff CCoonntteennttss

Verifying Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Unit Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Service Run-In Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

System Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6

TK 55676-19-IM-EN

Safety Precautions

Danger, Warning, Caution, and Notice

Thermo King recommends that all service be performed by a Thermo King dealer and to be aware of several general
safety practices.

Safety advisories appear throughout this manual as required. Your personal safety and the proper installation of this
unit depend 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 HHaazzaarrdd!!

WWhheenn aa TTrriiPPaacc EEvvoolluuttiioonn AAPPUU iiss iinnssttaalllleedd uunnddeerr tthhee ccaabb,, bbeehhiinndd ttrruucckk ffaaiirriinnggss,, sskkiirrttiinngg,, eettcc..,, tthhee ddiieesseell eexxhhaauusstt
oouuttlleett mmuusstt bbee rroouutteedd oouutt ttoo aann ooppeenn aarreeaa ttoo pprreevveenntt eexxhhaauusstt ffuummeess ffrroomm eenntteerriinngg tthhee ppaasssseennggeerr ccoommppaarrttmmeenntt
wwhhiicchh ccoouulldd rreessuulltt iinn ccaarrbboonn mmoonnooxxiiddee ppooiissoonniinngg oorr ddeeaatthh bbyy aasspphhyyxxiiaattiioonn..

DDAANNGGEERR

HHaazzaarrdd ooff EExxpplloossiioonn!!

NNeevveerr aappppllyy hheeaatt ttoo aa sseeaalleedd rreeffrriiggeerraattiioonn ssyysstteemm oorr ccoonnttaaiinneerr.. HHeeaatt iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh mmiigghhtt
ccaauussee aann eexxpplloossiioonn rreessuullttiinngg iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

DDAANNGGEERR

HHaazzaarrddoouuss GGaasseess!!

RReeffrriiggeerraanntt iinn tthhee pprreesseennccee ooff aann ooppeenn ffllaammee,, ssppaarrkk,, oorr eelleeccttrriiccaall sshhoorrtt pprroodduucceess ttooxxiicc ggaasseess tthhaatt aarree sseevveerree
rreessppiirraattoorryy iirrrriittaannttss wwhhiicchh ccaann ccaauussee sseerriioouuss iinnjjuurryy oorr ppoossssiibbllee ddeeaatthh..

DDAANNGGEERR

RReeffrriiggeerraanntt VVaappoorr HHaazzaarrdd!!

DDoo nnoott iinnhhaallee rreeffrriiggeerraanntt.. UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg wwiitthh rreeffrriiggeerraanntt oorr aa rreeffrriiggeerraattiioonn ssyysstteemm iinn aannyy ccoonnffiinneedd
aarreeaa wwiitthh aa lliimmiitteedd aaiirr ssuuppppllyy.. RReeffrriiggeerraanntt ddiissppllaacceess aaiirr aanndd ccaann ccaauussee ooxxyyggeenn ddeepplleettiioonn,, rreessuullttiinngg iinn
ssuuffffooccaattiioonn aanndd ppoossssiibbllee ddeeaatthh..

DDAANNGGEERR

RRiisskk ooff IInnjjuurryy!!

KKeeeepp yyoouurr hhaannddss,, ccllootthhiinngg,, aanndd ttoooollss cclleeaarr ooff ffaannss aanndd//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 ddeeaatthh..

TK 55676-19-IM-EN

7

SSaaffeettyy PPrreeccaauuttiioonnss

WWAARRNNIINNGG

HHaazzaarrdd ooff EExxpplloossiioonn!!

NNeevveerr cclloossee tthhee ccoommpprreessssoorr ddiisscchhaarrggee sseerrvviiccee vvaallvvee wwhheenn tthhee uunniitt iiss ooppeerraattiinngg.. NNeevveerr ooppeerraattee tthhee uunniitt wwiitthh
tthhee ddiisscchhaarrggee vvaallvvee cclloosseedd ((ffrroonntt sseeaatteedd)).. TThhiiss ccoonnddiittiioonn iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh ccaann ccaauussee aann
eexxpplloossiioonn..

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess wwhheenn wwoorrkkiinngg oonn aa uunniitt.. RReeffrriiggeerraanntt lliiqquuiidd,, ooiill,, aanndd bbaatttteerryy aacciidd ccaann
ppeerrmmaanneennttllyy ddaammaaggee yyoouurr eeyyeess.. SSeeee ““FFiirrsstt AAiidd””..

WWAARRNNIINNGG

EEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!

NNeevveerr ddrriillll hhoolleess iinnttoo tthhee uunniitt uunnlleessss iinnssttrruucctteedd bbyy TThheerrmmoo KKiinngg.. HHoolleess ddrriilllleedd iinnttoo hhiigghh vvoollttaaggee ccaabblleess ccoouulldd
ccaauussee aann eelleeccttrriiccaall ffiirree,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr eevveenn ddeeaatthh..

WWAARRNNIINNGG

RRiisskk ooff IInnjjuurryy!!

WWhheenn uussiinngg llaaddddeerrss ttoo iinnssttaallll oorr sseerrvviiccee rreeffrriiggeerraattiioonn ssyysstteemmss,, aallwwaayyss oobbsseerrvvee tthhee llaaddddeerr mmaannuuffaaccttuurreerr’’ss
ssaaffeettyy llaabbeellss aanndd wwaarrnniinnggss.. AA wwoorrkk ppllaattffoorrmm oorr ssccaaffffoollddiinngg iiss tthhee rreeccoommmmeennddeedd mmeetthhoodd ffoorr iinnssttaallllaattiioonnss aanndd
sseerrvviicciinngg..

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

AAllll mmoouunnttiinngg bboollttss mmuusstt bbee tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aapppplliiccaattiioonnss aanndd ttoorrqquueedd ttoo ssppeecciiffiiccaattiioonn.. IInnccoorrrreecctt bboolltt
lleennggtthhss aanndd iimmpprrooppeerr ttoorrqquuee ssppeecciiffiiccaattiioonnss ccaann ddaammaaggee eeqquuiippmmeenntt..

Battery Cable Installation and Routing

WWAARRNNIINNGG

HHaazzaarrdd ooff EExxpplloossiioonn!!

IImmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccaabblleess ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. BBaatttteerryy ccaabblleess mmuusstt bbee iinnssttaalllleedd,,
rroouutteedd,, aanndd sseeccuurreedd pprrooppeerrllyy ttoo pprreevveenntt tthheemm ffrroomm rruubbbbiinngg,, cchhaaffffiinngg,, oorr mmaakkiinngg ccoonnttaacctt wwiitthh hhoott,, sshhaarrpp,, oorr
rroottaattiinngg ccoommppoonneennttss..

WWAARRNNIINNGG

FFiirree HHaazzaarrdd!!

DDoo nnoott aattttaacchh ffuueell lliinneess ttoo bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo ccaauussee aa ffiirree aanndd
ccoouulldd ccaauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..

WWAARRNNIINNGG

HHaazzaarrdd ooff EExxpplloossiioonn!!

AAllwwaayyss ccoovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroomm mmaakkiinngg ccoonnttaacctt wwiitthh mmeettaall ccoommppoonneennttss dduurriinngg bbaatttteerryy
iinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall ccoouulldd ccaauussee tthhee bbaatttteerryy ttoo eexxppllooddee..

CCAAUUTTIIOONN

HHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!

SSeett aallll uunniitt eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbeeffoorree ccoonnnneeccttiinngg bbaatttteerryy ccaabblleess ttoo tthhee bbaatttteerryy ttoo pprreevveenntt
uunniitt ffrroomm ssttaarrttiinngg uunneexxppeecctteeddllyy aanndd ccaauussiinngg ppeerrssoonnaall iinnjjuurryy..

8

TK 55676-19-IM-EN

SSaaffeettyy PPrreeccaauuttiioonnss

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

DDoo nnoott ccoonnnneecctt ootthheerr mmaannuuffaaccttuurreerr’’ss eeqquuiippmmeenntt oorr aacccceessssoorriieess ttoo tthhee uunniitt uunnlleessss aapppprroovveedd bbyy TThheerrmmoo KKiinngg..
FFaaiilluurree ttoo ddoo ssoo ccaann rreessuulltt iinn sseevveerree ddaammaaggee ttoo eeqquuiippmmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..

Refrigerant Hazards

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

RReeffrriiggeerraanntt iinn aa lliiqquuiidd ssttaattee eevvaappoorraatteess rraappiiddllyy wwhheenn eexxppoosseedd ttoo tthhee aattmmoosspphheerree,, ffrreeeezziinngg aannyytthhiinngg iitt ccoonnttaaccttss..
WWeeaarr bbuuttyyll lliinneedd gglloovveess aanndd ootthheerr ccllootthhiinngg aanndd eeyyee wweeaarr wwhheenn hhaannddlliinngg rreeffrriiggeerraanntt ttoo hheellpp pprreevveenntt ffrroossttbbiittee..

Refrigerant Oil Hazards

WWAARRNNIINNGG

PPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!

PPrrootteecctt yyoouurr eeyyeess ffrroomm ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TThhee ooiill ccaann ccaauussee sseerriioouuss eeyyee iinnjjuurriieess.. PPrrootteecctt sskkiinn aanndd
ccllootthhiinngg ffrroomm pprroolloonnggeedd oorr rreeppeeaatteedd ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TToo pprreevveenntt iirrrriittaattiioonn,, wwaasshh yyoouurr hhaannddss aanndd
ccllootthhiinngg tthhoorroouugghhllyy aafftteerr hhaannddlliinngg tthhee ooiill.. RRuubbbbeerr gglloovveess aarree rreeccoommmmeennddeedd..

First Aid

RREEFFRRIIGGEERRAANNTT

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

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

• IInnhhaallaattiioonn:: Move victim to fresh air and use CPR (cardio 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 Aid are to protect the frozen area from further injury,
warm the affected area rapidly, and to maintain respiration.

RREEFFRRIIGGEERRAANNTT OOIILL

• EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.

• SSkkiinn:: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation
persists.

• IInnhhaallaattiioonn:: Move victim to fresh air and use CPR (cardio pulmonary resuscitation) or mouth-to-mouth resuscitation
to restore breathing, if necessary. Stay with victim until emergency personnel arrive.

• IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local poison control center or physician.

EENNGGIINNEE CCOOOOLLAANNTT

• EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.

• SSkkiinn:: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation
persists.

• IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local poison control center or physician.

EELLEECCTTRRIICCAALL SSHHOOCCKK

Take IMMEDIATE action after a person has received an electrical shock. Get quick medical assistance, if possible.

The source of the shock must be quickly stopped, by either shutting off the power or removing the victim. If the power
cannot be shut off, the wire should be cut with an non-conductive tool, such as a wood-handle axe or thickly insulated

TK 55676-19-IM-EN

9

SSaaffeettyy PPrreeccaauuttiioonnss

cable cutters. Rescuers should wear insulated gloves and safety glasses, and avoid looking at wires being cut. The
ensuing flash can cause burns and blindness.

If the victim must be removed from a live circuit, pull the victim away with a non-conductive material. Use wood, 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 body. After separating the victim from power source, immediately check for signs
of a pulse and respiration. If no pulse is present, start CPR (cardio pulmonary resuscitation). If a pulse is present,
respiration might be restored by using mouth-to-mouth resuscitation. Call for emergency medical assistance.

Heater Safety Precautions

IImmppoorrttaanntt:: Correct installation of this heater is necessary to ensure safe and proper operation. BBEEFFOORREE installing the

heater, thoroughly read and understand this manual and the heater manufacturer’s manuals included with
the heater.

DDAANNGGEERR

HHaazzaarrdd ooff EExxpplloossiioonn oorr FFiirree!!

FFaaiilluurree ttoo ffoollllooww tthheessee iinnssttrruuccttiioonn ccoouulldd 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 HHaazzaarrdd!!

TThhee ccoorrrreecctt iinnssttaallllaattiioonn ooff tthhee eexxhhaauusstt aanndd
ccoommbbuussttiioonn aaiirr iinnttaakkee hhoosseess iiss eexxttrreemmeellyy iimmppoorrttaanntt
ttoo pprreevveenntt ccaarrbboonn mmoonnooxxiiddee 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.

NNOOTTIICCEE

EEqquuiippmmeenntt DDaammaaggee!!

DDiissccoonnnneecctt tthhee hheeaatteerr hhaarrnneessss aatt tthhee bbaatttteerryy bbeeffoorree wweellddiinngg oonn tthhee ttrruucckk cchhaassssiiss ttoo pprreevveenntt ddaammaaggee ttoo tthhee
eelleeccttrroonniicc HHMMII ccoonnttrroolllleerr..

10

TK 55676-19-IM-EN

Tips For a Successful Installation

Before 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.

• Read this manual to understand where components are to be located and how they are to be installed.

• Thermo King offers numerous options such as Diesel Particulate Filter (DPF), Power Inverters, Hourmeters, etc.
which have separate installation instructions. These options should be installed simultaneously with the APU when
possible to help reduce overall installation time.

• Review the TriPac component drawings for important minimum/maximum dimensions and clearances that must be
taken into consideration when installing these components.

• Open all TriPac kits and inspect contents before beginning installation.

• Verify tools and special equipment required for the installation are available and in good working condition.

• Review component location diagram and discuss with the customer where each component will be installed on the
truck.

• It is recommended that one person performs the installation of all the components oouuttssiiddee the sleeper while a
second person installs all the components iinnssiiddee the sleeper. This will help minimize any damage to the sleeper’s
interior from grease, dirt, etc.

APU Installation

• DO NOT weld on any part of the tractor’s frame or drill holes in the top or bottom flanges. Serious structural
damage could occur. Consult your chassis manufacturer for further information.

• The APU is designed to be mounted 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 around APU before installing.

• The use of a motorcycle/ATV lift or modified floor jack to raise APU into position is recommended.

• Only the supplied spacer blocks and mounting claws must be used to install the APU to the chassis frame rail.

• If different mounting bolts are used they must be Grade 5 and of the correct length. DO NOT cut off excessive length
bolts.

• Verify the upper and lower APU mounting bolts are flush with the chassis frame rail before tightening.

• The mounting hardware securing the APU to the tractor’s frame must be correctly positioned and torqued using the
four-step tightening sequence described in the “APU Installation” section in this manual.

• All APU covers, guards or removable panels must be in place and installed securely while operating the system.

A/C Condenser Installation

• Always keep A/C system fittings capped and sealed until the installation of the refrigeration hoses.

• Determine the best location to mount the condenser onto the exterior of the sleeper.

• Verify all measurements before drilling any mounting holes.

• Verify there is no interference with any OEM electrical wiring, internal supports, etc. before drilling mounting holes.

• Confirm the condenser location does not interfere with the service or operation of existing tractor components.

• Provide protection to the tractor’s finish to prevent damage during the installation process.

• Use the stainless steel mounting hardware (supplied in the kit) to mount the condenser coil.

• Use the large fender washers (supplied in kit) inside the sleeper to provide additional support.

• All mounting holes must be sealed with silicone caulking to prevent moisture or fumes from entering the sleeper.

TK 55676-19-IM-EN

11

TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn

A/C Evaporator Installation

• Always keep A/C system fittings capped and sealed until the installation of the refrigeration hoses.

• Determine the best location for the A/C evaporator inside the sleeper, typically under the bunk.

• Verify there is no interference with any OEM electrical wiring, internal supports, etc. before drilling any mounting
holes.

• The evaporator should be mounted directly onto the floor mat inside the sleeper by using the supplied template to
locate the drain and mounting holes.

• Always install the drain valves (kazoos) onto evaporator drain tubes securely with hose clamps.

• The A/C vents should be located and installed to provide 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 sealed with silicone caulk to prevent moisture or exhaust fumes from entering the
sleeper.

• All edges of access holes made in fiberglass and wood composite floors must be sealed correctly with fiberglass
cloth and resin.

D2/D4 Heater Installation

• Determine the best location of the heater inside the sleeper, typically under the bunk. Allow clearance for
dismantling for service.

• Install heater so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or flammable
material.

• Heater must be mounted on a flat horizontal surface.

• 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.

• All edges of access holes made in fiberglass and wood composite floors must be sealed correctly with fiberglass
cloth and resin.

• Outside air intake and exhaust hoses must be installed correctly for the heater to operate safely.

• Exhaust hose should be mounted slightly downwards to help drain off condensation.

• Install exhaust hose so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or
flammable material.

• Inside air inlet and outlet ducts must be installed correctly for the heater to operate safely.

• Pulse fuel pump must be installed at a 15 to 35 degree angle from horizontal to operate correctly.

• Fuel pickup tube must be installed correctly in the fuel tank or the heater will not operate.

• Fuel line from the pickup tube to the fuel pump to the heater should be routed 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
closed.

• Do not route electrical wires, harness or battery cables together with fuel lines.

• BEFORE operating the heater, the fuel lines must be bled of air using the Heater Priming Harness (204-1144) or
damage to the fuel pump will result.

• The Diagnostic Code Reader (204-1143) must be used to setup and operate the heater in the run-in mode.

A/C Hose Connections and Routing

• Always keep A/C system fittings capped and sealed 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 and lubricate O-rings with PAG 100 refrigerant oil (2030502) when connecting refrigeration hose
fittings to component connection fittings.

12

TK 55676-19-IM-EN

TTiippss FFoorr aa SSuucccceessssffuull IInnssttaallllaattiioonn

• Refrigeration hoses should be installed onto components in such a way as to allow for vibration and movement of
the cab. THEY SHOULD NEVER BE STRETCHED TIGHT!

• All refrigeration connections should be tightened 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 supplied) for the refrigeration hoses may be required depending on the
installation.

• Always install the condenser’s receiver drier in the direction indicated by the arrow.

• Thermo King Evacuation Station (204-725) and Evacuation Station Operation and Field Application Instructions (TK-

40612) are recommended.

• The oil in the evacuation station vacuum pump should be changed after each use.

• The A/C system must be leak free. Check for leaks by using an electronic leak detector.

• The A/C system will be charged with 1.2 to 2.0 bs. (depending on hose lengths) of R134a.

Engine Coolant Hose Connections and Routing

The following steps are for APU’s equipped with Tractor Coolant Integration only.

• Coolant hoses should be routed from the APU to the tractor’s engine without any sharp bends or kinks.

• Coolant hoses should be installed and routed in such a way as to allow for vibration and movement. THEY SHOULD
NEVER BE STRETCHED TIGHT!

• Coolant hoses should be protected with supplied plastic sleeving and adequately secured to the chassis with clamps
and band wraps.

• Always keep coolant hoses from rubbing or chafing against sharp metal objects, rotating components or hot
objects.

• All coolant pipe fittings installed should be of proper material type, (i.e: brass to brass, or copper to copper).

• All coolant fittings should be assembled using pipe thread sealer to prevent leaks.

• Ball type shutoff valves (supplied) should be installed to allow the TriPac cooling system to be closed off and
isolated from the tractor’s engine cooling system.

• Shutoff valves and fittings must be adequately supported to prevent cracks or leaks from vibration.

Closed Loop Cooling

Do not start the APU’s engine without first adding coolant and bleeding all air from the system.

Electrical Wiring and HMI Controller Installation

• Electrical wiring should be installed and routed in such a way as to allow for vibration and 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 should be neatly routed and secured with band wraps or clamps.

• Do not route electrical wires, harness or battery cables together with fuel lines.

• Excess length of battery cables should be cut off to reduce voltage drop.

• Superlube (203-524) or equivalent should be applied to all electrical connections.

• All main power and ground accessory connections must be installed directly on top of the tractor’s battery terminal
posts and tightened securely. DO NOT INSTALL UNDER OEM BATTERY CABLES!

• The HMI should be visible and mounted away from windows, air vents, out of direct sunlight and not touching
anything to accurately measure air temperature.

TK 55676-19-IM-EN

13

TriPac Evolution Component Dimensions

APU

Figure 1. TriPac Evolution APU Dimensions (side and front)

14

TK 55676-19-IM-EN

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Figure 2. TriPac Evolution APU Dimensions (side and rear)

TK 55676-19-IM-EN

15

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Condenser

Figure 3. TriPac Evolution Condenser Dimensions

16

TK 55676-19-IM-EN

Evaporator

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Figure 4. TriPac Evolution Evaporator Dimensions

TK 55676-19-IM-EN

17

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Control Box

Figure 5. TriPac Evolution Control Box Dimensions

18

TK 55676-19-IM-EN

HMI

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.)

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Figure 6. TriPac Evolution HMI Controller Dimensions

TK 55676-19-IM-EN

19

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Standard Heater

Figure 7. Standard Heater Dimensions

20

TK 55676-19-IM-EN

High Output Heater

TTrriiPPaacc EEvvoolluuttiioonn CCoommppoonneenntt DDiimmeennssiioonnss

Figure 8. High Output Heater Dimensions

TK 55676-19-IM-EN

21

Required Tools and Additional Supplies

NNoottee:: While basic mechanics tools and refrigerant service equipment are a necessity, there are also special tools that

are required when installing Thermo King TriPac Units. For a complete listing of special tools, See “Special Tool
Requirements” Section 3 of the Thermo King TriPac Installation Standards Guide (TK 56498).

TOOLS SUPPLIES (as required)

1. Typical Mechanics Tools

2. Floor Jack or Motorcycle/ATV Lift

3. Drill Motor

4. Drill Bit Set

5. 7/8” dia. or 1” Step Reamer (for evaporator drain and controller
holes)

6. Hole Saws

• 1-1/4” dia. (for fuel tank pickup tube)

• 2-1/2” dia. (for heater outlet louver)

• 3” dia. (access hole for evaporator hoses and electrical

wiring)

• 4-1/4” dia. (mounting A/C louvers, routing A/C ducts through

bulkheads and heater mounting hole)

7. 7. Reciprocating Saw (return air opening)

8. 1/2” Drive Torque Wrench

9. Level

10. Tape Measure

11. Utility Knife

12. Caulk Gun

13. Tubing Cutter (for cutting fuel pickup tubes)

14. Strobe Light/Tachometer (204-436)

15. Digital Meter (204-615)

16. Leak Detector (204-756)

17. Hose Fitting Tool (204-1045)

18. Hose Cutting Tool (204-677)

19. Heater Priming Harness (204-1144)

20. Heater Diagnostic Tool (204-1143)

21. Shop Vacuum

1. 1/2” Brass Fittings (for coolant lines)

• 45 degree elbow, MPT x FPT

• 90 degree elbow, MPT x FPT

• Tee, FPT x FPT x FPT

• Hose Fitting, 1/2” NPT to 3/4” Hose

• Closed Nipple, 1/2” NPT

2. Teflon Pipe Thread Tape (for coolant fittings)

3. Antifreeze, up to 2 gallons (must be the correct type to match
original)

4. RTV Silicone

5. Sealing Putty (203-391)

6. PAG Refrigerant Oil (203-544)

7. Refrigerant 134A.

8. Return air wall louver aprox. 6” x 10” (when needed)

9. Shrink Tubing 0.51” to 0.16” w/adhesive (for battery cable
terminals)

10. Mounting Clamps #24 and #32 (to secure cables and hoses)

11. Band wraps (assorted sizes and lengths)

12. Upholstery Cleaner (aprox. 2 cans)

13. Cardboard or blankets (to protect interior)

14. Fiberglass Repair Kit (only used for fiberglass and wood
composite floors)

22

TK 55676-19-IM-EN

Typical Component Locations

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.

Figure 9. Typical TriPac Evolution System Component Locations

TK 55676-19-IM-EN

23

TTyyppiiccaall CCoommppoonneenntt LLooccaattiioonnss

TriPac Evolution Components with Truck Coolant Integration

Figure 10. TriPac Evolution Components with Truck Coolant Integration

1 APU (Auxiliary Power Unit) 8 Heater Exhaust Tube

2 A/C Condenser 9 Heater Intake Tube

3 A/C Receiver Drier 10 Heater Fuel Pump

4 A/C Evaporator 11 Diesel Fuel Pickup Tube

5 Control Box 12 Main Power Fuse (connects to truck’s batteries)

6 HMI Controller 13 Coolant Supply and Return Hoses (connects to truck’s engine)

7 Heater 14 Truck’s Heater Core (connects to truck’s engine)

24

TK 55676-19-IM-EN

TTyyppiiccaall CCoommppoonneenntt LLooccaattiioonnss

TriPac Evolution Components with Optional Closed Loop Cooling

Figure 11. TriPac Evolution Components with Optional Closed Loop Cooling

1 APU (Auxiliary Power Unit) 8 Heater Exhaust Tube

2 A/C Condenser 9 Heater Intake Tube

3 A/C Receiver Drier 10 Heater Fuel Pump

4 A/C Evaporator 11 Diesel Fuel Pickup Tube

5 Control Box 12 Main Power Fuse (connects to truck’s batteries)

6 HMI Controller 13 Coolant Expansion Tank

7 Heater

TK 55676-19-IM-EN

25

APU Installation

Standard Installation Method – Mounting Claws

IImmppoorrttaanntt:: See “TriPac Evolution Installation Standards” in Section 5 of the Thermo King TriPac Installation Standards

Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

Special Tools Required

Modified Floor Jack or Motorcycle/ATV Lift

1/2” Drive Torque Wrench

1. Remove top cover of TriPac APU to access and remove mounting hardware securing APU to shipping crate.

2. It is recommended that a modified floor jack or motorcycle/ATV lift be used to install the APU. Protection such as
cardboard, shop rags, etc. should be used under the APU to prevent damage during installation.

3. Raise the APU into position. From outside the APU, insert the 3/4 in. mounting bolts and washers through mounting
claws and spacer blocks (slots go down) and into APU’s frame mounting holes.

4. From inside the APU, loosely install washers, nut retainers and locking nuts in that order. DDOO NNOOTT OOIILL TTHHEE BBOOLLTT
TTHHRREEAADDSS!!

IImmppoorrttaanntt:: The following steps are critical and must be followed to ensure the safe installation of the APU to the

tractor’s frame.

5. With APU still supported by a lift:

a. Push APU and spacer blocks up tight to tractor frame.

b. Adjust height of the APU so top and bottom mounting claws and bolts are positioned flat on frame. Review

(Detail A).

c. Lightly tighten mounting hardware only enough to remove excess play.

6. Using a torque wrench, torque mounting bolts in four step increments starting with top bolts, then bottom bolts.
STEP 1: Torque top then bottom mounting bolts to 25 ft-lb. (33.9 N•m).

IImmppoorrttaanntt:: STOP and verify all mounting claws and bolts remained flat on frame (Detail A). If they are not, loosen

bolts, adjust as necessary and retighten again to 25 ft-lb. (33.9 N•m).

STEP 2: After first step is successfully completed, torque top then bottom bolts to 50 ft-lb. (67.8 N•m).

STEP 3: Next, torque top and then bottom bolts to 100 ft-lb. (135.6 N•m).

STEP 4: Finally, recheck all bolts to confirm they are at 100 ft-lb. (135.6 N•m)

IImmppoorrttaanntt:: DDOO NNOOTT OOVVEERR--TTOORRQQUUEE MMOOUUNNTTIINNGG BBOOLLTTSS!!

7. Remove the support lift and visually inspect installation for the following:

• Mounting claws and bolts are ccoorrrreeccttllyy installed. They should be square and flat on the frame ((DDeettaaiill AA)).

• If any mounting claws and bolts are iimmpprrooppeerrllyy installed on the frame (i/e. they resemble Details B & C) - adjust

as necessary.

• Damaged, deformed or cracked components during installation - mmuusstt bbee rreeppllaacceedd iimmmmeeddiiaatteellyy.

26

TK 55676-19-IM-EN

Figure 12. Standard Installation Method with Mounting Claws Shown

Detail C

INCORRECT

Detail B

INCORRECT

Detail A

Correct

56

ABA705-2

2

8

1

3

4

AAPPUU IInnssttaallllaattiioonn

TK 55676-19-IM-EN

27

Exhaust Pipe Installation

IImmppoorrttaanntt:: See “APU Exhaust Tailpipe Installation Standards” in Section 5 of the Thermo King TriPac Installation

Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

IImmppoorrttaanntt:: When the APU is installed under a sleeper, behind fairings, skirting, etc., the exhaust outlet must be routed

to an open area to prevent exhaust fumes from entering the passenger compartment which could result in
carbon monoxide poisoning or death by asphyxiation. Optional exhaust pipe extensions are available for
this purpose. Contact your nearest Thermo King Dealer.

Standard Short Exhaust Tailpipe

A short exhaust tailpipe is provided standard with each APU.

1. Install the short exhaust tailpipe (outlet facing down) onto the end of the muffler and secure with clamp.

Optional Exhaust Extension

The optional exhaust extension is used along with the standard short tailpipe.

1. Install the mounting bracket onto the side of the APU.

2. Install the extension pipe and clamp onto the end of the muffler.

3. Install the short exhaust tailpipe (supplied with APU) and clamp.

4. Face the tailpipe outlet down or towards the rear of the tractor.

5. Tighten all clamps securely.

Figure 13. Standard Short Exhaust Tailpipe and Optional Exhaust Extension Shown

28

TK 55676-19-IM-EN

A/C Condenser Installation

IImmppoorrttaanntt:: See “Condenser Installation Standards“ in Section 5 of the Thermo King TriPac Installation Standards

Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

Locate an area on the exterior of the sleeper to install the condenser that does not interfere with the operation of
existing truck components. If possible mount the condenser below the bunk level. This allows easier access to four 3/8”
bolts with large fender washers inside without disturbing interior panels.

IImmppoorrttaanntt:: Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid

drilling into the truck’s interior support members as this could void the tractor’s OEM warranty.

Special Tools Required

Tape Measure

Level

Drill Motor

3/8” Drill Bit

Caulk Gun and RTV Silicone Sealant

The condenser housing and coil assembly can be also installed with the hose fittings facing towards the roadside
((DDEETTAAIILL AA)) if needed. When doing so, the actual condenser coil must be removed from the housing and rotated so the
#8 fitting is on top by:

a. Rotating the complete condenser housing and coil assembly so the hose fittings are facing towards the

roadside.

b. Removing the condenser coil from the housing, and rotating it so the #8 fitting is positioned at the top, then

install it back into the condenser housing and tighten the hardware securely.

1. Measure and mark the exterior center line of the sleeper.

2. Center and level the condenser onto the sleeper with the #8 fitting located on top. Mark the mounting holes;
typically one in each corner. Drill four 3/8” mounting holes.

3. Apply a bead of RTV silicone along the entire condenser mounting flanges and around each of the four mounting
holes.

4. Install the condenser with 3/8” stainless mounting bolts and large fender washers from the inside, and 3/8” washers
and locking nuts on the outside. Tighten hardware securely.

TK 55676-19-IM-EN

29

AA//CC CCoonnddeennsseerr IInnssttaallllaattiioonn

Figure 14. Typical Condenser Installation Shown

30

TK 55676-19-IM-EN

A/C Receiver Drier Installation

IImmppoorrttaanntt:: See “Receiver Drier Installation Standards” in Section 5 of the Thermo King TriPac Installation Standards

Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

Special Tools Required

Drill Motor

3/8” Drill Bit

Level

NNoottee:: It is recommended to mount the receiver drier directly onto the sleeper to reduce hose flexing.

Locate an area on the exterior of the tractor to install the receiver drier.

Typical Mounting Locations:

a. Side-by-side Mount ((DDEETTAAIILL AA))

b. Mid-height Mount ((DDEETTAAIILL BB)).

c. High Mount ((DDEETTAAIILL CC)).

1. Position and level the receiver drier bracket and mark each of the two mounting holes. Drill two 3/8” holes.

2. Attach two large hose clamps to the bracket with 3/8” stainless mounting bolts, washers and locking nuts (installer
supplied) and tighten securely.

3. With the switch facing out, install the receiver drier onto the bracket and tighten the hose clamps securely.

Figure 15. Receiver Drier Installation Shown

TK 55676-19-IM-EN

31

Ambient Temperature Sensor Installation (Option)

ABA592-1

6-Pin (J2) Connector

Sensor Harness

Detail B

Detail A

Ambient Sensor

NNoottee:: The ambient temperature sensor is included in 120 Amp Alternator Option 073023

1. Locate ambient temperature sensor harness supplied with unit

2. Sensor should be mounted at highest point on either the receiver drier bracket or the condenser fan housing.

• DDEETTAAIILL AA - sensor can be mounted on either the receiver drier bracket or on the condenser fan housing as both

are at equal height.

• DDEETTAAIILL BB - sensor should be mounted to the condenser fan housing as it is higher than the receiver drier.

3. Attach sensor with the provided clamp and mounting hardware as shown.

4. Route sensor harness up inside the sleeper through existing access hole.

NNoottee:: Sensor harness should be secured with cable ties to the other harnesses already installed and routed into

sleeper.

5. Route the sensor harness to the control box:

a. Unplug 6-pin connector ((JJ22)) from controller.

b. Insert wire ((AATTSS)) securely into connector ((JJ22)) pinout #4.

c. Insert wire ((AATTSS__RRTTNN)) securely into connector ((JJ22)) pinout #5.

d. Reconnect 6-pin connector ((JJ22)) securely into controller.

e. Secure all wires with cable ties.

6. Go to TTKK MMoonniittoorr and select AAlltteerrnnaattoorr CCaappaacciittyy -- 112200 AAmmppss.

SSeeee UUnniitt SSeettuupp PPrroocceedduurreess aatt bbaacckk ooff mmaannuuaall..

Figure 16. Ambient Temperature Sensor Installation Shown

32

TK 55676-19-IM-EN

A/C Evaporator Installation

Preferred Location – Flush with Front Bulkhead

IImmppoorrttaanntt:: See “Evaporator Installation Standards” in Section 5 of the Thermo King TriPac Installation Standards

Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

A template is supplied to represent the amount of area needed to accommodate the evaporator. It also provides
locations for the two 7/8” drain holes and the 3” access hole.

IIMMPPOORRTTAANNTT AACCCCEESSSS HHOOLLEE IINNFFOORRMMAATTIIOONN::

• The location of the 3” access hole will be determined by your particular sleeper construction, including OEM
internal floor supports, electrical wiring, etc. It should be located directly behind the evaporator’s A/C fittings to
allow the refrigerant hoses with 90 degree fittings to be attached and routed down through the floor easily.

• Floors made from fiberglass covered wood construction require the edges of the 3” access hole be completely
sealed with fiberglass and epoxy resin.

• Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid drilling into
the truck’s support members.

Special Tools Required

Drill Motor

1/4” Drill Bit

7/8” Step Reamer

3” dia. Hole Saw

Reciprocating Saw

Caulk Gun and RTV Silicone Sealant

Sealing Putty (203-391)

Fiberglass Cloth and Resin Kit (if required)

1. Position the template flush with the bulkhead, mark the location of the 7/8” evaporator drain holes and the 3” access
hole. Remove the template.

a. Drill 1/4” pilot hole for the drain holes followed by a 7/8” step reamer.

b. Drill 3” access hole.

2. Cut and install a piece of split loom (or similar) around the inside edge of the 3” access hole to provide protection
for the hoses and wiring.

3. Reposition the evaporator mounting brackets attached to sides of the evaporator.

4. Set the evaporator in place and determine where the return air opening needs to be located on the bulkhead.

5. Mark the return air opening (minimum opening size 14'' x 7''). Remove the evaporator and cut the opening. Install
the evaporator to the floor with TEK screws.

6. Install a return air grille (installer supplied).

7. From underneath the sleeper:

a. Attach the two water valves (kazoos) onto the evaporator drain tubes and secure with supplied hose clamps

b. Seal around the drain tube access holes with sealing putty or silicone sealant.

c. Apply silicone sealant around the four evaporator mounting screws.

d. Seal any unused holes, cracks, or visible air gaps that might be found.

TK 55676-19-IM-EN

33

T

E

M

P

L

A

T

E

1

2

4

6

7

5

3

ARD332-3

14”x 7” minimum bulkhead

AA//CC EEvvaappoorraattoorr IInnssttaallllaattiioonn

Figure 17. Preferred Location Flush with Bulkhead Shown

34

TK 55676-19-IM-EN

AA//CC EEvvaappoorraattoorr IInnssttaallllaattiioonn

Alternative Location – Centered Under Bunk

IImmppoorrttaanntt:: See “Evaporator Installation Standards” in Section 5 of the Thermo King TriPac Installation Standards

Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

A template is supplied to represent the amount of area needed to accommodate the evaporator. It also provides
locations for the two 7/8” drain holes and the 3” access hole.

IIMMPPOORRTTAANNTT AACCCCEESSSS HHOOLLEE IINNFFOORRMMAATTIIOONN::

• The location of the 3” access hole will be determined by your particular sleeper construction, including OEM
internal floor supports, electrical wiring, etc. It should be located directly behind the evaporator’s A/C fittings to
allow the refrigerant hoses with 90 degree fittings to be attached and routed down through the floor easily.

• Floors made from fiberglass covered wood construction require the edges of the 3” access hole be completely
sealed with fiberglass and epoxy resin.

• Before drilling any holes, check for interference with internal wires, supports or interior panels. Avoid drilling into
the truck’s support members.

Special Tools Required

Drill Motor

1/4” Drill Bit

7/8” Step Reamer

3” dia. Hole Saw

Reciprocating Saw

Caulk Gun and RTV Silicone Sealant

Sealing Putty (203-391)

Fiberglass Cloth and Resin Kit (if required)

1. Position the template flush with the bulkhead, mark the location of the 7/8” evaporator drain holes and the 3” access
hole. Remove the template.

a. Drill 1/4” pilot hole for the drain holes followed by a 7/8” step reamer.

b. Drill 3” access hole.

2. Cut and install a piece of split loom (or similar) around the inside edge of the 3” access hole to provide protection
for the hoses and wiring.

3. Reposition the evaporator mounting brackets attached to the sides of the evaporator.

4. Install the evaporator to the floor with TEK screws.

5. Mark a location for a return air opening (minimum opening size 14'' x 7'') and cut the opening. Install a return air
grille (installer supplied).

6. From underneath the sleeper:

a. Attach the two water valves (kazoos) onto the evaporator drain tubes and secure with supplied hose clamps

b. Seal around the drain tube access holes with sealing putty or silicone sealant.

c. Apply silicone sealant around the four evaporator mounting screws.

d. Seal any unused holes, cracks, or visible air gaps that might be found.

TK 55676-19-IM-EN

35

36

TK 55676-19-IM-EN

Figure 18. Alternative Location Centered Under Bunk Shown

4

2

6

ARD333-2

1

Return

Air Vent

5

T

E

M

P

L

AT

E

3

14” x 7” minimum bulkhead opening

AA//CC EEvvaappoorraattoorr IInnssttaallllaattiioonn

D2/D4 Heater Installation

Heater Location

IImmppoorrttaanntt:: See “Heater Installation Standards“ in Section 7 of the Thermo King TriPac Installation Standards Guide (TK

56498). THESE STANDARDS MUST BE FOLLOWED! Correct installation of this heater is necessary to ensure
safe and proper operation. BEFORE installing the heater, thoroughly read and understand “Heater Safety
Precautions” section in this manual along with the heater manufacturer’s manuals included with the heater.

The location for mounting the heater will vary depending on the type of tractor. Typically the heater is mounted inside
the sleeper, under the bunk in a storage compartment. However, the heater may be mounted anywhere inside the
tractor provided you adhere to the following conditions:

• Install heater so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or flammable
material.

• Combustion air intake, exhaust and fuel inlet must be located outside the tractor.

• Install exhaust hose so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or
flammable material.

• Heater must be mounted on flat horizontal surface providing an air tight seal between heater and tractor.

• All floor matting, carpet, insulation, etc. must be removed to allow the heater to be mounted directly to the bare
floor.

• Heater harness may be repositioned to either side of the heater.

• Floors made of fiberglass covered wood construction require the edges of the access hole be sealed with fiberglass
and epoxy resin.

Drilling Hole In Floor

Special Tools Required

Drill Motor

Utility Knife

Center Punch

4-1/4” dia. Hole Saw

Fiberglass Cloth and Resin Kit (if required)

1. Position the heater’s metal mounting plate onto the floor mat

2. Use a utility knife to cut the floor mat around the outside edges of the plate. Remove floor mat to access the bare
floor.

3. With the mounting plate in position, center punch the four outer holes. Remove the mounting plate and mark an
“X” connecting the four center punched outer holes.

4. Center punch the center of the “X” and drill a 4-1/4” hole with a hole saw.

TK 55676-19-IM-EN

37

DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn

Figure 19. Drilling Hole In Floor Shown

Heater Subassembly and Installation

Turn the heater upside down and attach the following components:

1. Snap the air outlet hood onto the end of the heater.

2. Place the mounting plate onto the heater studs. Mounting hardware will be installed later.

3. Attach the short rubber hose and clamps onto the fuel inlet connection located at the base of the heater.

4. Insert the plastic fuel line all the way into the rubber hose until it bottoms out to prevent air gaps. Tighten both hose
clamps securely.

5. Attach the exhaust hose and metal clamp onto the fitting located under the OUTLET end of the heater. Turn metal
clamp to the center and tighten securely.

6. Insert the plastic air intake tube through the beveled opening of the small plastic mounting plate. Install the plastic
plate and tube onto studs located under the INLET end of the heater.

7. Install lock washers and nuts onto each of the mounting studs and tighten hardware securely

8. Install gasket to mounting plate.

9. The heater has two service data nameplates. Remove one and reinstall it onto the top of the heater so that it is
visible when the heater is installed.

10. Position the heater over the access hole with intake and exhaust hose and fuel line exiting the tractor. Attach the
heater to the floor with TEK screws and tighten securely.

NNoottee:: Tighten TEK screws sufficiently to ensure a positive seal between mounting plate and mounting surface. Do not

over tighten!

38

TK 55676-19-IM-EN

Figure 20. Heater Subassembly Shown

DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn

TK 55676-19-IM-EN

39

DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn

Exhaust and Combustion Air Intake Routing

DDAANNGGEERR

AAsspphhyyxxiiaattiioonn HHaazzaarrdd!!

TThhee ccoorrrreecctt iinnssttaallllaattiioonn ooff tthhee eexxhhaauusstt aanndd ccoommbbuussttiioonn aaiirr iinnttaakkee hhoosseess iiss eexxttrreemmeellyy iimmppoorrttaanntt ttoo pprreevveenntt
ccaarrbboonn mmoonnooxxiiddee ppooiissoonniinngg oorr aasspphhyyxxiiaattiioonn..

EEXXTTRREEMMEE CCAARREE MMUUSSTT BBEE TTAAKKEENN TTOO::

• Route the exhaust outlet hose and combustion air intake tube so they cannot be plugged by dirt, water or snow.

• Ensure the exhaust outlet and air inlet do not face into the tractor’s slip stream to prevent “ram air” effect.

• Keep exhaust outlet and air intake hoses a minimum of 12” apart.

• Install exhaust hose so it will maintain a minimum distance of 2.00 inches (50.8 mm) from any heat sensitive or
flammable material.

• The exhaust hose should be mounted slightly downwards to help drain off condensation.

• Install the protective cap onto the end of the exhaust hose.

• Route the exhaust hose to an open area to the rear or side of the tractor so fumes cannot build up and enter the cab
or the combustion air inlet tube to the heater.

• DDOO NNOOTT mount the exhaust hose to the tractor’s frame. It must be installed to the cab to allow for movement.

Exhaust and Combustion Air Intake Installation

1. Route the exhaust hose to an open area to the rear or side of the tractor positioned slightly downwards to help drain
off condensation and secure with clamps.

a. Drill a 1/8” hole in exhaust hose if necessary to allow for water drainage.

NNoottee:: Exhaust hose can be shortened to a minimum of 8” if required.

2. Attach metal end cap to exhaust hose.

3. Position air intake tube facing towards the rear of the tractor where it can pick up clean, fresh, moisture free air.

4. From underneath the sleeper:

a. Apply silicone sealant around ONLY the four heater mounting screws.

b. DO NOT apply any sealant around the access hole!

IImmppoorrttaanntt:: AALLWWAAYYSS VVEERRIIFFYY the two water valves (kazoos) are installed onto the evaporator drain tubes and are

secured with hose clamps.

40

TK 55676-19-IM-EN

DD22//DD44 HHeeaatteerr IInnssttaallllaattiioonn

Figure 21. Correct Exhaust and Combustion Air Intake Routing Shown

TK 55676-19-IM-EN

41

D2/D4 Heater Duct Installation

Duct Locations

IImmppoorrttaanntt:: See “Discharge and Return Air Duct Standards“ in Section 7 of the Thermo King TriPac Installation

Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

IIMMPPOORRTTAANNTT IINNFFOORRMMAATTIIOONN::

• UUSSEE SSUUPPPPLLIIEEDD HHEEAATTEERR DDUUCCTT HHOOSSEE OONNLLYY!! Do not use existing vehicle ducts or outlets. Ducts and outlets must
be capable of withstanding a minimum of 300F (148.9C) operating temperatures.

• Adjustable air vent must always be installed so it cannot blow hot air directly at living creatures (people, animals) or
objects sensitive to temperature.

• Do not position outlet so that it will blow hot air directly at operator or at thermostat.

• Position air outlet so that it cannot be obstructed.

• Use the supplied protective air intake grille on the air inlet side of the heater to prevent objects from being sucked in.

• Do not overtighten duct clamps.

• Do not lay or bundle the heater ducts with A/C ducts. They should not touch each other.

• Ensure provisions are made for proper air return ventilation.

The heater is equipped with a RReettuurrnn IInnlleett and DDiisscchhaarrggee OOuuttlleett for attaching the flexible heater duct hoses.

NNootteess:: A return air duct to the heater should be provided for best heating efficiency.

• Return Inlet must be provided to return air to the heater. It is typically mounted at the base of the bunk
directly opposite the discharge outlet vent.

• Discharge Outlet should be located at floor level to provide maximum heating comfort in the sleeper. It is
typically installed at the base of the bunk on one end.

• Heater ducts should be installed and routed with smooth bends and no kinks to provide maximum airflow.

Installation Procedures

Special Tools Required

Drill Motor

2-1/2” Hole Saw (for installing discharge air vent and return air grille)

3” Hole Saw (for routing ducts through compartment walls if required)

DDiisscchhaarrggee AAiirr

1. Find an appropriate location for the floor level discharge air vent and drill a 2-1/2” hole using the correct hole saw.

a. Unsnap rotating outer louver assembly from the mounting base.

b. Install the base into 2-1/2” hole and secure with supplied screws.

c. Reinstall rotating outer louver assembly back into the mounting base ring. Verify that it rotates freely.

2. Attach one end of the heater duct to the discharge outlet hood on the heater and secure with supplied clamp.

3. Route the heater duct to the floor level discharge air vent, cut as needed, attach to the end of the plastic louver vent
and secure with supplied hose clamp.

RReettuurrnn AAiirr

4. If a return air duct is not used, the protective grille must be installed onto the heater inlet.

5. Find an appropriate location for the floor level return air grille and drill a 2-1/2” hole using the correct hole saw.

a. Install return air grille into the 2-1/2” hole and secure with supplied screws.

6. Attach one end of return air duct to air inlet hood on heater and secure with supplied clamp.

a. Route return air duct to return air grille, cut as needed, attach to end of plastic louver vent and secure with

supplied hose clamp.

42

TK 55676-19-IM-EN

DD22//DD44 HHeeaatteerr DDuucctt IInnssttaallllaattiioonn

Figure 22. D2/D4 Heater Duct Installation Shown

TK 55676-19-IM-EN

43

A/C Duct Installation

A/C Vent Locations

NNoottee:: See “Evaporator Air Discharge Ducts and Vents Installation Standards“ in Section 6 of the Thermo King TriPac

Installation Standards Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

The evaporator is equipped with two air discharge outlets to attach the supplied flexible air ducts. The ducts will be
attached to plastic air vents that should be located and installed to provide maximum air circulation in the sleeper.
Suggested locations of the air vents:

• MMEEDDIIUUMM (above lower bunk level)

• HHIIGGHH (above upper bunk level)

NNoottee:: A/C air ducts and vents are typically routed and installed through closets or storage compartments.

IImmppoorrttaanntt:: Extreme care should always be taken when drilling holes in the various types of material found in sleepers

such as plastic, steel, aluminum, and upholstery.

To maximize APU efficiencies, the back flow damper kit (710676) must be installed when connecting the TriPac’s air conditioning discharge hose

(s) directly into the truck’s OEM HVAC duct(s). The damper will prevent the TriPac’s air from back flowing into the OEM HVAC housing. Failure to

install this kit may result in poor system performance.

IMPORTANT

Installation Procedures

Special Tools Required

Drill Motor

4-1/4” diameter Hole Saw
(for installing plastic A/C louver vents and for routing
ducts through compartment walls)

1. Find an appropriate location for the A/C vents and drill 4-1/4” diameter holes.

2. Attach one end of the flexible air duct to one of the air discharge outlets of the evaporator and secure with supplied
hose clamps

3. Route the flexible air duct through the A/C vent hole, cut excess duct as needed.

4. Unsnap rotating outer louver assembly from the mounting base.

5. Attach to flexible air duct to the end of the louver base with band wraps.

6. Push the mounting base back into 4-1/4” mounting hole and secure with supplied screws.

7. Reinstall rotating outer louver assembly back into the mounting base and verify that it rotates freely.

8. Install the second A/C vent in the same manner.

9. Verify flexible ducts are installed and routed with smooth bends and no kinks to provide maximum airflow.

10. Secure flexible ducts with large band wraps to prevent excess movement.

44

TK 55676-19-IM-EN

Figure 23. Typical A/C Duct Installation Shown

AA//CC DDuucctt IInnssttaallllaattiioonn

Figure 24. Example of a Back Flow Damper Shown

TK 55676-19-IM-EN

45

A/C Hose Installation

Installation Procedures

NNoottee:: See “Refrigerant Hose and Fittings Standards“ in Section 8 of the Thermo King TriPac Installation Standards

Guide (TK 56498). THESE STANDARDS MUST BE FOLLOWED!

Special Tools Required

Hose Fitting Tools (204-1045)

Hose Cutting Tool (204-677)

PAG Refrigerant Oil (2030502)

Torque Wrench

TTiigghhtteenn aallll ffiittttiinnggss aass ssppeecciiffiieedd iinn tthhee cchhaarrtt..

NNoottee:: Always use two wrenches while tightening refrigeration fittings.

Fitting Size Torque Specifications

#6 (3/8'') 11-13 lb-ft (15-17 N•m)

#8 (1/2'') 15-20 lb-ft (20-27 N•m)

#10 (5/8'') 21-27 lb-ft (28-37 N•m)

#12 (3/4'') 28-33 lb-ft (38-45 N•m)

Compressor Hose Connections

IImmppoorrttaanntt:: The suction and discharge hoses must be secured to the support bracket with the pre-installed bandwraps

exactly as shown in the illustration.

1. Begin refrigeration hose installation at the APU compressor fittings. Work away from the compressor towards the
other A/C system components to avoid hose slack inside the APU.

2. Start at the rear of the APU and route the #8 hose into the APU through the upper access hole and the #10 hose
through the lower access hole making sure you route them through the pre-installed bandwraps attached to the
support bracket and then to the compressor.

NNoottee:: Recommend routing the #8 hose first.

a. Cut the suction hose to the appropriate length, attach a ##1100,, 4455 ddeeggrreeee ffiittttiinngg ((wwiitthh sseerrvviiccee ppoorrtt)) and loosely

connect to the ssuuccttiioonn fitting on the compressor.

b. Cut the discharge hose to the appropriate length, attach a ##88,, 4455 ddeeggrreeee ffiittttiinngg ((wwiitthh sseerrvviiccee ppoorrtt)) and loosely

connect to the ddiisscchhaarrggee fitting on the compressor.

3. Gently pull the hoses towards the outside of the APU to remove slack.

a. Rotate compressor fittings as necessary to allow hoses to clear components and engine. Keep both hoses away

from fuel strainer, fuel fittings and bracket.

b. Position both hoses to the support bracket exactly as shown in the illustration and then tighten bandwraps

securely Cut off excess bandwrap length.

4. Tighten all refrigeration fittings as specified in the chart.

5. Re-torque pre-filter bowl to 25 in-lb (2.8 N•m) if it was loosened during the install. Use of tool 204-3103 is
recommended.

46

TK 55676-19-IM-EN

RCS1632

Hoses shown correctly routed and secured

with bandwraps to hose support bracket.

DISCHARGE HOSE ON TOP

SUCTION HOSE ON BOTTOM

Remove excess length

after tightening

Remove bottom panel

Underside of APU showing hoses correctly routed and

secured with bandwraps to the hose support bracket

IMPORTANT: Keep hoses away from

fuel strainer, fuel fittings, and bracket

AA//CC HHoossee IInnssttaallllaattiioonn

Figure 25. Suction and Discharge Hoses Shown Correctly Routed and Secured

CCoommpprreessssoorr ttoo EEvvaappoorraattoorr

6. From the APU, route the ##1100 ssuuccttiioonn hhoossee up through the 3” access hole in the tractor floor to the evaporator:

a. Cut the hose to the appropriate length, attach a ##1100 ffiittttiinngg and connect to the #10 suction fitting on the

evaporator

AAPPUU ttoo CCoonnddeennsseerr

7. From the APU, route the ##88 ddiisscchhaarrggee hhoossee to the condenser coil:

a. Cut the hose to the appropriate length, attach a ##88 ffiittttiinngg and connect to the #8 discharge fitting located near the

top of the condenser coil.

EEvvaappoorraattoorr ttoo RReecceeiivveerr DDrriieerr

8. Fabricate a ##66 hhoossee and fitting and attach onto the ##66 lliiqquuiidd lliinnee ffiittttiinngg on the evaporator:

a. Route the hose down through the 3” access hole in the tractor floor to the receiver drier.

b. Cut the hose to the appropriate length, attach a ##66 ffiittttiinngg and connect to the OOUUTTLLEETT end indicated by arrow on

the receiver drier.

CCoonnddeennsseerr ttoo RReecceeiivveerr DDrriieerr

9. Fabricate a ##66 hhoossee and fitting and attach onto the ##66 ffiittttiinngg on the condenser coil:

a. Route the hose to the receiver drier.

b. Cut the hose to the appropriate length, attach a ##66 ffiittttiinngg and connect to the IINNLLEETT end on the receiver drier.

10. Tighten all fittings as specified in the chart.

11. Reinstall and secure APU side panel.

NNoottee:: The bottom pan will be reinstalled in a later step.

TK 55676-19-IM-EN

47

RSC137-1

#1

0

#

6

#6

EVAPORATOR

CONDENSER

RECEIVER

DRIER

#1

0

#

8

#

6

#6

#8

LIQUID

COMPRESSOR

OUTLET

INLET

S

U

C

T

I

O

N

IMPORTANT: The suction and discharge hoses must be secured to the refrigerant hose

support bracket exactly as shown in the previous illustration.

AA//CC HHoossee IInnssttaallllaattiioonn

Figure 26. A/C Hose Diagram Shown

48

TK 55676-19-IM-EN

A/C System Evacuation and Leak Check Procedures

Evacuation Procedures

NNoottee:: See “System Evacuation Standards“ in Section 12 of the Thermo King TriPac Installation Standards Guide (TK

56498). THESE STANDARDS MUST BE FOLLOWED!

Evacuation Procedures

Thermo King Evacuation Station (P/N 204-725)
Recommended

Evacuation Station Operation and Field Application
Instructions (TK 40612)

Electronic Leak Detector (204-756)

Gauge Set with R134a Adapters

NNoottee:: The oil in the evacuation station vacuum pump should be changed after each use.

IImmppoorrttaanntt:: Always use recommended vacuum equipment. Before each use, check that there are no leaks in the vacuum

equipment either in the pump itself or in the hoses.

1. Connect the gauge manifold to the suction and discharge service ports of the APU’s compressor.

2. Connect the service line of the gauge manifold to the vacuum pump and micron gauge.

3. Open the gauge manifold and vacuum pump valves and gauge manifold hand valves

4. Start the vacuum pump and evacuate until system reaches 500 microns.

5. Once the system reaches 500 microns, continue evacuation for one additional hour.

NNoottee:: To save installation time, while the system is being evacuated, continue on to the electrical installation beginning

with “Control Box and Main Harness Installation” . Return and complete this procedure later.

6. Close the vacuum pump valve, switch off the pump, checking that the gauge reading for the vacuum pump does not
exceed 2000 microns in the following five minutes. If vacuum level exceeds 2000 microns before five minutes, and
continues to rise, proceed to the LLeeaakk CChheecckk PPrroocceedduurreess section below.

7. If vacuum level remains below 2000 microns for 5 minutes the system is leak free and ready to be filled with
refrigerant

8. Close manifold hand valves and remove evacuation equipment.

Leak Check Procedures

NNoottee:: See “System Leak Check Standards“ in Section 12 of the Thermo King TriPac Installation Standards Guide (TK

56498). THESE STANDARDS MUST BE FOLLOWED!

1. Add vapor R-134a to the unit until bottle pressure is reached.

2. Thoroughly leak check the system with an electronic leak detector.

3. If leak(s) are found, recover leak check charge.

4. Repair any leaks and re-evacuate system.

TK 55676-19-IM-EN

49

AA//CC SSyysstteemm EEvvaaccuuaattiioonn aanndd LLeeaakk CChheecckk PPrroocceedduurreess

Figure 27. Gauge Manifold and Vacuum Pump Shown Connected to APU

50

TK 55676-19-IM-EN

Control Box and Main Harness Installation

Control Box Location

Choose a location inside the tractor’s sleeper for the control box. The box can be mounted horizontally or vertically.
Make sure the location chosen allows access for:

• Installation of wiring

• Servicing of interface board components

• Operation of the reset switch.

NNoottee:: DDOO NNOOTT install the control box at this time. It will be installed AFTER all the TriPac electrical harnesses have been

connected.

DDPPFF UUnniittss OOnnllyy

Install the Small Engine Control Module (SECM) and harnesses now. Refer to TK 55727-19-IM for details.

PPoowweerr IInnvveerrtteerr OOppttiioonn OOnnllyy

Install the power inverter now. Refer to TK 55855-19-IM for details.

HHoouurrmmeetteerr OOppttiioonn OOnnllyy

Install the hourmeters and harness now. Refer to TK 55701-19-MS for details

Main Harness Installation Procedures

IImmppoorrttaanntt:: Before making any electrical connections, confirm the Heater and APU battery cables are not connected to

the battery.

NNoottee:: Excessive harnesses lengths should be doubled up and secured with band wraps. DO NOT CUT THE WIRE

HARNESSES!

NNoottee:: Exercise care when mating the connection. Always check the male pins for straightness before attempting to

mate connectors. If any resistance is felt when mating the connector, recheck the male pin alignment.

1. Position the control box inside the truck and remove the cover.

2. Route MMaaiinn EElleeccttrriiccaall HHaarrnneessss from APU up into sleeper through 3” access hole in the floor and into the control
box.

3. Connect 2200--ppiinn connector to mating connector ((JJ1144)) on interface board.

4. Connect 66--ppiinn connector to mating connector ((JJ55)) on interface board.

5. Attach the separate CCHH--0011 wire with the terminal ring onto interface board ground stud labeled CH ((JJ1166)) and torque
to 18 lb-in (2 N•m).

IImmppoorrttaanntt:: IMPORTANT: The CH-01 wire terminal ring must be positioned correctly onto the ground stud and tightened

properly or the unit will not operate.

6. Connect 1100--ppiinn connector to mating connector ((JJ66)) on interface board.

7. 44--ppiinn connector ((77CCLL,, 77CCLLAA,, CCOOIILLSSEENN,, CCOOIILLSSEENN--RRTTNN)) will be attached to mating connector on A/C evaporator
harness that will be installed in a later step.

8. 22--ppiinn connector ((SSBBYY,, 22AA)) is for Standby Truck Integration Switch (OPTION).

9. Attach 22 wire with terminal ring onto interface board power stud ((JJ1155 22)) and torque to 18 lb-in (2 N•m).

IImmppoorrttaanntt:: The 2 wire terminal ring must be positioned correctly onto the power stud as shown on decal located on

control box cover.

TK 55676-19-IM-EN

51

CCoonnttrrooll BBooxx aanndd MMaaiinn HHaarrnneessss IInnssttaallllaattiioonn

Figure 28. Main Harness Connections to Control Box Shown

52

TK 55676-19-IM-EN

HMI Installation

HMI Location

• Choose a location inside the tractor’s sleeper for the HMI controller that is easily accessible and visible from the
drivers bunk.

• The HMI should be visible and mounted away from windows, air vents, out of direct sunlight to accurately measure
air temperature.

Installation Procedures

Special Tools Required

Level

Drill Motor

Drill Bits

Locate the HHMMII CCoonnttrroolllleerr HHaarrnneessss with the 88--ppiinn connectors on each end supplied loose in the installation kit.

1. Connect one 8-pin harness connector to the HMI ((JJ3344)) connector on the main controller board inside the control
box.

2. From the control box, route the harness behind the interior walls (if applicable) to the location chosen to install the
HMI controller.

3. Unsnap the rear mounting base from the controller and route the 8-pin harness connector through the access hole.

• Position and level the mounting base and install securely.

4. Push the connector firmly into the rear of the controller and snap the controller back onto the mounting base.

DDPPFF UUnniittss OOnnllyy -- EExxhhaauusstt MMoonniittoorr aanndd RReeggeenneerraattiioonn SSwwiittcchh

Install the exhaust monitor and regeneration switch now. Refer to TK 55727-19-IM for details.

TK 55676-19-IM-EN

53

RCS1676

4

3

2

1

RCS1677

HHMMII IInnssttaallllaattiioonn

Figure 29. HMI Harness Connections Shown

NNoottee:: Attach the supplied Operator Manual nameplate in a location inside the tractor chosen by the driver.

Figure 30. Online Access to Operator Manual Nameplate Shown

54

TK 55676-19-IM-EN

D2/D4 Heater Wiring Installation

Special Tools Required

Wire Cutters

Terminal Crimping Tool

Locate the heater harness supplied in the kit. Remove the two small plastic bags attached to the harness containing the
fuel pump electrical connector components and the in-line fuse assembly. Retain these for installation later.

1. Connect the 16-pin connector to the heater:

a. use a large bladed screwdriver to pull the locking tab out ((ttoo uunnlloocckk)) from the connector body.

b. connect the two 16-pin connectors together.

c. push locking tab back in ((ttoo lloocckk)) the connector body.

2. Route the heater control harness connectors into the control box, but DDOO NNOOTT make any connections to the
interface board at this time. They will be connected later after the Heater Start-Up Procedures are completed.

3. The 8-pin connector (with 4 wires) is used for diagnostic purposes only.

4. Route the fuel pump harness out of the sleeper through the 3” access hole. It will be assembled and connected to
the fuel pump in a later step

Figure 31. Heater Harness Connections Shown

TK 55676-19-IM-EN

55

2

3

1

RCS1662

4

SENSOR HARNESS

HEATER HARNESS

GREY

RED

BROWN/WHITE

BLACK

DD22//DD44 HHeeaatteerr WWiirriinngg IInnssttaallllaattiioonn

Remote Temperature Sensor - D4 Heater Only

1. Insert the Espar Remote Temperature Sensor all the way into the holder at the rear of the HMI mounting base as
shown and route the sensor harness down to the control box the same way the HMI harness was routed.

2. Locate the 14-pin heater harness connector. This connector should not be connected to the interface board at this
time.

3. Carefully remove approximately 203 mm (8.00 in.) of both the outer and inner harness sleeving from the connector
end of the Espar Heater Harness to gain access to the 8 individual wires.

4. Measure approximately 102 to 152 mm (4.00 to 6.00 in.) from the connector and splice the following two wires
together using butt splice connectors:

a. Brown/White wire from heater harness to Black wire from the sensor harness.

b. Grey wire from heater harness to RED wire from the sensor harness.

c. Seal the splice connections.

NNoottee:: The 14-pin heater connector should not be connected to the interface board at this time. It will be connected

later after the Heater Start-Up Procedures are completed.

Figure 32. Remote Temperature Sensor Installation and Wiring Shown

56

TK 55676-19-IM-EN

A/C Wiring Installation

NNoottee:: Excessive harnesses lengths should be doubled up and secured with band wraps. DO NOT CUT THE WIRE

HARNESSES!

1. Route the A/C harness to the control box.

2. Connect 4-pin connector (7CL, 7CLA, COILSEN, COILSEN-RTN) to the mating connector located on the main harness
installed earlier.

3. Connect 6-pin connector to AC COND connector (J2).

4. Connect 4-pin connector to AC EVAP connector (J1).

5. Route harnesses (7CF, 7CF-RTN) and (7CL, 7CLA) out of the sleeper through the 3” access hole towards the
condenser coil.

6. Attach connector (7CL, 7CLA) to the receiver drier binary switch.

7. Attach connector (7CF, CH-08) to the condenser fan harness.

8. Install control box securely with TEK screws in location chosen earlier.

DDPPFF UUnniittss OOnnllyy

Install the following DPF components. Refer to TK 55727-19-IM for details.

• Valve box

• Battery cables and harnesses

• Ambient air sensor

• Pressure transducer

• Air intake and air pressure hoses

TK 55676-19-IM-EN

57

AA//CC WWiirriinngg IInnssttaallllaattiioonn

Figure 33. A/C Harness Connections Shown

58

TK 55676-19-IM-EN

Standby Truck Integration Harness with Switch
(Option)

Special Tools Required

Digital Meter (204-615)

Drill Motor

1/2” Drill Bit

Access the tractor’s ignition switch wires at rear of the switch:

a. Turn ignition switch to the ““AACCCCEESSSSOORRYY”” position and use a digital meter to locate a wire connection with NO

POWER (0 Vdc).

b. Turn ignition switch to the ““OONN”” position and re-check for voltage at the same wire connection tested earlier. If

voltage is present, this is where the IGN wire will be connected.

Typically the standby switch is installed in the dashboard in a location that is easily accessible for the driver.

1. Remove dash panel (if required). Mark and drill 1/2” hole.

2. Install the standby switch, nameplate and nut. Confirm the 2A wire on the switch is facing UP and then tighten the
nut securely.

3. Connect IGN wire with in-line fuse to:

WIRE VEHICLE CONNECTION

IGN

“ON” circuit of ignition switch

or

“ON” circuit of fuse panel

4. Route the standby switch harness to the control box and connect the 2-pin connector ((SSBBYY aanndd 22AA)) to the mating
pigtail connector found on the main harness installed earlier.

DDPPFF UUnniittss OOnnllyy

Install the DPF regeneration switch now. Refer to TK 55727-19-IM for details.

TK 55676-19-IM-EN

59

SSttaannddbbyy TTrruucckk IInntteeggrraattiioonn HHaarrnneessss wwiitthh SSwwiittcchh ((OOppttiioonn))

Figure 34. Standby Harness with Switch Connections Shown

60

TK 55676-19-IM-EN

Standby Truck Integration Harness without Switch
(Option)

Special Tools Required

Digital Meter (204-615)

Access the tractor’s ignition switch wires at rear of the switch:

a. Turn ignition switch to the ““AACCCCEESSSSOORRYY”” position and use a digital meter to locate a wire connection with NO

POWER (0 Vdc).

b. Turn ignition switch to the ““OONN”” position and re-check for voltage at the same wire connection tested earlier. If

voltage is present, this is where the IGN wire will be connected.

1. Connect IIGGNN wire with in-line fuse to:

WIRE VEHICLE CONNECTION

IGN

2. Route the standby switch harness to the control box and connect the 2-pin connector ((SSBBYY aanndd 22AA)) to the mating
pigtail connector found on the main harness installed earlier.

DDPPFF UUnniittss OOnnllyy

Install the DPF regeneration switch now. Refer to TK 55727-19-IM for details.

“ON” circuit of ignition switch

or

“ON” circuit of fuse panel

TK 55676-19-IM-EN

61

SSttaannddbbyy TTrruucckk IInntteeggrraattiioonn HHaarrnneessss wwiitthhoouutt SSwwiittcchh ((OOppttiioonn))

Figure 35. Standby Harness without Switch Connections Shown

62

TK 55676-19-IM-EN

Fuel Pickup Tube Installation

Preferred Installation – Optional Adapter Plate (10–379)

NNoottee:: Some OEM’s offer a fuel tank option which provides three auxiliary fuel fitting connections. With this option, the

fuel pickup tube and adapter plate are not needed. Simply route and connect the APU’s fuel supply and return
lines and the heater’s fuel supply line to these fittings. Always check your fuel tank for these fittings before
installing the fuel pickup tube or adapter plate.

DDAANNGGEERR

HHaazzaarrdd ooff EExxpplloossiioonn!!

UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg iinn oorr aarroouunndd tthhee aarreeaa ooff tthhee ddiieesseell ffuueell ttaannkk.. DDiieesseell ffuueell vvaappoorrss aarree ppootteennttiiaallllyy
eexxpplloossiivvee.. DDoo nnoott ssmmookkee wwhhiillee wwoorrkkiinngg nneeaarr tthhee ddiieesseell ffuueell ttaannkk..

TThhee ffoolllloowwiinngg iinnssttaallllaattiioonn iiss ffoorr OOEEMM ffuueell ttaannkkss eeqquuiippppeedd wwiitthh aann aauuxxiilliiaarryy ffuueell lleevveell sseennddeerr ((FFLLSS)) 55 bboolltt
mmoouunnttiinngg ffllaannggee..

Special Tools Required

Tape Measure

Tubing Cutter

Torque Wrench

IMPORTANT INSTALLATION TIPS

• Identify and mark APU FUEL SUPPLY pickup tube for reference later.

• Remove protective caps from ends of pickup tubes prior to installation.

• Do not apply any type of sealant material to fuel pickup assembly. Doing so will result in plugged fuel lines.

1. Locate auxiliary FLS mounting flange and block off plate on tractor’s fuel tank. Remove block off plate and clean
surface area of all dirt, grease, etc.

2. Install adapter plate 10-379 (counter sunk holes facing up) and the gasket. Secure with the supplied screws and
torque to 90 lb-in. (10.2 N•m) maximum.

3. The APU diesel engine fuel supply tube is 24” and heater fuel supply tube is 23”.

a. Measure and cut APU diesel fuel supply tube 2” shorter than fuel tank diameter.

b. Measure and cut heater fuel supply tube 3” shorter than fuel tank diameter. The heater fuel supply tube is

identified by not having a fitting.

4. Loosen and slide the hardware to top of the pickup tube assembly.

5. Spread pickup tubes approximately 12” apart then squeeze pickup tubes back together and insert tubes and
bushing into hole of adapter plate.

6. Tip back-up washer and insert into hole of adapter plate.

a. With back-up washer on underside of adapter plate, thread nut onto bushing and hand tighten.

b. OPTION - Install supplied fuel pump bracket for fuel heater.

c. Position pickup tube as needed to facilitate fuel line connections and tighten nut to 16 to 18 ft-lb. (21 to 24 N•m).

7. Install supplied warning nameplate onto fuel tank in a visible area near fuel cap.

TK 55676-19-IM-EN

63

FFuueell PPiicckkuupp TTuubbee IInnssttaallllaattiioonn

Figure 36. Optional Adapter Plate Installation Shown

64

TK 55676-19-IM-EN

FFuueell PPiicckkuupp TTuubbee IInnssttaallllaattiioonn

Alternative Installation – Drilling Hole In Fuel Tank

NNoottee:: Some OEM’s offer a fuel tank option which provides three auxiliary fuel fitting connections. With this option, the

fuel pickup tube and adapter plate are not needed. Simply route and connect the APU’s fuel supply and return
lines and the heater’s fuel supply line to these fittings. Always check your fuel tank for these fittings before
installing the fuel pickup tube or adapter plate.

DDAANNGGEERR

HHaazzaarrdd ooff EExxpplloossiioonn!!

UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg iinn oorr aarroouunndd tthhee aarreeaa ooff tthhee ddiieesseell ffuueell ttaannkk.. DDiieesseell ffuueell vvaappoorrss aarree ppootteennttiiaallllyy
eexxpplloossiivvee.. DDoo nnoott ssmmookkee wwhhiillee wwoorrkkiinngg nneeaarr tthhee ddiieesseell ffuueell ttaannkk..

DDAANNGGEERR

HHaazzaarrdd ooff EExxpplloossiioonn!!

DDiieesseell ffuueell vvaappoorrss aarree ppootteennttiiaallllyy eexxpplloossiivvee.. UUssee eexxttrreemmee ccaauuttiioonn wwhheenn ddrriilllliinngg hhoolleess iinn oorr aarroouunndd ddiieesseell ffuueell
ttaannkkss.. SSppaarrkkss ffrroomm aann eelleeccttrriicc ddrriillll oorr ddrriillll bbiitt ccoouulldd ccaauussee aann eexxpplloossiioonn.. DDrraaiinn aallll ddiieesseell ffuueell ffrroomm tthhee ttaannkk aanndd
uussee nniittrrooggeenn oorr aann iinneerrtt ggaass ttoo ppuurrggee tthhee ddiieesseell vvaappoorrss ffrroomm tthhee ttaannkk pprriioorr ttoo ddrriilllliinngg iinnttoo oorr aarroouunndd tthhee ffuueell
ttaannkk.. KKeeeepp tthhee ddiieesseell ffuueell ttaannkk ffiilllleedd wwiitthh iinneerrtt ggaass wwhhiillee ddrriilllliinngg..

Special Tools Required

Tape Measure

Drill Motor

Step Reamer Bit

1-1/4” Hole Saw

Tubing Cutter

Heavy Grease

Torque Wrench

IIMMPPOORRTTAANNTT IINNSSTTAALLLLAATTIIOONN TTIIPPSS

• Identify and mark APU FUEL SUPPLY pickup tube for reference later.

• Remove protective caps from ends of pickup tubes prior to installation.

• Do not apply any type of sealant material to fuel pickup assembly. Doing so will result in plugged fuel lines.

• Check for internal baffles in fuel tank BEFORE drilling any holes.

1. Tape paper template (supplied with pickup tube) onto tractor’s fuel tank and center punch three holes. Remove
template from tank.

2. Drill a 1/4” pilot hole then drill:

a. 1/2” diameter outer holes first with step reamer.

b. 1-1/4” diameter inner hole next with hole saw.

c. Thoroughly clean and flush the tank to remove any chips.

3. The APU diesel engine fuel supply tube is 24” and the heater fuel supply tube is 23”.

a. Measure and cut APU diesel fuel supply tube 2” shorter than fuel tank diameter.

b. Measure and cut heater fuel supply tube 3” shorter than fuel tank diameter. The heater fuel supply tube is

identified by not having a fitting.

4. Loosen and slide hardware to top of pickup tube assembly.

5. Spread pickup tubes approximately 12” apart then squeeze pickup tubes back together and insert tubes and
bushing into hole of adapter plate.

6. Tip back-up washer and insert it to fuel tank hole.

a. With back-up washer on underside of fuel tank hole, thread nut onto bushing and hand tighten.

TK 55676-19-IM-EN

65

FFuueell PPiicckkuupp TTuubbee IInnssttaallllaattiioonn

b. OPTION - Install supplied fuel pump bracket for fuel heater.

c. Position pickup tube as needed to facilitate fuel line connections and tighten nut to 16 to 18 ft-lb. (21 to 24 N•m).

7. Install supplied warning nameplate onto fuel tank in a visible area near fuel cap.

Figure 37. Alternative Installation Drilling Hole In Fuel Tank Shown

66

TK 55676-19-IM-EN

Heater Fuel Pump and Fuel Line Installation

Special Tools Required

Utility Knife

Hose Cutting Tool (204-677)

IImmppoorrttaanntt:: Proper mounting angle of the fuel pump is necessary to allow any air or vapor in the fuel lines to pass

through the pump rather than cause a blockage (Detail’s A and B).

The fuel pump can be installed using either the L-bracket or the fuel tank mounting bracket (both are supplied).

L-Bracket Installation Procedures

1. Choose a protected mounting location close to the fuel pick-up tube and heater.

2. Install the fuel pump into the supplied rubber mounting clamp and attach the L-bracket.

3. Position the fuel pump at a 15 to 35 degree angle with the outlet end facing up (outlet end has connector and
smaller barb fitting) and secure the clamp and bracket. ((DDeettaaiill AA)).

Fuel Tank Bracket Installation Procedures

1. Loosen the fuel pickup tube nut and position the supplied fuel pump bracket under the nut then re-tighten the nut to
16 to 18 ft-lb. (21 to 24 N•m).

NNoottee:: The bracket goes under the nut, not under the washer or rubber gasket.

2. Install the fuel pump into the supplied rubber mounting clamp and attach the rubber clamp to the tank mounted
bracket securely.

Fuel Line Installation Procedures

1. Attach the rubber hose connection to the outlet end of the fuel pump and secure with supplied hose clamp.

2. Route the plastic fuel line (installed earlier on the heater) to the fuel pump and cut to length. Insert the fuel line into
the rubber hose connection until it butts up tight with the fuel pump’s outlet pipe ((DDeettaaiill BB)). Secure with supplied
hose clamp.

• The fuel line must be installed correctly to prevent air bubbles ((DDEETTAAIILL BB)).

• The fuel line from the pickup tube, to fuel pump, to heater should be routed at a continuous rise.

• Only use a hose cutter or utility knife to cut plastic fuel lines. Do not use a wire cutter as this will pinch the plastic
fuel line closed.

3. Attach fuel line from the fuel pick-up supply to the inlet end of the fuel pump and secure with supplied hose clamp.

NNoottee:: The heater fuel pickup supply tube is identified by not having a fitting.

TK 55676-19-IM-EN

67

B

Max. 2’6”

Fuel

Tank

Max. 2’

Max. 6’6”

Max. 20’

Inlet

Outlet

35°

15°

P

r

efer

able

Not Permissable

FUEL PUMP

ANGLE

A

L-BRACKET

FUEL TANK BRACKET

ABA316-1

HHeeaatteerr FFuueell PPuummpp aanndd FFuueell LLiinnee IInnssttaallllaattiioonn

Figure 38. Heater Fuel Pump and Fuel Line Installation Shown

68

TK 55676-19-IM-EN

APU Fuel Line Installation

Special Tools Required

Utility Knife

NNoottee:: Be sure to connect the APU’s fuel supply line to the fuel SUPPLY pickup tube connection identified and marked

earlier

1. Route APU fuel supply line to SSUUPPPPLLYY connection of fuel pickup tube, cut to proper length and attach with
compression fittings.

2. Route APU fuel return line to RREETTUURRNN connection of fuel pickup tube, cut to proper length and attach with
compression fittings.

3. Route and secure all fuel lines with adequate clamps.

Figure 39. APU Fuel Line Installation Shown

TK 55676-19-IM-EN

69

Tractor Coolant Hose Installation

Preferred Installation – APU Coolant Hoses Tee’d Directly Into Tractor’s
Heater Hoses

NNoottee:: Skip this step if your APU has the Closed Loop Cooling Option.

Coolant Hose Routing and Connections

NNoottee:: If the Arctic Block Temperature Sensor Option is to be installed, it should be installed at this time.

Each coolant hose installation will be different. Carefully review the tractor’s engine cooling system to determine the
best method for installing the cooling hoses and hand valves. Consult tractor dealer or OEM for assistance in
identifying correct coolant hoses or engine fittings required for proper installation.

NNoottee:: All APU coolant hoses should be installed in such a way as to allow the hand valves to isolate the APU cooling

system from the tractor’s cooling system. This hand valve must be located as close to the tractor’s engine as
possible.

TThheeoorryy ooff OOppeerraattiioonn

With the tractor’s engine shut off, and the TriPac APU engine operating, warm coolant is circulated from the APU
engine up to the tractor’s engine and then back to the APU engine. This keeps the tractor’s engine warm allowing for
easier cold starts.

• When the TriPac APU engine is running and coolant temperature reaches normal operating temperature of 180 F (82
C), the thermostat will open allowing hot coolant to flow from the APU OOUUTTLLEETT fitting forward to the tractor’s
engine.

• Hot coolant enters the tractor’s engine block through an IINNLLEETT fitting typically located near the water pump.

• Hot coolant circulates through the tractor’s engine block and exits an OOUUTTLLEETT fitting typically used for the heater.

• Warm coolant then returns to the TriPac APU and enters the IINNLLEETT fitting.

• Warm coolant circulates through the APU’s engine block to absorb heat before being pumped back out to the
tractor’s engine.

• Hand valves are installed to allow the APU’s cooling system to be isolated from the tractor’s cooling system to allow
for component servicing.

Installation Procedures

Special Tools Required

Utility Knife

Pipe Thread Sealer

1. Drain coolant from tractor’s radiator and engine. Keep for re-use.

2. Locate HHEEAATTEERR IINNLLEETT coolant hose on tractor’s engine:

a. Cut tractor’s heater inlet hose and install pipe fittings, elbow, tee fitting and hand valve.

b. From the hand valve, connect and route a new coolant hose back to the OOUUTTLLEETT fitting located on the APU.

c. CCLLOOSSEE hand valve.

3. Locate HHEEAATTEERR OOUUTTLLEETT coolant hose on the tractor’s engine:

a. Cut tractor’s heater outlet hose and install pipe fittings, elbow, tee fitting and hand valve.

b. From shutoff valve, connect and route a new coolant hose back to the IINNLLEETT fitting located on the APU

precooler.

c. OOPPEENN hand valve.

4. Install protective plastic sleeving on all coolant hoses and secure coolant hoses with clamps.

5. Make sure the APU OOUUTTLLEETT hand valve (tractor inlet, next to water pump) is cclloosseedd. If this valve is left open,
coolant will be sitting on top of the TriPac thermostat and not allow the TriPac engine to bleed air.

70

TK 55676-19-IM-EN

HEA

T

ER

HO

SE

ABA715-1

OUTLET

OUTLET

INLET

TRACTOR HEATER

CORE

INLET

NOTICE

This truck is equipped with auxiliary power

unit. Coolant system must be bled after

main engine coolant system servicing.

HEA

T

ER

HO

SE

6

APU

HO

SE

TRACTOR

ENGINE

TTrraaccttoorr CCoooollaanntt HHoossee IInnssttaallllaattiioonn

NNoottee:: The system will be bled of air later by following the “A/C System Charging and APU Engine Start-up

Procedures”.

a. Add coolant removed earlier back into the tractor’s radiator.

b. DDOO NNOOTT start the tractor’s engine at this time.

6. Install supplied coolant nameplate in a visible area near the tractor’s coolant fill cap.

Figure 40. APU Coolant Hoses Tee’d Directly Into Tractor’s Heater Hoses Shown

TK 55676-19-IM-EN

71

TTrraaccttoorr CCoooollaanntt HHoossee IInnssttaallllaattiioonn

Alternative Installation – APU Coolant Hoses Attached Directly To
Fittings On Tractor’s Engine

NNoottee:: Skip this step if your APU has the Closed Loop Cooling Option.

Coolant Hose Routing and Connections

NNoottee:: If the Arctic Block Temperature Sensor Option is to be installed, it should be installed at this time.

Each coolant hose installation will be different. Carefully review the tractor’s engine cooling system to determine the
best method for installing the cooling hoses and hand valves. Consult tractor dealer or OEM for assistance in
identifying correct coolant hoses or engine fittings required for proper installation.

NNoottee:: All APU coolant hoses should be installed in such a way as to allow the hand valves to isolate the APU cooling

system from the tractor’s cooling system. This hand valve must be located as close to the tractor’s engine as
possible.

TThheeoorryy ooff OOppeerraattiioonn

With the tractor’s engine shut off, and the TriPac APU engine operating, warm coolant is circulated from the APU
engine up to the tractor’s engine and then back to the APU engine. This keeps the tractor’s engine warm allowing for
easier cold starts.

• When the TriPac APU engine is running and coolant temperature reaches normal operating temperature of 180 F (82
C), the thermostat will open allowing hot coolant to flow from the APU OOUUTTLLEETT fitting forward to the tractor’s
engine.

• Hot coolant enters the tractor’s engine block through an IINNLLEETT fitting typically located near the water pump.

• Hot coolant circulates through the tractor’s engine block and exits an OOUUTTLLEETT fitting typically used for the heater.

• Warm coolant then returns to the TriPac APU and enters the IINNLLEETT fitting.

• Warm coolant circulates through the APU’s engine block to absorb heat before being pumped back out to the
tractor’s engine.

• Hand valves are installed to allow the APU’s cooling system to be isolated from the tractor’s cooling system to allow
for component servicing.

Installation Procedures

Special Tools Required

Utility Knife

Pipe Thread Sealer

1. Drain coolant from tractor’s radiator and engine. Keep for re-use.

2. Use the tractor’s heater hoses as a guide to locate an IINNLLEETTplug on the engine before the water pump. Remove
plug and:

a. Install hose fittings, short section of coolant hose and hand valve.

b. From the hand valve, install a hose fitting and route a new coolant hose back to the OUTLET fitting located on

the APU.

c. CCLLOOSSEE hand valve.

3. Use the tractor’s heater hoses as a guide to locate an OOUUTTLLEETT plug on the engine block. Remove plug and:

a. Install hose fittings, short section of coolant hose and hand valve.

b. From the hand valve, install a hose fitting and route a new coolant hose back to the IINNLLEETT fitting located on the

APU precooler.

c. OOPPEENN hand valve.

4. Install protective plastic sleeving on all coolant hoses and secure coolant hoses with clamps.

5. Make sure the APU OOUUTTLLEETT hand valve (tractor inlet, next to water pump) is cclloosseedd. If this valve is left open,
coolant will be sitting on top of the TriPac thermostat and not allow the TriPac engine to bleed air.

72

TK 55676-19-IM-EN

TRACTOR

ENGINE

OUTLET

OUTLET

INLET

TRUCK HEATER

CORE

INLET

ABA716-1

NOTICE

This truck is equipped with auxiliary power

unit. Coolant system must be bled after

main engine coolant system servicing.

6

CO

O

LANT

HO

SE

APU

HO

SE

TTrraaccttoorr CCoooollaanntt HHoossee IInnssttaallllaattiioonn

NNoottee:: The system will be bled of air later by following the “A/C System Charging and APU Engine Start-up

Procedures”.

a. Add coolant removed earlier back into the tractor’s radiator.

b. DDOO NNOOTT start the tractor’s engine at this time.

6. Install supplied coolant nameplate in a visible area near the tractor’s coolant fill cap.

Figure 41. APU Coolant Hoses Attached Directly To Fittings On Tractor’s Engine Shown

TK 55676-19-IM-EN

73

Arctic Switch (Option)

Installation Procedures

CCAAUUTTIIOONN

RRiisskk ooff IInnjjuurryy!!

AAllwwaayyss wweeaarr ssaaffeettyy ggoogggglleess aanndd wwoorrkk gglloovveess wwhheenn wwoorrkkiinngg wwiitthh aannttiiffrreeeezzee.. TThhee AAPPUU aanndd ttrraaccttoorr’’ss eennggiinnee
ccoooollaanntt ssyysstteemm sshhoouulldd bbee aatt aammbbiieenntt tteemmppeerraattuurree ttoo pprreevveenntt hhoott,, pprreessssuurriizzeedd ccoooollaanntt ffrroomm ccaauussiinngg ppaaiinnffuull
bbuurrnnss ttoo eexxppoosseedd sskkiinn aanndd eeyyeess..

CCAAUUTTIIOONN

RRiisskk ooff IInnjjuurryy!!

TToo pprreevveenntt tthhee AAPPUU ffrroomm ssttaarrttiinngg uunneexxppeecctteeddllyy,, sseett aallll eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn BBEEFFOORREE
ccoonnnneeccttiinngg wwiirreess ttoo bbaatttteerryy..

1. Locate Arctic Option harness ((WWTT22,,WWTT22--RRTTNN)) band wrapped inside unit, near top, right side of frame. Un-band and
route harness and connector out of unit, through hole in right side of frame, behind pre-cooler coil. Secure
connector to anchor provided on outside of panel as shown in illustration.

2. Locate IINNLLEETT coolant hose and measure approximately 6.00 in. (152.4 mm) out from APU.

3. Slide sleeving away to expose coolant hose and mark 3.00 in. (76.2 mm) to be removed.

4. Clamp off each side of coolant hose with a hose crimper to prevent excessive coolant loss.

5. Use a hose cutter and remove 3.00 in. (76.2 mm) section of coolant hose.

6. Install tube and sensor assembly with hose clamps.

IImmppoorrttaanntt:: When tube and sensor assembly is installed horizontally sensor must face down, when installed vertically

sensor must face towards APU ((DDEETTAAIILL AA)).

7. Plug sensor harness to mating 2-pin connector ((WWTT22,, WWTT22--RRTTNN)) located outside APU.

8. Provide a drip loop and secure all wires adequately with supplied band wraps.

9. Operate unit, check for leaks and reinstall sleeving on coolant hose.

74

TK 55676-19-IM-EN

Figure 42. Arctic Switch Installation Shown

AArrccttiicc SSwwiittcchh ((OOppttiioonn))

TK 55676-19-IM-EN

75

Heater Fuel Pump Connections

CCAAUUTTIIOONN

RRiisskk ooff IInnjjuurryy!!

TToo pprreevveenntt tthhee AAPPUU ffrroomm ssttaarrttiinngg uunneexxppeecctteeddllyy,, sseett aallll eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn BBEEFFOORREE
ccoonnnneeccttiinngg wwiirreess ttoo bbaatttteerryy..

1. Route the heater fuel pump harness down to the fuel pump and cut the wires to the correct length.

a. Strip wire ends, slide on rubber sealing boots, attach pin terminals securely with crimping tool.

b. Insert pin terminals into connector body until they lock in place.

NNoottee:: The pump is not polarity sensitive. The wires can be installed in either location of the connector body.

c. Snap locking cover closed on connector body.

d. DDOO NNOOTT connect the fuel pump harness to the fuel pump at this time. The fuel pump harness will be attached

later after the fuel pump has been primed.

Figure 43. Heater Fuel Pump Connections Shown

76

TK 55676-19-IM-EN

Fuse Holder and APU Battery Connections

DDPPFF UUnniittss OOnnllyy — Route and connect the battery cables to the fuse holder, valve box and DPF now. Refer to TK 55727­19-IM for details.

PPoowweerr IInnvveerrtteerr OOppttiioonn OOnnllyy — Route and connect the power inverter cables to the battery and fuse holder now. Refer
to TK 55855-19-IM.

IImmppoorrttaanntt BBaatttteerryy CCaabbllee IInnssttaallllaattiioonn IInnffoorrmmaattiioonn

IImmppoorrttaanntt:: Do not attach both the positive and the negative cables to a single battery. For best results, attach the

positive cable to the first battery and the negative cable to the last battery as shown.

1. FFUUSSEE HHOOLLDDEERR

a. Mount fuse holder securely to battery box structure with (installer supplied) 1/4-20 hardware within 12.0 inches

(304.8 mm) of positive battery terminal. It is not acceptable to leave fuse holder loose or tied to other cabling.

b. DDOO NNOOTT install fuse at this time.

2. PPOOSSIITTIIVVEE BBAATTTTEERRYY CCAABBLLEE AANNDD VVOOLLTTAAGGEE SSEENNSSIINNGG WWIIRREE

a. Route positive cable with voltage sensing wire from TriPac to fuse holder.

b. Cut battery cable to length and strip 1/2 to 3/4 in. (13 to 19 mm) of insulation from cable end.

c. Slide heat shrink tubing and terminal ring with ssmmaallll hhoollee onto end of cable. Attach terminal ring firmly to cable

d. Position heat shrink tubing to cover exposed wires on terminal ring and use a heat gun to shrink tubing in place.

e. Install cable onto fuse holder stud and only hand tighten nut.

f. Cut voltage sensing wire to length, strip end, attach in-line fuse with splice connector.

g. Slide heat shrink tubing and terminal ring onto other end of in-line fuse. Attach terminal ring firmly to wire.

h. Position heat shrink tubing to cover exposed wires on terminal ring and use a heat gun to shrink tubing in place.

This wire will be attached in the step 3.

3. SSHHOORRTT PPOOSSIITTIIVVEE BBAATTTTEERRYY CCAABBLLEE

a. Fabricate short cable (from the excess positive cable) that reaches from the battery positive terminal to fuse

holder and strip 1/2 to 3/4 in. (13 to 19 mm) of insulation from cable ends.

b. Slide heat shrink tubing and terminal ring with ssmmaallll hhoollee onto end of cable. Attach terminal ring firmly to cable.

c. Slide heat shrink tubing and terminal ring with llaarrggee hhoollee onto other end of cable. Attach terminal ring firmly to

cable.

d. Position heat shrink tubing to cover exposed wires on terminal rings and use a heat gun to shrink tubing in

place.

e. Install battery cable end with ssmmaallll hhoollee terminal ring followed by the voltage sensing wire onto the fuse holder

stud and only hand tighten nut.

f. Install battery cable end with llaarrggee hhoollee terminal ring connector onto the battery’s PPOOSSIITTIIVVEE (+) connection and

tighten securely.

g. Apply Superlube (PN 203-524) onto the battery’s connection.

4. NNEEGGAATTIIVVEE BBAATTTTEERRYY CCAABBLLEE

a. Route negative cable from TriPac to tractor’s negative battery, cut to length and strip 1/2 to 3/4 in. (13 to 19 mm)

of insulation from cable end.

b. Slide supplied heat shrink tubing and terminal ring onto end of cable. Attach terminal ring firmly to end of cable.

c. Position heat shrink tubing to cover exposed wires on terminal ring and use a heat gun to shrink tubing in place.

d. Install negative cable terminal lug onto the battery’s NNEEGGAATTIIVVEE (-) connection and tighten securely.

e. Apply Superlube (PN 203-524) onto the battery’s connection.

5. FFUUSSEE

a. Remove nuts from fuse holder and place fuse onto the studs and on top of sensing wire and battery cables lugs,

then reinstall nuts.

TK 55676-19-IM-EN

77

FFuussee HHoollddeerr aanndd AAPPUU BBaatttteerryy CCoonnnneeccttiioonnss

b. Tighten the nuts to 120 in-lb (13.5 N•m) and close the fuse holder cover securely.

78

TK 55676-19-IM-EN

Priming the Heater Fuel Pump (Heat Option)

IImmppoorrttaanntt:: It is important the heater fuel pump be primed before attempting to operate the heater for the first time.

Failure to prime the pump will cause the unit to shutdown, set diagnostic codes and cause damage to the
fuel pump.

Special Tools Required

Heater Priming Harness (204-1144)

NNoottee:: Verify there is a sufficient amount of fuel in the fuel tank before beginning the priming procedures.

The heater uses a pulse style fuel pump. You must use the heater priming harness to operate the fuel pump to prime
the system. Applying continuous power to the pump will not work

1. Attach the HHeeaatteerr PPrriimmiinngg HHaarrnneessss connector to the heater fuel pump.

2. Attach the alligator clips to the battery:

• RREEDD to((++)) PPoossiittiivvee BBaatttteerryy CCoonnnneeccttiioonn

• BBLLAACCKK to((––)) NNeeggaattiivvee BBaatttteerryy CCoonnnneeccttiioonn

3. Turn the priming harness switch to the ““OONN”” position.

4. The flasher unit will operate the fuel pump (ON/OFF/ON/OFF) to prime the system.

5. Allow the system to operate for approximately 5 minutes to bleed air from the fuel lines.

NNoottee:: RRuunnnniinngg tthhee ffuueell ppuummpp lloonnggeerr tthhaann 55 mmiinnuutteess wwiillll ccaauussee tthhee hheeaatteerr ttoo eemmiitt eexxcceessssiivvee wwhhiittee ssmmookkee

wwhheenn ooppeerraatteedd..

6. Check fuel lines and system for leaks.

7. Turn the priming harness switch to the ““OOFFFF”” position. Disconnect the positive and then the negative battery
connections.

8. Disconnect the priming harness connector from the heater fuel pump.

9. Attach the heater fuel pump harness onto the heater fuel pump.

Figure 44. Heater Fuel Pump Priming Harness Connections.

TK 55676-19-IM-EN

79

Heater Start-Up Procedures

NNoottee:: See Operating and Diagnostic Manual TK 53024-19-OD for further diagnosis and service procedures if needed.

Special Tools Required

Heater Diagnostic Tool (204-1143)

Diagnostic Tool Overview

The diagnostic tool is used to read out, display and delete faults stored in the heater's electronic control box. It may also
be used to start and run the heater.

• The test duration is limited to a maximum of 120 minutes.

• The electronic control box can store up to 5 faults.

• The current fault is displayed as "AF" and a 2-digit number and is always written in memory location F1.

• The stored faults "F1" to "F5" can be queried.

• The four keypads are used to operate the Diagnostic Tool.

Figure 45. Heater Diagnostic Tool

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Connecting Diagnostic Tool

1. Connect only the 2-pin connector ((RReedd,, BBrroowwnn)) heater power wire (installed earlier in the control box) to mating
connector (J9) on the interface board.

NNoottee:: DDOO NNOOTT connect the 14-pin connector at this time. It will be connected after the Heater Start-Up Procedures have

been completed.

2. Connect the adapter harness to the Diagnostic Tool.

3. Connect the 8-pin diagnostic connector to the mating connector located on the heater harness inside the sleeper
near the heater.

NNoottee:: The two remaining adapter harness connectors shown in the illustration are not used.

Figure 46. Diagnostic Tool Connections to Heater

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Perform the Start-Up

AAuuttoommaattiicc DDeetteeccttiioonn — Five seconds after the diagnostic tool has been connected to the heater using the adapter
cable, the automatic detection starts to determine the type of heater to which the diagnostic unit is connected.

NNoottee:: If the automatic detection was successful, if necessary, the heater is briefly started and then switches off again.

• Display until the automatic detection is completed.

• Heater Icon will display when heater has been detected.

• Confirm flashing symbol with the confirmation button.

Possible Displays:

• If no errors/faults exist go to Heater Start-up.

• If errors/faults exist go to Clearing Faults.

• Communication error exist Go to Unable to Perform the Diagnosis.

Heater Start-Up —The heater will begin a four minute start up process:

• Blower will start slow and heater will ignite.

• Heat and blower will ramp up to high boost mode.
With the heater operating check the following:

• Exhaust and intake hoses are installed and functioning correctly.

• Heat is blowing out of the heat duct inside the sleeper.

Press confirmation button to stop heater.

• Heater will begin a four-minute cool-down mode.
Disconnect Diagnostic Unit from the heater harness and connect the 14-pin
heater harness connector to the interface board (J13).

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Clearing Faults

DDiissppllaayy ccuurrrreenntt ffaauulltt iinn ffaauulltt mmeemmoorryy

Simultaneously press the backward and forward control buttons to display active
or current faults in memory.

Display: e.g. AF: 12

Display fault memory F1 – F5

Press either the backward or forward control buttons to display any faults in
memory.

HHeeaatteerr SSttaarrtt--UUpp PPrroocceedduurreess

Display: e.g. F1: 20

Record all fault codes. Refer to the diagnostic manual for an explanation of fault
code diagnosis.

Display current fault in fault memory again.

Simultaneously press the backward and forward control buttons to display active
or current faults in memory.

Display: e.g. AF: 12

Delete the fault memory and as a result, at the same time cancel the control box
lock.

Current fault or fault F1 – F5

Press confirmation button to clear all faults and cancel control box lock.

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dEL will display

Press confirmation button again to confirm deletion.
The fault memory is deleted and the control box is unlocked.

Continue with Heater Start-Up or Diagnosis.

QQuuiitt SSttaarrtt--UUpp

Switch Off Heater
Press confirmation button, heater is switched off.

PPeerrffoorrmm tthhee DDiiaaggnnoossiiss AAggaaiinn

Press activation button, display is activated.

UUnnaabbllee ttoo PPeerrffoorrmm tthhee DDiiaaggnnoossiiss

Automatic detection was unsuccessful.
Display if the automatic detection was not successfully completed.

Possible causes:

• Diagnostic harness not connected to heater harness

• Adapter plug not seated in diagnostic harness

• Defective diagnostic cable

• Defective heater.

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A/C System Charging and APU Engine Start-up
Procedures

This is a multi-step procedure consisting of:

a. adding a partial refrigerant charge to the system

b. verifying APU engine has the proper amount of oil

c. bleeding air from the APU cooling system

d. bleeding air from the APU fuel lines

e. running the APU with the A/C operating and adjusting the engine rpm’s

f. system fluids leak check

g. verifying alternator output voltage

h. adding a full refrigerant charge to the system

Adding Refrigerant Charge

IImmppoorrttaanntt:: Before starting the APU engine, oil and coolant levels must be checked to prevent damage to the engine

and the A/C system must have a partial charge of refrigerant added to prevent damage to the A/C
compressor. See “Bleeding the Coolant System” and “Bleeding the Fuel Lines” before adding a partial
refrigerant charge.

Special Tools Required

R134a Refrigerant

Scale

1. Connect refrigerant bottle to gauge manifold and place it on the scale.

2. Open refrigerant bottle valve for liquid and purge the charging line.

3. Keep the low pressure side valve of the gauge manifold closed. Open the high pressure side valve.

4. Add refrigerant until reaching 1 lb. 8 oz. of R-134a.

5. Close refrigerant bottle valve and the high side valve of the gauge manifold.

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APU Engine Start-up Procedures

IImmppoorrttaanntt:: To avoid damage to the APU engine and A/C compressor, verify the APU engine has proper amount of oil

and the A/C system has a partial refrigerant charge bbeeffoorree starting the engine.

IImmppoorrttaanntt:: Units equipped with the Closed Loop Cooling Option only - Check sight glass on overflow tank to confirm

coolant level before starting the APU’s engine.

TriPac APU Oil Specifications

Oil Capacity 4.5 qts.(including filter) 6.5 qts. Maximum

Oil Type 10W-30 for temperatures at or above -13 F (-25 C)

5W-30 for temperatures at or below -13 F (-25 C)

Bleeding the Coolant System – APU’s Equipped with Traditional
Tractor Coolant Integration

1. Verify AAPPUU OOUUTTLLEETT hand valve is CCLLOOSSEEDD (tractor inlet, next to water pump). If this valve is left open, coolant will
be sitting on top of the TriPac thermostat and not allow the TriPac engine to bleed air.

2. Open the AAPPUU IINNLLEETT hand valve.

3. Place a clean container under the bleed line to catch coolant that is drained.

4. Open the bleed petcock on the APU engine to allow air to bleed out.

5. When a steady stream of coolant flows from the bleed line, close the petcock.

6. Open the AAPPUU OOUUTTLLEETT hand valve.

7. Replace drained coolant from the TriPac back into the tractor’s radiator.

8. Bleed TriPac fuel system. See “Bleeding the Fuel Lines”.

IImmppoorrttaanntt:: Verify the APU engine has proper amount of oil and the A/C system has a partial refrigerant charge

before starting the engine.

NNoottee:: See “Service Run-In Test” before performing the Run-in Procedures.

9. Start the TriPac engine.

10. The remaining air in the system will be forced to the tractor radiator and the TriPac APU should now be bled of all
air.

Bleeding the Coolant System – APU’s Equipped with Closed Loop
Cooling Option

IImmppoorrttaanntt:: Do not start the engine without bleeding the air out of the engine block. If an engine runs with air trapped in

the block, the engine may be damaged. The high water temperature switch may not protect an engine that
has air trapped in the block, because the high water temperature switch is designed to protect an engine
from overheating due to failures in the cooling system and the loss of coolant.

Often when a TriPac unit cooling system is refilled, air is trapped in the engine block and/or under the thermostat. Use
the following procedure to bleed air out of the block and the cooling system:

1. Place a clean container under the TriPac bleed line to catch the coolant that is drained.

2. Open bleed petcock on the TriPac engine to allow air to bleed out.

NNoottee:: Units built prior to September 2006 have the bleed petcock on top of the thermostat housing. On theses units,

remove the water pump bleeder bolt and bleed the air until there is a stead stream of coolant. Then reinstall the
water pump bleeder bolt.

3. Slowly pour coolant into the expansion tank until a steady stream of coolant flows from the bleed line, then close
the bleed petcock.

4. Slowly pour coolant to the expansion tank until the coolant level is at the top of the window in the expansion tank.

5. Install the expansion tank cap.

6. Bleed the TriPac fuel system. See “Bleeding the Fuel Lines”.

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IImmppoorrttaanntt:: Verify the APU engine has proper amount of oil and the A/C system has a partial refrigerant charge before

starting the engine.

7. Start the TriPac engine and use a non-contact thermometer pointed at the water pump bleeder bolt to monitor the
coolant temperature. The water pump bleeder bolt located next to the bleed petcock on the water pump.

8. When the temperature reaches 150 F (66 C) for units with a 160 F (71 C) thermostats, or 170 F (76 C) for units with
180 F (82 C) thermostats, shut off the engine for 2 minutes to allow the thermostat to heat soak and open completely
to purge air out of block, head, and water pump.

9. After 2 minutes, re-start the engine.

10. Remove the expansion tank cap and slowly pour coolant to the expansion tank until the coolant level is at the top of
the window in the expansion tank, then reinstall the expansion tank cap.

Repeat steps 8 through 10 until the coolant level stabilizes. The TriPac APU cooling system should now be bled of all air.

Figure 47. Water Pump Bleeder Bolt and Bleed Petcock Locations Shown

TK 55676-19-IM-EN

1. Water Pump Bleeder Bolt 2. Bleed Petcock

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Fuel Return Line Fitting

Engine Speed Adjustment Screw

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Bleeding the Fuel Lines

1. Locate the On/OFF switch inside the APU and turn the switch “ON”.

2. Crack open the fuel return line banjo fitting on the APU engine.

3. At the HMI:

a. press MAIN POWER Key “ON”

b. press APU SYSTEM Key “ON”

c. press MODE Key to “AC”

d. press FAN Key to set fan speed

e. press UP or DOWN Keys to set the thermostat to 50 F (10 C)

f. multiple start attempts will be required to start the engine.

NNoottee:: The fuel pump only runs when the engine is turning over. If the engine cranks for 30 seconds and fails to start,

a start fault shutdown will be generated. This alarm code will have to be cleared before attempting another
start sequence.

4. Close the fuel return line banjo fitting when a steady flow of fuel is observed.

5. Allow engine to start.

Figure 48. Fuel Return Line Fitting and Engine Speed Adjustment Screw Shown

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Verifying Engine Operation

YOU MUST VERIFY AND ADJUST ENGINE RPM’S

IMPORTANT

EEnnggiinnee RRPPMM AAddjjuussttmmeenntt PPrroocceedduurree

NNoottee:: See Engine RPM Adjustment tag attached to APU engine or procedure below.

1. Start APU/Engine

2. Adjust engine speed to 2400–2500 RPM RPMs

3. Allow engine to reach operating temperature.

4. Add compressor and alternator load to the engine, adjust engine speed to 2350 RPMs

Figure 49. Engine RPM Adjustment Tag Shown

With the engine running:

• check cooling system for leaks

• check for fuel leaks

• check for oil leaks

• check for exhaust leaks

• verify with a digital meter that the charging voltage at the battery cables is at least 13.6 Vdc.

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Unit Setup Procedures

Before performing the Run In Procedure and then release unit to customer, the TriPac EVOLUTION control system must
be setup. You will program the system configuration and programmable features based on unit options and customer
requirements. This procedure will use the TK Monitor communication software that is on the TriPac EVOLUTION
Interface Board.

NNoottee:: For additional information about TK Monitor refer to TK 55739, Section 6, A51A, Communication Using TK

Monitor.

NNoottee:: An Internet connection is not required to operate TK Monitor.

RReeqquuiirreedd TToooollss

• PC computer with Internet Explorer 8 or higher.

• Interconnect cable USB to Mini-B (TK 204-2000)

EEnntteerr TTKK MMoonniittoorr

1. Turn the unit on by pressing the MMooddee button on the HMI (the knob on the left) for 2 seconds.

2. With control box cover removed. Check the green “heartbeat” LED on the Interface Board. It will flash rapidly when
first turned on. After several seconds the flashing rate will slow to the normal rate of one blink per second.

3. Locate the USB Mini-B connector (J39) near the lower right of the Interface Board.

4. Connect the USB interconnect cable to the Interface Board and a laptop computer running Microsoft Windows and
Internet Explorer 8 or higher.

5. Open a “My Computer” window on the computer.

6. Locate and double click on the ““TTKK MMoonniittoorr”” drive. This will open up a window showing about 8 files.

Figure 50. USB Mini-B Connector (J39) Shown

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Figure 51. Window With 8 Drives Shown

7. Double click ““SSTTAARRTT..BBAATT”” to launch TK Monitor.

8. TK Monitor opens as an Internet Explorer window to the DDaasshhbbooaarrdd Screen. On the left is a menu of the different
screens available in TK Monitor. A different screen may be select by mouse-clicking any one of them.

9. Select the UUnniitt SSeettuupp Screen. This screen allows the technician to configure the unit based on installed options and
input unit identification information – an important set up procedure after installation of the unit.

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Figure 52. Unit Setup Screen Shown

IMPORTANT STEPS FOR EACH TRIPAC EVOLUTION INSTALLATION

10. Select AAlltteerrnnaattoorr CCaappaacciittyy. Choose the alternator model installed:

a. 65 Amps (Default)

b. 120 Amps

11. Select EEnnggiinnee CCoooolliinngg Option:

a. SSttaannddaarrdd: The APU engine cooling system is connected to the truck cooling system. Sensor WT2 is mounted on

the pre-cooler coil.

b. SSttaannddaarrdd ++ AArrccttiicc (Default): The APU engine cooling system is connected to the truck cooling system. The

Arctic Option is installed. Sensor WT2 is mounted on the adapter tube in the coolant return line.

c. CClloosseedd LLoooopp: The APU engine cooling system is not connected to the truck cooling system. Closed Loop

Cooling Tank is installed. Sensor WT2 is disconnected or not installed.

12. Enter UUnniitt SSeerriiaall NNuummbbeerr: Record the 10-digit TriPac EVOLUTION unit serial number from the unit identification
plate.

13. Enter UUnniitt IIDD: Enter a unique unit ID number. The truck number is commonly used. Can be any combination of six
letters and numbers. It will help identify data logger downloads

14. Select UUppddaattee UUnniitt SSeettuupp:

a. Setup information will be saved.

b. Controller will restart so selections will take effect.

c. TK Monitor will lose connection and must be restarted.

PPrrooggrraammmmaabbllee FFeeaattuurree SSeettuupp

NNoottee:: The Battery Voltage Restart Value and Real Time Clock should always be set.

The TriPac EVOLUTION system allows customizing of many operating features. Refer to Diagnostic Manual TK 55739,
Section 3, Software for more information about programmable features. Changes directed by the customer should be
made at this time.

15. Restart TK Monitor. Select the PPrrooggrraammmmaabbllee SSeettuupp screen.

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Figure 53. Programmable Setup Screen Shown

16. Set BBaatttteerryy VVoollttaaggee RReessttaarrtt VVaalluuee:

a. Determine truck low voltage alarm setting.

b. Set TriPac Battery Voltage Restart Value to at least 0.2 volts higher than truck alarm setting. (Default 12.2 volts) -

should not be higher than 12.4 volts.

c. TriPac EVOLUTION Unit Setup Procedures

17. Make any customer directed changes to other programmable settings.

18. Set Real Time Clock:

a. Click on the Set System Clock check box.

b. The Real Time Clock will be set to the time on the connected computer.

19. Select UUppddaattee SSeettuupp:

a. Setup information will be saved.

b. Controller will restart so selections will take effect.

c. TK Monitor will lose connection and must be restarted.

Service Run-In Test

Before delivery of a TriPac EVOLUTION unit to the customer it must complete a 10 hour run-in with the engine under
load. The Run-In Test in the Service Test screen will cause both the air conditioning system (using a low temperature
setpoint) and the heating system (using a high temperature setpoint) to run for 10 hours.

NNoottee:: For additional information about TK Monitor refer to Diagnostic Manual TK 55739, Section 6, A51A,

Communication Using TK Monitor.

1. Verify there is sufficient fuel in the fuel tank to operate the system for 10 hours.

2. CClloosseedd LLoooopp CCoooolliinngg OOppttiioonn OOnnllyy - Place a clean container under the overflow hose of the APU’s overflow tank.
This is to catch any coolant that may be expelled during the initial 10 hour engine run-in.

3. Start TK Monitor. Select SSeerrvviiccee TTeesstt from the menu.

4. On the Service Test Screen select RRuunn IInn Test.

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5. Select the RRuunn TTeesstt button.

6. The APU engine will start and heater will ignite.

NNoottee:: Do not start truck after Service Test is initiated or the run in test will terminate.

7. Disconnect computer from the interface board – it is not required to complete the test. This test will stop
automatically at the end of 10 hours.

8. A shutdown alarm will display on the HMI.

9. Reconnect computer and start TK Monitor.

10. Go to the Alarm screen.

11. Clear the code 54, Test Mode Timeout.

12. If any other alarms are listed diagnose and repair as required. Refer to Diagnostic Manual TK 55739, Section 5,
Diagnostics.

13. Check engine oil level. Add oil as required.

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System Check List

APU Mounting Bolts Positioned, Tightened and Torqued to Specs.

Coolant Hoses Routed and Secured Properly

Condenser Mounting Bolts Secured and Sealed with Silicone

A/C Receiver Drier Mounting Bolts Secured

A/C Evaporator Mounting Bolts Secured

Evaporator Drain Tube Water Valves (Kazoos) Installed

A/C Refrigeration Tubing Routed and Secured

All Wiring Harnesses Routed, Connected and Secured

A/C System Charged, Free of Leaks and Operates Correctly

Heater Intake and Exhaust Hoses Routed Safely and Secured

Heater System Operates Correctly

All Fuel Lines are Routed Safely and Secured

All Fuel Line Connections are Tight and Leak Free

All Guards, Covers and Grilles Installed Securely

3” access hole in the sleeper floor is completely caulked from both inside and underneath

Verified any unused holes in the sleeper floor are completely sealed closed with caulking

All System Run-In Procedures Performed

Coolant Levels for Truck and APU are Topped Off

Unit Operated For 10 Hours

Thoroughly Clean and Vacuum Interior of Sleeper

Release to Customer

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Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainable
transport temperature control solutions. Thermo King has been providing transport temperature control solutions
for a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since

1938. For more information, visit www.thermoking.com or www.tranetechnologies.com.

Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications
without notice. We are committed to using environmentally conscious print practices.

TK 55676-19-IM-EN 28 Nov 2020

Supersedes TK 55676-19-IM (Rev.4)-EN (February 2015) ©2020 Trane Technologies