trailer edition precedent™ - thermo king...©2020tranetechnologies tk55774-2-im-en introduction...

Revision A

August 2018 TTKK 5555777744--22--IIMM--EENN

Trailer EditionPrecedent™Multi-Temperature Systems

IInnssttaallllaattiioonn MMaannuuaall ((BB))C-600M, S-610M and S-610DE Remote Evaporator Installation

Installation Manual

©2020 Trane Technologies TK 55774-2-IM-EN

IntroductionInstallation Manual (A) TK 55745 covers the installation of the Host Unit. This manual was written to assist with theinstallation of the remote evaporators and the necessary procedures required to complete the Thermo King Precedentmulti-temperature installation onto trailers specifically designed and built for refrigerated applications.

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

• Are an experienced mechanic

• Can safely lift 34 kilos (75 lbs.)

• Are certified or trained in the repair and maintenance of diesel powered refrigeration systems

• Have a basic understanding of electricity and electrical wiring

• Have the necessary tools and equipment to complete the installation

OPTIONS: Installation instructions for Thermo King optional equipment are available on line @thermoking.com oriService.

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

TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aappppllyy ttoo aannyy eeqquuiippmmeenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rreeppaaiirreeddoorr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..””

MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyyootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorraannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouullddoonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauusseeddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..

Revision HistoryRevision A (08/18) Released new manual format.

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TK 55774-2-IM-EN 3

SSaaffeettyy PPrreeccaauuttiioonnss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 55Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Battery Installation and Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Refrigerant Oil Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

First Aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

PPrreecceeddeenntt MMuullttii--TTeemmppeerraattuurree SSeelleeccttiioonn GGuuiiddee .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 99

RReeqquuiirreedd TToooollss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1111

RReeccoovveerriinngg HHoollddiinngg CChhaarrggee ffrroomm HHoosstt UUnniitt .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1122

IImmppoorrttaanntt IInnssttaallllaattiioonn RReeqquuiirreemmeennttss.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1144

IInnssttaalllliinngg EEvvaappoorraattoorrss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2244Ceiling Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Mounting Stud or Bolt Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

HHoosstt TTuubbee CCoonnnneeccttiioonnss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2255Single and Multiple Evaporator Configurations (except X, Y and Z). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Configuration X Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Configuration Y Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Configuration Z Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

EEvvaappoorraattoorr TTuubbee CCoonnnneeccttiioonnss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 3333S-3 – Two Compartment Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

S-3 – Three Compartment Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

S-3 + S-3 – Two Compartment Trailers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

S-3 + S-3 – Configuration X Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Zone 2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Zone 3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

S-3 + S-3 – Configuration Y Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Zone 2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Zone 3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

S-3 + S-3 – Configuration Z Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Zone 2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Zone 3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

WWiirree CCoonnnneeccttiioonnss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 5511Host and Evaporator Wire Connections – Zone 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Zone 2 – Single Evaporators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Table of Contents

4 TK 55774-2-IM-EN

Zone 2 – Parallel Evaporators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Host and Evaporator Wire Connections – Zone 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Zone 3 – Single Evaporators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Zone 3 – Parallel Evaporators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

DE Host and Evaporator Wire Connections – Zone 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Zone 3 – Single Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

DDrraaiinn HHoossee RReessiissttaannccee WWiirree IInnssttaallllaattiioonn GGuuiiddee .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 5577

DDrraaiinn HHoossee IInnssttaallllaattiioonn.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6600Single S-3 Applications (Detail I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

For S-3 + S-3 Applications (Detail II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

For Wall Mounted Tube Applications (Detail III). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

For Wall Mounted Channel Applications (Detail IV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Optional Drain Hose Support (Detail V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Front Drain Hose Applications (Detail VI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

LLeeaakk CChheecckk,, EEvvaaccuuaattiioonn aanndd CChhaarrggiinngg PPrroocceedduurreess .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6622Unit Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Leak Check the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Evacuate the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Charge the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

IInnssttaalllliinngg CCaapp PPlluuggss aanndd EEvvaappoorraattoorr CCoovveerrss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6666

DDEE CCrriittiiccaall IInnssttaallllaattiioonn RReeqquuiirreemmeennttss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6688

UUnniitt CChheecckk LLiisstt .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 7700

EEvvaappoorraattoorr DDiimmeennssiioonnss aanndd WWeeiigghhttss .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 7722

TTaabbllee ooff CCoonntteennttss

TK 55774-2-IM-EN 5

Safety PrecautionsDanger, Warning, Caution, and NoticeThermo King recommends that all service be performed by a Thermo King dealer and to be aware of several generalsafety practices.

Safety advisories appear throughout this manual as required. Your personal safety and the proper installation of thisunit 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 unsafepractices.

Indicates a situation that could result in equipment or property-damage only accidents.

General PracticesDDAANNGGEERR

HHaazzaarrddoouuss VVoollttaaggee!!DDaannggeerroouuss tthhrreeee pphhaassee AACC eelleeccttrriicc ppoowweerr iiss pprreesseenntt wwhheenneevveerr tthhee uunniitt iiss ooppeerraattiinngg iinn eeiitthheerr DDiieesseell MMooddee oorrEElleeccttrriicc MMooddee aanndd wwhheenneevveerr tthhee uunniitt iiss ccoonnnneecctteedd ttoo aa ssoouurrccee ooff eexxtteerrnnaall ssttaannddbbyy ppoowweerr.. VVoollttaaggeess ooff tthhiissmmaaggnniittuuddee ccaann bbee lleetthhaall.. EExxeerrcciissee eexxttrreemmee ccaauuttiioonn wwhheenn wwoorrkkiinngg oonn tthhee uunniitt..

DDAANNGGEERRHHaazzaarrdd ooff EExxpplloossiioonn!!NNeevveerr aappppllyy hheeaatt ttoo aa sseeaalleedd rreeffrriiggeerraattiioonn ssyysstteemm oorr ccoonnttaaiinneerr.. HHeeaatt iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh mmiigghhttccaauussee aann eexxpplloossiioonn rreessuullttiinngg iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..

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

DDAANNGGEERRRReeffrriiggeerraanntt VVaappoorr HHaazzaarrdd!!DDoo nnoott iinnhhaallee rreeffrriiggeerraanntt.. UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg wwiitthh rreeffrriiggeerraanntt oorr aa rreeffrriiggeerraattiioonn ssyysstteemm iinn aannyy ccoonnffiinneeddaarreeaa wwiitthh aa lliimmiitteedd aaiirr ssuuppppllyy.. RReeffrriiggeerraanntt ddiissppllaacceess aaiirr aanndd ccaann ccaauussee ooxxyyggeenn ddeepplleettiioonn,, rreessuullttiinngg iinnssuuffffooccaattiioonn aanndd ppoossssiibbllee ddeeaatthh..

DDAANNGGEERRRRiisskk ooff IInnjjuurryy!!KKeeeepp yyoouurr hhaannddss,, ccllootthhiinngg,, aanndd ttoooollss cclleeaarr ooff ffaannss aanndd//oorr bbeellttss wwhheenn wwoorrkkiinngg oonn aa uunniitt tthhaatt iiss rruunnnniinngg oorr wwhheennooppeenniinngg oorr cclloossiinngg ccoommpprreessssoorr sseerrvviiccee vvaallvveess.. LLoooossee ccllootthhiinngg mmiigghhtt eennttaannggllee mmoovviinngg ppuulllleeyyss oorr bbeellttss,, ccaauussiinnggsseerriioouuss iinnjjuurryy oorr ppoossssiibbllee ddeeaatthh..

6 TK 55774-2-IM-EN

WWAARRNNIINNGGHHaazzaarrdd ooff EExxpplloossiioonn!!NNeevveerr cclloossee tthhee ccoommpprreessssoorr ddiisscchhaarrggee sseerrvviiccee vvaallvvee wwhheenn tthhee uunniitt iiss ooppeerraattiinngg.. NNeevveerr ooppeerraattee tthhee uunniitt wwiitthhtthhee ddiisscchhaarrggee vvaallvvee cclloosseedd ((ffrroonntt sseeaatteedd)).. TThhiiss ccoonnddiittiioonn iinnccrreeaasseess iinntteerrnnaall pprreessssuurree,, wwhhiicchh ccaann ccaauussee aanneexxpplloossiioonn..

WWAARRNNIINNGGPPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess wwhheenn wwoorrkkiinngg oonn aa uunniitt.. RReeffrriiggeerraanntt lliiqquuiidd,, ooiill,, aanndd bbaatttteerryy aacciidd ccaannppeerrmmaanneennttllyy ddaammaaggee yyoouurr eeyyeess.. SSeeee ““FFiirrsstt AAiidd””..

WWAARRNNIINNGGEEqquuiippmmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!NNeevveerr ddrriillll hhoolleess iinnttoo tthhee uunniitt uunnlleessss iinnssttrruucctteedd bbyy TThheerrmmoo KKiinngg.. HHoolleess ddrriilllleedd iinnttoo hhiigghh vvoollttaaggee ccaabblleess ccoouullddccaauussee aann eelleeccttrriiccaall ffiirree,, sseevveerree ppeerrssoonnaall iinnjjuurryy,, oorr eevveenn ddeeaatthh..

WWAARRNNIINNGGRRiisskk ooff IInnjjuurryy!!WWhheenn uussiinngg llaaddddeerrss ttoo iinnssttaallll oorr sseerrvviiccee rreeffrriiggeerraattiioonn ssyysstteemmss,, aallwwaayyss oobbsseerrvvee tthhee llaaddddeerr mmaannuuffaaccttuurreerr’’ssssaaffeettyy llaabbeellss aanndd wwaarrnniinnggss.. AA wwoorrkk ppllaattffoorrmm oorr ssccaaffffoollddiinngg iiss tthhee rreeccoommmmeennddeedd mmeetthhoodd ffoorr iinnssttaallllaattiioonnss aannddsseerrvviicciinngg..

NNOOTTIICCEEEEqquuiippmmeenntt DDaammaaggee!!AAllll mmoouunnttiinngg bboollttss mmuusstt bbee tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aapppplliiccaattiioonnss aanndd ttoorrqquueedd ttoo ssppeecciiffiiccaattiioonn.. IInnccoorrrreecctt bboollttlleennggtthhss aanndd iimmpprrooppeerr ttoorrqquuee ssppeecciiffiiccaattiioonnss ccaann ddaammaaggee eeqquuiippmmeenntt..

Battery Installation and Cable Routing

WWAARRNNIINNGGHHaazzaarrdd ooff EExxpplloossiioonn!!AAnn iimmpprrooppeerrllyy iinnssttaalllleedd bbaatttteerryy ccoouulldd rreessuulltt iinn aa ffiirree,, eexxpplloossiioonn,, oorr iinnjjuurryy.. AA TThheerrmmoo KKiinngg aapppprroovveedd bbaatttteerryymmuusstt bbee iinnssttaalllleedd aanndd pprrooppeerrllyy sseeccuurreedd ttoo tthhee bbaatttteerryy ttrraayy..

WWAARRNNIINNGGHHaazzaarrdd 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,, oorrrroottaattiinngg ccoommppoonneennttss..

WWAARRNNIINNGGFFiirree HHaazzaarrdd!!DDoo nnoott aattttaacchh ffuueell lliinneess ttoo bbaatttteerryy ccaabblleess oorr eelleeccttrriiccaall hhaarrnneesssseess.. TThhiiss hhaass tthhee ppootteennttiiaall ttoo ccaauussee aa ffiirree aannddccoouulldd ccaauussee sseerriioouuss iinnjjuurryy oorr ddeeaatthh..

WWAARRNNIINNGGHHaazzaarrdd ooff EExxpplloossiioonn!!AAllwwaayyss ccoovveerr bbaatttteerryy tteerrmmiinnaallss ttoo pprreevveenntt tthheemm ffrroommmmaakkiinngg ccoonnttaacctt wwiitthh mmeettaall ccoommppoonneennttss dduurriinngg bbaatttteerryyiinnssttaallllaattiioonn.. BBaatttteerryy tteerrmmiinnaallss ggrroouunnddiinngg aaggaaiinnsstt mmeettaall ccoouulldd ccaauussee tthhee bbaatttteerryy ttoo eexxppllooddee..

SSaaffeettyy PPrreeccaauuttiioonnss

TK 55774-2-IM-EN 7

CCAAUUTTIIOONNHHaazzaarrddoouuss SSeerrvviiccee PPrroocceedduurreess!!SSeett aallll uunniitt eelleeccttrriiccaall ccoonnttrroollss ttoo tthhee OOFFFF ppoossiittiioonn bbeeffoorree ccoonnnneeccttiinngg bbaatttteerryy ccaabblleess ttoo tthhee bbaatttteerryy ttoo pprreevveennttuunniitt ffrroomm ssttaarrttiinngg uunneexxppeecctteeddllyy aanndd ccaauussiinngg ppeerrssoonnaall iinnjjuurryy..

NNOOTTIICCEEEEqquuiippmmeenntt 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

WWAARRNNIINNGGPPeerrssoonnaall 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

WWAARRNNIINNGGPPeerrssoonnaall PPrrootteeccttiivvee EEqquuiippmmeenntt ((PPPPEE)) RReeqquuiirreedd!!PPrrootteecctt yyoouurr eeyyeess ffrroomm ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TThhee ooiill ccaann ccaauussee sseerriioouuss eeyyee iinnjjuurriieess.. PPrrootteecctt sskkiinn aannddccllootthhiinngg ffrroomm pprroolloonnggeedd oorr rreeppeeaatteedd ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt ooiill.. TToo pprreevveenntt iirrrriittaattiioonn,, wwaasshh yyoouurr hhaannddss aannddccllootthhiinngg tthhoorroouugghhllyy aafftteerr hhaannddlliinngg tthhee ooiill.. RRuubbbbeerr gglloovveess aarree rreeccoommmmeennddeedd..

First AidRREEFFRRIIGGEERRAANNTT

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

• 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. Washcontaminated clothing before reuse.

• IInnhhaallaattiioonn:: Move victim to fresh air and use CPR (cardio pulmonary resuscitation) or mouth-to-mouth resuscitationto 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 irritationpersists.

• IInnhhaallaattiioonn:: Move victim to fresh air and use CPR (cardio pulmonary resuscitation) or mouth-to-mouth resuscitationto 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 irritationpersists.

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


8 TK 55774-2-IM-EN

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 powercannot be shut off, the wire should be cut with an non-conductive tool, such as a wood-handle axe or thickly insulatedcable cutters. Rescuers should wear insulated gloves and safety glasses, and avoid looking at wires being cut. Theensuing 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 fromcurrent flowing through the victim’s body. After separating the victim from power source, immediately check for signsof 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.


TK 55774-2-IM-EN 9

Precedent Multi-Temperature Selection Guide

10 TK 55774-2-IM-EN

NNootteess

TK 55774-2-IM-EN 11

Required Tools

NNoottee:: Equipment such as scales, gauges, refrigerant leak detectors and torque wrenches must be in good workingcondition and routinely calibrated to assure accurate readings.

1. Safety Glasses

2. Tape Measure

3. Screwdrivers – Phillips and Straight Blade

4. Drill and Drill Bits

5. Hole Saw

6. Torque Wrench

7. Box and Open Wrenches – 7/16”, 1/2”, 9/16’. 5/8” and 3/4”

8. 12” Adjustable Wrench

9. Crow’s Feet – 7/8” 1” and 1–3/8”

10. Tap and Die Set (Europe Only)

11. Wire Stripper

12. Wire Crimper – for Insulated Terminals

13. Electronic Leak Detector

14. Tube Benders

15. Tube Cutter

16. Tube Swages

17. Tube Brushes

18. Scotch Brite Pads

19. Torch Set

20. 15% Solder (203–364 and Flux (203–365)

21. Heat Shield

22. Manifold Set

23. Evacuation Station (TK 204–725)

24. Reclaiming Station

25. Refrigerant Oil

26. Refrigerant and Scale

27. Dry Nitrogen

28. Battery Charger (60 Amp Minimum)

29. Mechanical Lift (modified drywall lift)

12 TK 55774-2-IM-EN

Recovering Holding Charge from Host Unit

Precedent Multi-Temperature Host Units are shipped with a 35 kPa (5 psi) holding charge of R-404A refrigerant. Thisholding charge of approximately 1 kg (2 lbs.) of refrigerant must be recovered.

IImmppoorrttaanntt:: SSEEVVEERREE CCOOMMPPRREESSSSOORR DDAAMMAAGGEE will result from operating the host unit’s engine before completing theentire system installation which includes:

• Recovering the holding charge of R-404A from the host unit

• Releasing the holding charge of nitrogen from the remote evaporators

• Connecting and soldering all refrigeration tubing from the host unit to the remote evaporators

• Leak testing the system

• Evacuation and clean-up of system

• Charging the system with refrigerant.

NNoottee:: The host unit must be placed in the Evacuation Mode to open the normally closed solenoid valves throughoutthis procedure. See “Leak Check, Evacuation and Charging Procedures,” p. 62.

1. Set refrigerant device to recover R-404A vapor.

2. Recover refrigerant vapor from the host unit to 0 kPa (0 psi) from the receiver outlet valve and suction service valve.

3. Remove the manifold gauge lines from the receiver outlet valve and suction service valve. Leave service valvesopen to port to acts as vents.

Make sure holding charge from host unit has been recovered before proceeding to prevent personal injury!

NNoottee:: It is important to minimize the amount of time the refrigeration tubes are uncapped and open to ambientconditions. Always keep the tubes capped until ready to connect and solder refrigeration lines.

4. Unsolder caps from the hot gas, liquid, and suction tubes on the host unit.

NNoottee:: ONLY remove the caps from both suction tubes if required for your application.

TK 55774-2-IM-EN 13

RReeccoovveerriinngg HHoollddiinngg CChhaarrggee ffrroomm HHoosstt UUnniitt

14 TK 55774-2-IM-EN

Important Installation Requirements

EEVVAAPPOORRAATTOORR LLOOCCAATTIIOONN

• The best air flow is achieved when the evaporator is installed an equal distance from each side wall.

• It is recommended that moving bulkheads not be allowed closer than 1229.4 mm (48.4 in.) or 1 pallet + 4.00 inchesfrom the evaporator ((DDeettaaiill II)).

• The minimum clearance from the bottom of to the top of the cargo and all sides of the evaporator except theevaporator outlet should be 101 mm (4.00 in.) ((DDeettaaiill II)).

NNoottee:: This minimum clearance does not refer to the trailer LOAD LINE.

• The evaporator should be located a minimum of 51 mm (2.00 in.) from the trailer wall ((DDeettaaiill IIIIII)).

DDEEFFRROOSSTT DDRRAAIINNSS

• The defrost drain tube should be offset 35.5 mm (1.4 in.) from the mounting holes ((DDeettaaiill IIII)).

• The evaporator must be properly mounted to provide a slope towards the drain. This is accomplished by addingone 3/8 in. and one 3/16 in. washers on the drain side and only one 3/8 in. washer on the other side at eachmounting surface ((DDeettaaiill IIIIII)).

• Defrost drains must exit the evaporator at a 45° angle and have a minimum downward gradient of 267 mm (10.50in.) from the trailer ceiling to the top of the drain in the trailer wall ((DDeettaaiill IIIIII)).

WWAALLLL DDRRAAIINN TTUUBBEE RREEQQUUIIRREEMMEENNTTSS –– ((DDeettaaiillss IIII aanndd IIIIII))

• Drain Tubes should be made of CPVC (Chlorinated Polyvinyl Chloride) thermoplastic.

• Drain Tubes should be 1.00 in ID (inside diameter)

EELLEECCTTRRIICCAALL WWIIRRIINNGG

IImmppoorrttaanntt:: DO NOT CUT THE SENSOR HARNESSES!

• All electrical harnesses must secured by clamps at least every 600 mm (24.00 in).

• Additional harnesses (options, etc.) can be secured with tie bands to the harness that are secured with clamps.

TK 55774-2-IM-EN 15

IImmppoorrttaanntt IInnssttaallllaattiioonn RReeqquuiirreemmeennttss

16 TK 55774-2-IM-EN

TTRROOUUGGHH LLOOCCAATTIIOONN –– ((DDeettaaiillss IIVV-- VVIIII))

• The OEM and Dealer should discuss trough locations based on application before the trailer is built.

• Only one trough is required.

• The trough should be located in such a way as to allow for proper routing of the suction tube(s). Three compartmenttrailers may have two suction tubes in the trough.

• A ceiling trough is recommended. If that is not possible, a wall trough should be located to allow the lowest suctiontube to be at least 25 mm (1.00 in.) above the remote evaporator suction fitting once secured to the trough.

RREEFFRRIIGGEERRAANNTT TTUUBBIINNGG aanndd CCOONNNNEECCTTIIOONNSS

• Thermo King requires the use of bulk rolled refrigeration grade tubing and tube benders to reduce fittings andsolder joints where applicable.

• The use of large radius bends is preferred over copper fitting joints.

• It is important to minimize the amount of time the refrigeration tubes are uncapped and open to ambient conditions.Always keep tubes capped until ready to connect and solder.

• Always check tubes and copper fittings for obstructions prior to assembly and soldering.

• The use of 15% silver solder for joining all remote refrigeration tubes is required.

• Suction and liquid tubes are to be insulated when outside the trough. Hot gas tubes are to be 100% insulated.

• All refrigeration tubing must be secured by clamps at least every 600 mm (24.00 in.).

• All dual evaporator installations require two suction tubes ((DDeettaaiillss VV aanndd VVIIII)).

• Configuration X installations require two suction tubes: 1–1/8 in. for Zone 2 and 7/8 in. for Zone 3.

• Configuration Y installations require two suction tubes: 7/8 in. for Zone 2 and 1–1/8 in. for Zone 3.

• Configuration Z installations require 1–1/8 in. suction tubes for both Zone 2 and Zone 3.

• All soldering of tubes should be done according to the best practices solder document, Section 16 of the Certi-TechProfessional Manual.

• It is required that nitrogen or another inert gas be used to purge the tubes while soldering. This prevents oxidationand formation of scale inside tubes.

IImmppoorrttaanntt:: The following procedures should be followed to correctly purge the tubes with nitrogen when soldering.

1. Midseat the suction and discharge service valves on the host unit.

2. On one remote evaporator in each zone, connect a 6 power source to the HGS and SOL terminal strip. This activatesthe Hot Gas Solenoid to allow nitrogen to flow.

3. Connect a nitrogen supply hose to the access port on the same remote evaporator that the power source wasconnected. Make sure the supply hose fitting has a Schrader valve depressor to open the Schrader valve on theaccess port.

4. Adjust the nitrogen flow to 5–10 CFH.

5. The nitrogen supply and 6 volt power source must be maintained while soldering the remote and host unitconnections.


TK 55774-2-IM-EN 17


18 TK 55774-2-IM-EN

HHOOSSTT UUNNIITT RREETTUURRNN AAIIRR

• In lane configurations, care must be taken to avoid the inner walls obstructing return air to the host. Not only is hostperformance impaired, but temperature management will suffer if the return air does not over the return air sensor.

DDOOOORR SSWWIITTCCHHEESS

• Door switches are recommended for all multi-temperature installations. Door switches automatically turn offremote evaporators when the corresponding door is opened. This helps reduce the entry of warm, moist air into theload space.

DDOOOORR CCUURRTTAAIINNSS

• It is always recommended to use a good quality insulated curtains on all doors to help limit the amount of warm,moist air from entering the load space during door openings.

FFUULLLL LLEENNGGTTHH LLAANNEESS

• Always consider using a Precedent DE (Dual Evaporator) unit where full length lanes are required. This is the mostefficient and cost effective solution for these demanding applications, and a product unique to Thermo King.


TK 55774-2-IM-EN 19

9966 iinn.. WWIIDDEE TTRRAAIILLEERR IINNSSTTAALLLLAATTIIOONNMMAATTRRIIXX

NNoottee:: The installation of parallel S3+S3 on a 96” wide trailer may be too tight due to variations of trailer wallthicknesses. Since remote evaporators allow for the drain hose to exit the front, you can install a parallel S3+S3based on the assumptions shown below.

THESE ARE EXAMPLES, NOT SPECIFICATIONS. THE TRAILER OEM AND DEALERS ARE EXPECTED TO VALIDATETHESE CALULATIONS

ASSUMING THE DRAIN IS COMING OUT THE SIDE OF THE EVAPORATOR:

Trailer Width 96” 96” 96” 96” 96”

Wall Thickness 4” 3.5” 3” 2.5” 2”

Difference 88” 89” 90” 91” 92”

Evaporator Clearance from Road Side Wall 2” 2” 2” 2” 2”

Evaporator Clearance from Curb Side Wall 2” 2” 2” 2” 2”

S3+S3 Width 86.81” 86.81” 86.81” 86.81” 86.81”

Space Left –2.81” –1.81” –0.81” 0.19”* 1.19”

S2+S2 Width 59.85” 59.85” 59.85” 59.85” 59.85”

Space Left 24.15” 25.15” 26.15” 27.15” 28.15”

* Not Ideal

ASSUMING THE DRAIN IS COMING OUT THE FRONT OF THE EVAPORATOR:

Trailer Width 96” 96” 96” 96” 96”

Wall Thickness 4” 3.5” 3” 2.5” 2”

Difference 88” 89” 90” 91” 92”

Evaporator Clearance from Road Side Wall 1” 1” 1” 1” 1”

Evaporator Clearance from Curb Side Wall 1” 1” 1” 1” 1”

S3+S3 Width 86.81” 86.81” 86.81” 86.81” 86.81”

Space Left -0.81” –0.19”* 1.19” 2.19” 3.19”

S2+S2 Width 59.85” 59.85” 59.85” 59.85” 59.85”

Space Left 24.15” 25.15” 26.15” 27.15” 28.15”

* Not Ideal

ASSUMING THE DRAIN IS COMING OUT THE FRONT OF THE EVAPORATOR:

Trailer Width 96” 96” 96” 96” 96”

Wall Thickness 4” 3.5” 3” 2.5” 2”

Difference 88” 89” 90” 91” 92”

Evaporator Clearance from Road Side Wall 0.5” 0.5” 0.5” 0.5” 0.5”

Evaporator Clearance from Curb Side Wall 0.5” 0.5” 0.5” 0.5” 0.5”

S3+S3 Width 86.81” 86.81” 86.81” 86.81” 86.81”

Space Left 0.19”* 1.19” 2.19” 3.19" 4.19”

S2+S2 Width 59.85” 59.85” 59.85” 59.85” 59.85”

Space Left 27.15” 28.15” 29.15” 30.15” 31.15”

* Not Ideal


20 TK 55774-2-IM-EN

DDEEFFRROOSSTT DDRRAAIINN TTUUBBEE CCOONNNNEECCTTOORR IINNSSTTAALLLLAATTIIOONN

IImmppoorrttaanntt:: The instructions below must be followed to prevent defrost drain tube water leaks.

All remote evaporators are equipped with quick disconnect fitting that connects the drain pan to the drain tubes ((DDeettaaiillII)).

To properly install the drain tube, make sure that the tube is ffuullllyy inserted past the o-ring and up to the stop inside thecoupler ((DDeettaaiill IIII)).

NNoottee:: The fitting will grip the tube before it seals with the o-ring.

When the tube is in the correct position, the o-ring will seal and the teeth will grip the tube keeping it in place. Check thefit by pulling on the tube(s) to insure that it will not pull out of the fitting ((DDeettaaiill IIIIII)).

To disconnect the tube from the fitting ((DDeettaaiill IIVV)):

1. Press the collet into the fitting.

2. Hold the collet in place and pull the tube out.

NNoottee:: The fitting can be reused. Clean any burrs off the tube before re-inserting it into the fitting.


TK 55774-2-IM-EN 21


22 TK 55774-2-IM-EN

EEVVAAPPOORRAATTOORR CCAAPP PPLLUUGGSS

Cap plugs are provided to plug the two evaporator mounting access holes located directly above the drain pan. Theseplugs must be installed to prevent water in the drain pan from spilling out of these holes and into the cargo area. Seethe following illustration for details.


TK 55774-2-IM-EN 23

TTRRAANNSSVVEERRSSEE DDRRAAIINN KKIITT ((OOppttiioonnaall))

The optional transverse drain kit allows the drain tube to be installed and routed down and out the back of theevaporator as shown in the following illustration.


24 TK 55774-2-IM-EN

Installing EvaporatorsCeiling Preparation

• For ceiling mounting ssttuudd applications, weld a nut (same thread as stud) onto a 44.45 mm (1.75 in.) hole saw andturn the nut onto mounting stud using a socket wrench ((DDeettaaiill II)).

• For ceiling mounting bboolltt applications, weld a bolt (same thread as tapped hole) onto a 44.45 mm (1.75 in.) hole sawand turn into tapped mounting hole using a socket wrench ((DDeettaaiill II)).

• Alternative method is to remove mounting studs or bolts and use a hole saw with a standard pilot drill small enoughto run up into threaded hole without damaging the threads. Reinstall mounting studs or bolts.

Mounting Stud or Bolt RequirementsThe mounting studs or bolts used to attach the evaporator(s) to the ceiling must be 10.0 mm, (0.50 in., Grade 5, U.S.applications only), medium carbon steel, 120000 PSI tensile strength, cadmium plate and dichromate finish. Studs toextend below ceiling 38.0 mm (1.50 in.) to 50.1 mm (2.00 in.)

NNoottee:: The installation kit provides both 10.0 mmmetric and 0.50 in. imperial nuts and washers. Be sure to use thecorrect ones for your application.

IImmppoorrttaanntt:: Evaporator must be properly mounted to provide a slope towards drain. This is accomplished by addingone 3/8 in. and one 3/16 in. washers on the drain side and only one 3/8 in. washer on the other side at eachmounting surface ((DDeettaaiill IIVV)).

1. Remove evaporator cover to access mounting holes.

2. Install aluminum spacers onto ceiling mounting studs and raise the evaporator into position. Secure evaporatoronto mounting studs with flat washers and locking nuts ((DDeettaaiill IIII)). Torque to 81.3 N•m (60 ft-lb).

3. Install mounting bolts, lock washers (installer supplied) and flat washers onto the evaporator and raise into position.Install aluminium spacers and secure evaporator to ceiling ((DDeettaaiill IIIIII)). Torque to 81.3 N•m (60 ft-lb).

4. A properly installed evaporator will slope slightly toward the drain tubes to allow for water drainage. Two additionalwashers are included in the kit to help assist sloping the evaporator towards the drain ((DDeettaaiill IIVV))..

TK 55774-2-IM-EN 25

Host Tube ConnectionsSingle and Multiple Evaporator Configurations (except X, Y and Z)SSiinnggllee EEvvaappoorraattoorr IInnssttaallllaattiioonnss

1. SSuuccttiioonn TTuubbee- Install 77//88 iinn.. xx 77//88 iinn.. coupling (Item A) onto one suction tube of host unit. Fabricate 7/8 in. suctiontube, install onto coupling and connect to 7/8 in. suction tube in trough.

NNoottee:: The second suction tube remains capped.

2. LLiiqquuiidd TTuubbee - Install 33//88 iinn.. xx 11//22 iinn.. coupling (Item B) onto liquid tube of host unit. Fabricate 1/2 in. liquid tube,install onto coupling and connect to 1/2 in. liquid tube in trough.

3. HHoott GGaass TTuubbee - Install 55//88 iinn.. xx 55//88 iinn.. coupling (Item C) onto hot gas tube of host unit. Fabricate 5/8 in. hot gastube, install onto coupling and connect to 5/8 in. hot gas tube in trough.

NNoottee:: Continue to steps 4 and 5 below.

MMuullttiippllee EEvvaappoorraattoorr IInnssttaallllaattiioonnss ((SSeeee IImmppoorrttaanntt nnoottee bbeellooww))

IImmppoorrttaanntt:: Configurations X, Y and Z require two different size Suction tubes and a 1/2” Hot Gas tube routed to theremote evaporators for proper operation. Refer to the specific X, Y and Z instructions in this manual.

1. SSuuccttiioonn TTuubbeess- Install 77//88 iinn.. xx 77//88 iinn.. couplings (Item A) onto each suction tube of host unit. Fabricate 7/8 in.suction tubes, install onto each coupling and connect to 7/8 in. suction tubes in trough.

2. LLiiqquuiidd TTuubbee - Install 33//88 iinn.. xx 11//22 iinn.. coupling (Item B) onto liquid tube of host unit. Fabricate 1/2 in. liquid tube,install onto coupling and connect to 1/2 in. liquid tube in trough.

3. HHoott GGaass TTuubbee - Install 55//88 iinn.. xx 11//22 iinn.. coupling (Item D) onto hot gas tube of host unit. Fabricate 1/2 in. hot gastube, install onto coupling and connect to 1/2 in. hot gas tube in trough.

4. Insulation should be added to all visible segments of suction and liquid tubes not covered by trailer trough cover.Hot gas tubes should be covered 100%.

5. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) betweenclamps.

NNoottee:: Ceiling trough shown, wall trough is similar.

Fittings Requirement

Item Description P/N

A 7/8 in. x 7/8 in. Coupling 553740

B 3/8 in. x 1/2 in. Coupling 552865

C 5/8 in. x 5/8 in. Coupling 556523

D 5/8 in. x 1/2 in. Coupling 553627

Tubing Clamps Required

Tube With Insulation Without Insulation

Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35

26 TK 55774-2-IM-EN

HHoosstt TTuubbee CCoonnnneeccttiioonnss

TK 55774-2-IM-EN 27

Configuration X OnlyIImmppoorrttaanntt:: Configuration X installation requires two different size suction tubes routed to the remote evaporators for

proper operation:

• 77//88 iinn..suction tube from the host unit to the S3 evaporator in Zone 3.

• 11--11//88 iinn.. suction tube from the host unit to the S3 + S3 remote evaporators in Zone 2

NNoottee:: Due to the difficulty in bending and forming 1-1/8 in. copper tubing, elbows and fittings may be used as shown.

1. SSuuccttiioonn TTuubbee ##11 - Install a 77//88 iinn.. xx 77//88 iinn.. coupling (Item A) onto first suction tube at rear of host unit. Fabricate a7/8 in. tube, attach onto coupling and connect to 7/8 in. suction tube in trough.

2. SSuuccttiioonn TTuubbee ##22 - Install a 77//88 xx 11--11//88 iinn.. coupling (Item B) onto second suction tube at rear of the host unit.Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item C) to connect to 1-1/8 in. suction tube intrough.

3. LLiiqquuiidd TTuubbee - Install a 33//88 iinn.. xx 11//22 iinn.. coupling (Item D) onto liquid tube of host unit. Fabricate a 1/2 in. liquid tube,install onto the 1/2 in. coupling and connect to 1/2 in. liquid tube in trough.

4. HHoott GGaass TTuubbee - Install a 55//88 iinn.. xx 55//88 iinn.. coupling (Item E) onto hot gas tube of host unit. Fabricate a 5/8 in. hot gastube, install onto the 5/8 in. coupling and connect to 5/8 in. hot gas tube in trough.

5. Insulation should be added to all visible segments of suction and liquid tubes not covered by the trailer troughcover. Hot gas tubes should be covered 100%.



Fittings Required


A 7/8 in. x 7/8 in. Coupling 553740

B 7/8 in. x 1-1/8 in. Coupling 666022

C 1-1/8 in. x 1-1/8 in. Elbow 553682


E 5/8 in. x 5/8 in. Coupling 556523



Liquid G42 G14

Hot Gas G42 N/A

Suction (7/8 in.) G58 G35

Suction (1-1/8 in.) G66 G58


28 TK 55774-2-IM-EN


TK 55774-2-IM-EN 29

Configuration Y OnlyIImmppoorrttaanntt:: Configuration Y installation requires two different size suction tubes routed to the remote evaporators for

proper operation:

• 77//88 iinn. suction tube from the host unit to the S3 remote evaporator in Zone 2.

• 11--11//88 iinn.. suction tube from the host unit to the S3 + S3 evaporators in Zone 3


1. SSuuccttiioonn TTuubbee ##11 - Install a 77//88 xx 11--11//88 iinn.. coupling (Item A) onto first suction tube at rear of host unit. Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item B) to connect to 1-1/8 in. suction tube in trough

2. SSuuccttiioonn TTuubbee ##22 - Install a 77//88 iinn.. xx 77//88 iinn.. coupling (Item C) onto second suction tube at rear of the host unit.Fabricate a 7/8 in. tube, attach to coupling and connect to 7/8 in. suction tube in trough.

3. LLiiqquuiidd TTuubbee - Install a 33//88 iinn.. xx 11//22 iinn.. coupling (Item D) onto liquid tube of host unit. Fabricate a 1/2 in. liquid tube,attach to coupling and connect to 1/2 in. liquid tube in trough.

4. HHoott GGaass TTuubbee - Install a 55//88 iinn.. xx 55//88 iinn.. coupling (Item E) onto hot gas tube of host unit. Fabricate a 5/8 in. hot gastube, attach to coupling and connect to 5/8 in. hot gas tube in trough.




Fittings Required


A 7/8 in. x 1-1/8 in. Coupling 666022

B 1-1/8 in. x 1-1/8 in. Elbow 553682



E 5/8 in. x 5/8 in. Coupling 556523


Tubes With Insulation Without Insulation

Liquid G42 G14

Hot Gas G42 N/A




30 TK 55774-2-IM-EN


TK 55774-2-IM-EN 31

Configuration Z OnlyIImmppoorrttaanntt:: Configuration Z installations require two 1-1/8 in. suction tubes routed to the remote evaporators for proper

operation:

• 11--11//88 iinn.. suction tube from the host unit to the S3 + S3 evaporators in Zone 2.

• 11--11//88 iinn.. suction tube from the host unit to the S3 + S3 evaporators in Zone 3.


1. SSuuccttiioonn TTuubbee ##11 - Install a 77//88 xx 11--11//88 iinn.. coupling (Item A) ontofirst suction tube at rear of host unit. Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item B) to connect to 1-1/8 in. suction tube in trough.

2. SSuuccttiioonn TTuubbee ##22 - Install a 77//88 xx 11--11//88 iinn.. coupling (Item A) onto second suction tube at rear of the host unit.Fabricate a 1-1/8 in. tube, attach to coupling and use 1-1/8 in. elbows (Item B) to connect to 1-1/8 in. suction tube intrough.

3. LLiiqquuiidd TTuubbee - Install a 33//88 iinn.. xx 11//22 iinn.. coupling (Item C) onto liquid tube of host unit. Fabricate a 1/2 in. tube, attachto coupling and connect to 1/2 in. liquid tube in trough.

4. HHoott GGaass TTuubbee - Install a 55//88 iinn.. xx 55//88 iinn.. coupling (Item D) onto hot gas tube of host unit. Fabricate a 5/8 in. tube,attach to coupling and connect to 5/8 in. hot gas tube in trough.




Fittings Required


A 7/8 in. x 1-1/8 in. Coupling 666022

B 1-1/8 in. x 1-1/8 in. Elbow 553682





Liquid G42 G14

Hot Gas G42 N/A



32 TK 55774-2-IM-EN


TK 55774-2-IM-EN 33

Evaporator Tube ConnectionsS-3 – Two Compartment TrailersZZoonnee 22 CCoonnnneeccttiioonnss

1. SSuuccttiioonn TTuubbee -- Fabricate one 77//88 iinn.. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow(Item A), attach 7/8 in. preformed tube and connect to evaporator 7/8 in. fitting in ZZoonnee 22. Solder all fittings.

2. HHoott GGaass TTuubbee -- Fabricate a 55//88 iinn.. hot gas tube from host unit and route in trough, install 5/8 in. x 1/2 in. elbow(Item B), attach 1/2 in. preformed tube and connect to evaporator 1/2 in. fitting in ZZoonnee 22. Solder all fittings.

3. LLiiqquuiidd TTuubbee -- Fabricate a 11//22 iinn.. liquid tube from host unit and route in trough, install 1/2 x 3/8 in. elbow (Item C),attach 3/8 in. preformed tube and connect to evaporator 3/8 in. fitting in ZZoonnee 22. Solder all fittings.

4. Secure all tubing with provided clamps per chart. Maximum separation should be 600 mm (24.00 in.) betweenclamps



Fittings Required for SINGLE Evaporator Installations

Item Descriptions P/N

A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 1/2 in. Elbow 665733

C 1/2 in. x 3/8 in. Elbow 554142



Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35

34 TK 55774-2-IM-EN

EEvvaappoorraattoorr TTuubbee CCoonnnneeccttiioonnss

TK 55774-2-IM-EN 35

S-3 – Three Compartment TrailersZZoonnee 22 aanndd 33 CCoonnnneeccttiioonnss

1. SSuuccttiioonn TTuubbeess ––Fabricate two 77//88 iinn.. suction tubes from host unit and route in trough, install 7/8 in. x 7/8 in. elbows(Item A), attach one 7/8 in. preformed tube to evaporator in ZZoonnee 22 and another to the evaporator in ZZoonnee 33.

2. HHoott GGaass TTuubbeess::

• ZZoonnee 22 –– Fabricate a 55//88 iinn.. hot gas tube from host unit and route in trough, install 5/8 in. x 5/8 in. x 1/2 in. tee(Item B), attach a 1/2 in. preformed tube and connect it to the evaporator in ZZoonnee 22.

• ZZoonnee 33 –– From the tee, fabricate another 55//88 iinn.. hhoott ggaass ttuubbee,, attach a 5/8 in. x 1/2 in. elbow (Item B) andconnect it to the 1/2 in. preformed tube and to the evaporator in ZZoonnee 33.

3. LLiiqquuiidd TTuubbeess

• ZZoonnee 22 --Fabricate a 11//22 iinn.. liquid tube from host unit and route in trough, install 1/2 x 1/2 in. x 3/8 in. tee (Item D),attach 3/8 in. preformed tube and connect it to the evaporator in ZZoonnee 22.

• ZZoonnee 33 -- From the tee, fabricate another 11//22 iinn.. liquid tube, attach a 1/2 in. x 3/8 in. elbow (Item C) and connect itto the 3/8 in






A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 1/2 in. Elbow 665733

C 1/2 in. x 3/8 in. Elbow 554142

Fittings Required for MULTIPLE Evaporator Installations


A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 5/8 in. x 1/2 in. Tee 660620

C 5/8 in. x 1/2 in. Elbow 665733

D 1/2 in. x 1/2 in. x 3/8 in. Tee 552181

E 1/2 in. x 3/8 in. Elbow 554142



Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35


36 TK 55774-2-IM-EN


TK 55774-2-IM-EN 37

S-3 + S-3 – Two Compartment TrailersNNoottee:: You must connect one suction tube from the host to each evaporator.

ZZoonnee 22 CCoonnnneeccttiioonnss

1. SSuuccttiioonn TTuubbee ##11 --Fabricate a 77//88 iinn.. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow(Item A), attach 7/8 in. preformed tube and connect to the first evaporator 7/8 in. fitting in ZZoonnee 22.

2. SSuuccttiioonn TTuubbee ##22 --Fabricate a second 77//88 iinn.. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in.elbow (Item A), attach 7/8 in. preformed tube and connect to the second evaporator 7/8 in. fitting in ZZoonnee 22.

3. HHoott GGaass TTuubbee - Fabricate a 55//88 iinn.. hot gas tube from host unit and route in trough, install 5/8 in. x 5/8 in. elbow(Item B), fabricate a 5/8 in. tube, connect to 5/8 in. x 1/2 in x 1/2 in. tee (Item C) and attach 1/2 in. preformed tube andconnect to evaporator 1/2 in. fitting in ZZoonnee 22.

4. LLiiqquuiidd TTuubbee - Fabricate a 11//22 iinn.. liquid tube from host unit and route in trough, install 1/2 in. x 1/2 in. elbow (Item D),fabricate a 1/2 in. tube, connect to 1/2 in. a 3/8 in. x 3/8 in. tee (Item E), attach 3/8 in. preformed tubes and connect toevaporator 3/8 in. fitting in ZZoonnee 22.






A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 5/8 in. Elbow 552187

C 5/8 in. x 1/2 in. x 1/2 in. Tee 611044

D 1/2 in. x 1/2 Elbow 551483

E 1/2 in. x 3/8 in. x 3/8 in. Tee 611042



Liquid G42 G14

Hot Gas G42 N/A

Suction G58 G35


38 TK 55774-2-IM-EN


TK 55774-2-IM-EN 39

S-3 + S-3 – Configuration X OnlyZone 2 ConnectionsNNoottee:: Due to the difficulty in bending and forming 1–1/8 in. copper tubing, elbows and fittings may be used.

NNoottee:: You must connect one suction tube from the host to each evaporator.

1. LLiiqquuiidd TTuubbee - Fabricate 11//22 iinn.. liquid tube from the host unit and route in the trough:

• install 1/2 in. x 1/2 in. x 1/2 in. tee (Item A), fabricate a 1/2 in. tube and route in trough to ZZoonnee 33.

• from the 1/2 in. x 1/2 in. x 1/2 in. tee (Item A), fabricate a 1/2 in. tube, attach to a 1/2 in. x 3/8 in. x 3/8 in. tee (ItemB) and 3/8 in. tube and connect to 3/8 in. fitting of 1st evaporator in ZZoonnee 22.

• from the 1/2 in. x 3/8 in. x 3/8 in. tee (B), fabricate a 3/8 in. tube and connect to 3/8 in. fitting of 2nd evaporator inZZoonnee 22. Solder all fittings.

2. SSuuccttiioonn TTuubbee ZZOONNEE 22 - Fabricate a 11--11//88 iinn.. suction tube from host unit and route in trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item C), attach a 7/8 in. tube and connect to 7/8 in. fitting of 2nd evaporator inZZoonnee 22.

• from the 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item C), install a 7/8 in. 90 degree elbow (Item D), attach a 7/8 in. tube andconnect to 7/8 in. fitting of 1st evaporator in ZZoonnee 22. Solder all fittings.

3. SSuuccttiioonn TTuubbee ZZOONNEE 33 - Fabricate a 77//88 iinn.. suction tube from the host unit and route in the trough to the ZZoonnee 33.

4. HHoott GGaass TTuubbee - Fabricate a 55//88 iinn.. hot gas tube from the host unit and route in the trough:

• install 5/8 in. x 5/8 in. x 5/8 in. tee (Item E), fabricate a 5/8 in. tube and route in the trough to ZZoonnee 33.

• from the 5/8 in. x 5/8 in. x 5/8 in. tee (Item E), attach a 5/8 in. x 1/2 in. x 1/2 in. tee (Item F) and 1/2 in. tube andconnect it to the 1/2 in. fitting of the 1st evaporator in ZZoonnee 22.

• From the 5/8 in. x 1/2 in. x 1/2 in. tee (Item F), attach a 1/2 in. tube and connect it to the 1/2 in. fitting of the 2ndevaporator in ZZoonnee 22.






A 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

B 1/2 in. x 3/8 in. x 3/8 in. Tee 611042

C 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

D 7/8 in. x 90° Street Elbow 553325

E 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

F 5/8 in. x 1/2 in. x 1/2 in. Tee 611044


40 TK 55774-2-IM-EN



Liquid G42 G14

Hot Gas G42 N/A




TK 55774-2-IM-EN 41

Zone 3 Connections1. SSuuccttiioonn TTuubbee - Fabricate a 77//88 iinn.. suction tube from host unit and route in trough, install 7/8 in. x 7/8 in. elbow (Item

A), attach 7/8 in. preformed tube and connect to evaporator 7/8 in. fitting in ZZoonnee 33.

2. LLiiqquuiidd TTuubbee - Fabricate a 11//22 iinn.. liquid tube from 1/2 in. tee from ((ZZoonnee 22)) evaporator unit, route in trough, install 1/2 in. x 3/8 in. elbow (Item B), attach 3/8 in. preformed tubes and connect to evaporator 3/8 in. fitting in ZZoonnee 33.

3. HHoott GGaass TTuubbee - Fabricate a 55//88 iinn.. hot gas tube from 5/8 in. tee from ((ZZoonnee 22)) evaporate unit, route in trough, install5/8 in. x 1/2 in. elbow (Item C), attach 1/2 in. preformed tube and connect to evaporator 1/2 in. fitting in ZZoonnee 33..



NNoottee:: Ceiling trough shown, wall trough similar.



A 7/8 in. x 7/8 in. Elbow 553326

B 1/2 in. x 3/8 in. Elbow 554142

C 5/8 in. x 1/2 in. Elbow 665733



Liquid G42 G14

Hot Gas G42 N/A



42 TK 55774-2-IM-EN


TK 55774-2-IM-EN 43

S-3 + S-3 – Configuration Y OnlyZone 2 ConnectionsNNoottee:: Due to the difficulty in bending and forming 1–1/8 in. copper tubing, elbows and fittings may be used as shown.

IImmppoorrttaanntt:: You must connect one suction tube to each evaporator.

1. SSuuccttiioonn TTuubbee - Fabricate a 77//88 iinn.. suction tube from the host unit and route in the trough:

• install 7/8 in. x 7/8 in. elbow, (Item A) attach a 7/8 in. tube and connect to 7/8 in. fitting of the evaporator in ZZoonnee22.

2. HHoott GGaass TTuubbee - Fabricate a 55//88 iinn.. hot gas tube from host unit and route in trough:

• install 5/8 in. x 5/8 in. x 5/8 in. tee (B), fabricate a 5/8 in. tube and route in trough to ZZoonnee 33.

• from the 5/8 in. x 5/8 in. x 5/8 in. tee, attach a 5/8 in. x 1/2 in. x 1/2 in. tee and 1/2 in. tube and connect to 1/2 in.fitting of evaporator in ZZoonnee 22.

3. LLiiqquuiidd TTuubbee - Fabricate 11//22 iinn.. liquid tube from host unit and route in trough:

• install 1/2 in. x 1/2 in. x 1/2 in. tee (Item C), fabricate a 1/2 in. tube and route in trough to ZZoonnee 33.

• from the 1/2 in. x 1/2 in. x 1/2 in. tee, fabricate a 1/2 in. tube, attach to a 1/2 in. x 3/8 in. x 3/8 in. tee and 3/8 in. tubeand connect to 3/8 in. fitting of evaporator in ZZoonnee 22.






A 7/8 in. x 7/8 in. Elbow 553326

B 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

C 1/2 in. x 1/2 in. x 1/2 in. Tee 552296



Liquid G42 G14

Hot Gas G42 N/A



44 TK 55774-2-IM-EN


TK 55774-2-IM-EN 45

Zone 3 ConnectionsNNoottee:: Due to the difficulty in bending and forming 1–1/8 in. copper tubing, elbows and fittings may be used.


1. SSuuccttiioonn TTuubbee ––Fabricate a 11--11//88 iinn.. suction tube from host unit and route in trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item A), and use 7/8 in. elbows (Item B) to connect 7/8 in. tubes to 7/8 in.fittings of each evaporator in ZZoonnee 33.

2. HHoott GGaass TTuubbee- Fabricate a 55//88 iinn.. hot gas tube from host unit and route in trough:

• install 5/8 in. x 5/8 in. x 5/8 in. tee (Item C), and connect the 5/8 in. tubes to 5/8 in. fittings of each evaporator inZZoonnee 33.


• install 1/2 in. x 1/2 in. x 1/2 in. tee (Item D), and connect 1/2 in. tubes to 1/2 in. fittings of each evaporator in ZZoonnee33.





A 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

B 7/8 in. x 7/8 in. Elbow 553326

C 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

D 1/2 in. x 1/2 in. x 1/2 in. Tee 552296



Liquid G42 G14

Hot Gas G42 N/A




46 TK 55774-2-IM-EN


TK 55774-2-IM-EN 47

S-3 + S-3 – Configuration Z OnlyZone 2 ConnectionsNNoottee:: Due to the difficulty in bending and forming 1–1/8 in. copper tubing, elbows and fittings may be used as shown.

IImmppoorrttaanntt:: You must connect one suction tube to each evaporator.


• install 1/2 in. x 1/2 in. x 1/2 in. tee (Item A), fabricate a 1/2 in. tube and route in trough to ZZoonnee 33.

• from the 1/2 in. x 1/2 in. x 1/2 in. tee, fabricate a 1/2 in. tube, attach to a 1/2 in. x 3/8 in. x 3/8 in. tee (Item B) and 3/8in. tube and connect to 3/8 in. fitting of 1st evaporator in ZZoonnee 22.

• from the 1/2 in. x 3/8 in. x 3/8 in. tee, fabricate a 3/8 in. tube and connect to 3/8 in. fitting of 2nd evaporator inZZoonnee 22.

2. SSuuccttiioonn TTuubbee ZZOONNEE 22 - Fabricate a 11--11//88 iinn.. suction tube from host unit and route in trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item C), attach a 7/8 in. tube and connect to 7/8 in. fitting of 2nd evaporator inZZoonnee 22.

• from the 1-1/8 in. x 7/8 in. x 7/8 in. tee, install a 7/8 in. 90 degree elbow (Item D), attach a 7/8 in. tube and connectto 7/8 in. fitting of 1st evaporator in ZZoonnee 22.

3. SSuuccttiioonn TTuubbee ZZOONNEE 33 - Fabricate a 11--11//88 iinn.. suction tube from the host unit and route in trough to ZZoonnee 33.

4. HHoott GGaass TTuubbee - Fabricate a 55//88 iinn.. hot gas tube from host unit and route in the trough:

• install 5/8 in. x 5/8 in. x 5/8 in. tee (Item E), fabricate a 5/8 in. tube and route in trough to ZZoonnee 33.

• from the 5/8 in. x 5/8 in. x 5/8 in. tee, attach a 5/8 in. x 1/2 in. x 1/2 in. tee (Item F) and 1/2 in. tube and connect to 1/2 in. fitting of 1st evaporator in ZZoonnee 22.

• From the 5/8 in. x 1/2 in. x 1/2 in. tee, attach a 1/2 in. tube and connect to 1/2 in. fitting of 2nd evaporator in ZZoonnee22.





A 1/2 in. x 1/2 in. x 1/2 in. Tee 552296

B 1/2 in. x 3/8 in. x 3/8 in. Tee 611042

C 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

D 7/8 in. x 90° Street Elbow 553325

E 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

F 5/8 in. x 1/2 in. x 1/2 in. Tee 611044



Liquid G42 G14

Hot Gas G42 N/A




48 TK 55774-2-IM-EN


TK 55774-2-IM-EN 49

Zone 3 ConnectionsNNoottee:: Due to the difficulty in bending and forming 1–1/8 in. copper tubing, elbows and fittings may be used.


1. SSuuccttiioonn TTuubbee - Fabricate a 11--11//88 iinn.. suction tube from host unit and route in trough:

• install 1-1/8 in. x 7/8 in. x 7/8 in. tee (Item A), and use 7/8 in. elbows (Item B) to connect 7/8 in. tubes to 7/8 in.fittings of each evaporator in ZZoonnee 33.

2. HHoott GGaass TTuubbee - Fabricate a 55//88 iinn.. hot gas tube from host unit and route in trough:

• install 5/8 in. x 5/8 in. x 5/8 in. tee (Item C), and connect 5/8 in. tubes to 5/8 in. fittings of each evaporator in ZZoonnee33.


• install 1/2 in. x 1/2 in. x 1/2 in. tee (Item D), and connect 1/2 in. tubes to 1/2 in. fittings of each evaporator in ZZoonnee33.






A 1-1/8 in. x 7/8 in. x 7/8 in. Tee 558968

B 7/8 in. x 7/8 in. Elbow 553326

C 5/8 in. x 5/8 in. x 5/8 in. Tee 550904

D 1/2 in. x 1/2 in. x 1/2 in. Tee 552296



Liquid G42 G14

Hot Gas G42 N/A




50 TK 55774-2-IM-EN


TK 55774-2-IM-EN 51

Wire ConnectionsHost and Evaporator Wire Connections – Zone 2Zone 2 – Single Evaporators1. Connect ZZOONNEE 22--SSeennssoorr HHaarrnneessss (1E33293) at host unit ((DDeettaaiill II))..

• Route harness into evaporator and connect to mating three connectors ((DDeettaaiill IIII)).

• DDOO NNOOTT CCUUTT TTHHEE SSEENNSSOORR HHAARRNNEESSSS!! Loop excess harness back on its self and secure with cable ties ((DDeettaaiillIIIIII)).

2. Connect ZZOONNEE 22--CCoonnttrrooll HHaarrnneessss (1E33290) at host unit ((DDeettaaiill II)).

• Route harness into evaporator, cut to length, strip ends (DH2, SLS2, LLS2, HGS2 and SC2), attach terminalconnectors and connect to terminal block ((DDeettaaiill IIVV)).

3. Connect ZZOONNEE 22--FFaann 11 HHaarrnneessss (1E33414) at host unit ((DDeettaaiill II)).

• Route harness into evaporator, cut to length, strip ends (FM21 and CH21), attach terminal connectors andconnect to terminal block and ground stud ((DDeettaaiill IIVV)).

4. Connect ZZOONNEE 22--FFaann 22 HHaarrnneessss (2C25318) at host unit (DDeettaaiill II).

• Route harness into evaporator, cut to length, strip ends (FM22 and CH), attach terminal connectors and connectto terminal block and ground stud ((DDeettaaiill IIVV)).

5. Connect SS--33 EEvvaappoorraattoorrss OOnnllyy —— ZZOONNEE 22 -- FFaann 33 HHaarrnneessss (2C25319) at host unit ((DDeettaaiill II)).


Zone 2 – Parallel Evaporators1. Connect ZZOONNEE 22--SSeennssoorr HHaarrnneessss (1E33293) at host unit ((DDeettaaiill II))..

• Route harness into the ffiirrsstt eevvaappoorraattoorr oonnllyy and connect to mating three connectors ((DDeettaaiill IIII)).

NNoottee:: Although sensors are present in both evaporators, the harness is connected to one evaporator only.



• Route harness into ffiirrsstt eevvaappoorraattoorr, cut to length, strip ends (DH2, SLS2, LLS2, HGS2 and SC2), attach terminalconnectors and connect to terminal block ((DDeettaaiill VV)).

3. Connect ZZOONNEE 22--FFaann 11 HHaarrnneessss (1E33414) at host unit (DDeettaaiill II).

• Route harness into ffiirrsstt eevvaappoorraattoorr, cut to length, strip ends (FM21 and CH21), attach terminal connectors andconnect to terminal block and ground stud ((DDeettaaiill VV)).


• Route harness into ffiirrsstt eevvaappoorraattoorr, cut to length, strip ends (FM22 and CH), attach terminal connectors andconnect to terminal block and ground stud ((DDeettaaiill VV)).

5. SS--33 EEvvaappoorraattoorrss OOnnllyy —— Connect ZZOONNEE 22 --FFaann 33 HHaarrnneessss (2C25319) at host unit (DDeettaaiill II).


6. SS--33 EEvvaappoorraattoorrss OOnnllyy —— Interconnect Harness (1E39857) is used with S-3 evaporators.

• Route harness into the ffiirrsstt eevvaappoorraattoorr and connect wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH andCH) to terminal block and ground studs ((DDeettaaiill VV)).

• Route harness into the sseeccoonndd eevvaappoorraattoorr and connect wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CHand CH) to terminal block and ground studs ((DDeettaaiill VV)).

7. Secure all harnesses with adequate clamps or ties.

52 TK 55774-2-IM-EN

WWiirree CCoonnnneeccttiioonnss

TK 55774-2-IM-EN 53

Host and Evaporator Wire Connections – Zone 3Zone 3 – Single Evaporators1. Connect ZZOONNEE 33--SSeennssoorr HHaarrnneessss (1E33292) at host unit ((DDeettaaiill II))..






• Route harness into evaporator, cut to length, strip ends (FM31 and CH31) attach terminal connectors andconnect to terminal block and ground stud ((DDeettaaiill IIVV)).





Zone 3 – Parallel Evaporators1. Connect ZZOONNEE 33--SSeennssoorr HHaarrnneessss (1E33292) at host unit ((DDeettaaiill II))..

• Route harness into the ffiirrsstt eevvaappoorraattoorr oonnllyy and connect to mating three connectors ((DDeettaaiill IIII)).

NNoottee:: Although sensors are present in both evaporators, the harness is connected to one evaporator only.



• Route harness into the ffiirrsstt eevvaappoorraattoorr, cut to length, strip ends (DH3, SLS3, LLS3, HGS3 and SC3), attachterminal connectors and connect to terminal block ((DDeettaaiill VV)).


• Route harness into ffiirrsstt eevvaappoorraattoorr, cut to length, strip ends (FM31 and CH31) attach terminal connectors andconnect to terminal block and ground stud ((DDeettaaiill VV)).





6. SS--33 EEvvaappoorraattoorrss OOnnllyy —— IInntteerrccoonnnneecctt HHaarrnneessss (1E39857) is used with S-3 evaporators.

• Route wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH, and CH) into ffiirrsstt eevvaappoorraattoorr, cut to length, stripends, attach terminal connectors and connect to terminal block and ground stud ((DDeettaaiill VV)).

• Route wires (HGS, SLS, LLS, FM1, FM2, FM3, DH, SC, CH, CH, and CH) into sseeccoonndd eevvaappoorraattoorr, cut to length,strip ends, attach terminal connectors and connect to terminal block and ground stud ((DDeettaaiill VV)).



54 TK 55774-2-IM-EN


TK 55774-2-IM-EN 55

DE Host and Evaporator Wire Connections – Zone 3Zone 3 – Single Evaporator1. Connect ZZOONNEE 33--SSeennssoorr HHaarrnneessss (1E37605) at host unit ((DDeettaaiill II))..





3. Connect ZZOONNEE 33--FFaann 11 HHaarrnneessss (1E33417) at host unit (Detail I).

• Route harness into evaporator. cut to length, strip ends (FM32 and CH), attach terminal connectors and connectto terminal block and ground stud ((DDeettaaiill IIVV)).



5. SS--33 EEvvaappoorraattoorrss OOnnllyy —— CCoonnnneecctt ZZOONNEE 33 --FFaann 33 HHaarrnneessss ((2C25321) at host unit (DDeettaaiill II).




56 TK 55774-2-IM-EN


TK 55774-2-IM-EN 57

Drain Hose Resistance Wire Installation Guide

IImmppoorrttaanntt:: The following information is provided as a guide to help ensure the proper routing of the drain hoseresistance wires. You should supplement this guide with whatever other documentation is required for yourfacility.

DDAANNGGEERRFFiirree HHaazzaarrdd!!NNeevveerr bbuunnddllee eevvaappoorraattoorr ddrraaiinn hhoossee rreessiissttaannccee wwiirreess ttooggeetthheerr aass tthhee aammoouunntt ooff hheeaatt pprroodduucceedd ccoouulldd rreessuulltt iinnaa ffiirree!!

IImmppoorrttaanntt:: The following points must be followed during installation:

• DO NOT CUT HEATER RESISTANCE WIRES!

• DO NOT install more than one heater resistance wire into each drain tube.

• DO NOT “ball up”or bundle heater resistance wires inside drain tubes.

• DO NOT use band wraps to hold heater resistance wires.

• DO NOT cover or wrap heater resistance wires.

• DO NOT pinch the end of the heater resistance wires tight.

IInnssttaallllaattiioonn PPrroocceedduurreess

1. Pull resistance wire straight out from evaporator drain tube.

2. Locate the evaporator defrost drain furthest from truck/trailer wall (i.e. in the middle of the truck/trailer), andmeasure 33.00 in. (838 mm) of resistance wire from drain pan outlet ((DDeettaaiill II)).

3. Bend resistance wire at this point and double it over ((DDeettaaiill IIII)).

4. After doubling resistance wire over take excess wire and insert it back into evaporator drain tube ((DDeettaaiill IIIIII)).

I II III

RCS1147

58 TK 55774-2-IM-EN

5. Insert doubled over end of resistance wire into drain, Tee, or 90 degree connector ((DDeettaaiill IIVV)) and then intocrossover drain tube ((DDeettaaiill VV)).

NNoottee:: The use of either white or blue drain tubes is acceptable when interconnecting multiple evaporators.

6. Attach drain Tee or 90 degree connector to evaporator drain tube and push connector on firmly to engage O-ring((DDeettaaiill VVII)).

IV V VI

RCS1148

7. Pull resistance wire through interconnecting drain tube as far as possible and make sure it is not bunched up ((DDeettaaiillVVIIII)).

8. Insert other resistance wire into other drain Tee connector and as shown ((DDeettaaiill VVIIIIII)).

IImmppoorrttaanntt:: At no time should resistance wires from one side of the drain pan overlap the resistance wires from theother side.

9. Attach interconnecting drain tube to opposite Tee connector by pushing Tee connector on firmly to engage O-ring((DDeettaaiill IIXX)).

VIII IXVII

RCS1149

DDrraaiinn HHoossee RReessiissttaannccee WWiirree IInnssttaallllaattiioonn GGuuiiddee

TK 55774-2-IM-EN 59

10. Attach Tee connector to evaporator drain tube by pushing Tee connector on firmly to engage O-ring ((DDeettaaiill XX)).

11. Attach and route evaporator drain tube over to truck/trailer wall drain. Insert resistance wire into truck/trailer walldrain and pull it as far down wall drain as possible ((DDeettaaiill XXII)).

XIX

RCS1150

IImmppoorrttaanntt:: Only one resistance wire should be installed in the wall defrost drain tube. Only the resistance wire fromthe drain tube closest to the wall should be installed in the trailer drain tube. See illustration below.

RCS1151-1

DDrraaiinn HHoossee RReessiissttaannccee WWiirree IInnssttaallllaattiioonn GGuuiiddee

60 TK 55774-2-IM-EN

Drain Hose InstallationAAllll RReemmoottee EEvvaappoorraattoorrss

IImmppoorrttaanntt:: DO NOT CUT RESISTANCE WIRES.

NNootteess::

1. For proper drainage the drain hose must slope down continuously from the evaporator to the wall drainswith no kinks or droop.

2. See “Important Installation Notes” on pages 24- 27 and “Drain Hose Resistance Wire Installation Guide” onpages 64- 65 for detailed instructions on the proper installation procedures of the drain hose and resistancewires.

3. Make sure drain tubes are properly seated on tube fittings before mounting to evaporator.

Single S-3 Applications (Detail I)1. Route resistance wires from the evaporator through the plastic drain hoses and insert the entire length of one

resistance wire into each wall drain tube.

2. Connect the single drain hose to the wall drain tube using a short piece of plastic drain hose and clamp as required.

3. Replace one drain t-fitting with elbow fitting.

For S-3 + S-3 Applications (Detail II)1. Route resistance wires from the evaporator through the plastic drain hoses and insert the entire length of one

resistance wire into each wall drain tubes.

2. Connect each drain hose to each wall drain tube using a short piece of plastic drain hose and clamps as required.

For Wall Mounted Tube Applications (Detail III)Insert the entire length of one resistance wire into each wall drain tube. Connect the plastic drain hose from theevaporator.

For Wall Mounted Channel Applications (Detail IV)Insert the entire length of one resistance wire into each plastic drain hose. Feed the plastic drain hose down through thewall channel until it exits the bottom of the trailer.

Optional Drain Hose Support (Detail V)The use of the optional drain hose support bracket is recommended when the evaporator is mounted sideways(transverse).

Front Drain Hose Applications (Detail VI)Install drain t-fittings to allow drain tube to exit the front of the evaporator. Insert the entire length of one resistancewire into each drain hose, and route hose out the front of the cover to the wall drain.

TK 55774-2-IM-EN 61

DDrraaiinn HHoossee IInnssttaallllaattiioonn

62 TK 55774-2-IM-EN

Leak Check, Evacuation and Charging ProceduresUnit Set-upThe SR-4 Multi-Temp microprocessor must be placed in Evacuation Test to evacuate and charge the unit. When themicroprocessor is in the Evacuation Test it opens all the normally closed solenoid valves in the refrigeration system.This allows the refrigeration system to be evacuated properly. Refer to the appropriate Diagnostic Manual for completeinformation about the microprocessor. Use the following procedure to set-up the unit and place the microprocessor inthe Evacuation Test mode:

1. Press the OONN key to turn the unit on.

2. Before the unit starts, press the MMEENNUU key. The first screen in the Main Menu (either the Language or AlarmsDisplay) will appear.

3. Press the EEXXIITT key and the unlabeled soft key at the same time, and hold them down for 5 seconds to enter theMaintenance Menu. The first Maintenance Menu feature will appear.

4. Press the NNEEXXTT (or BBAACCKK) key to scroll through the Maintenance Menu features until the Evacuation Test appears.

5. Press the SSEELLEECCTT key to enter the Evacuation Test.

6. Connect a battery charger to the unit battery. The battery charge must have an output of at least 15 amperes. Thiswill maintain the charge level of the battery during the time required to evacuate and charge the unit. TheEvacuation Test is used to open unit valves as required for evacuation. Failure to connect a battery charger mayresult in the battery voltage falling too low to reliably operate the microprocessor and valves.

7. The microprocessor is now in the Evacuation Test. The refrigeration system is set-up for leak checking, evacuationand charging.

Leak Check the SystemNNoottee:: Refer to Diagnosing Thermo King Refrigeration Systems (TK-5984-10) for leak detection procedures.

1. Connect leak test gas (R-404A) supply to center hose of gauge manifold.

2. Attach gauge manifold hoses to suction and discharge service valves.

3. Open suction and discharge valves and pressurize system to 25 psi with leak test gas. Monitor system pressure forone minute.

4. If pressure drops rapidly, there is a large leak. Do not continue until large leak is identified and corrected. If pressuredoes not change or drops slowly, add enough leak test gas to raise system up to bottle pressure.

5. Check connections made during installation for leaks using electronic leak detector.

6. Recover test gas to repair leaks. System must be vented while repairing solder joint leaks. Pressurize system andcheck again after a leak has been repaired.

7. If no leaks are found, recover test gas to 0 psi.

Evacuate the SystemIImmppoorrttaanntt:: Do not evacuate the system until it is leak free. A unit with less than full refrigerant charge should be leak

checked and all leaks must be repaired.

NNoottee:: The use of the Thermo King Evacuation Station (P/N 204-725 or 204-744) and Evacuation Station Operation andField Application Instruction (TK-40612-2) is required.

1. Be sure all refrigerant has been recovered from the unit.

2. Connect a vacuum pump and gauge manifold for three-point evacuation to the suction service valve, dischargeservice valve, and receiver tank outlet valve.

3. Verify proper operation of the Evacuation Station as shown in the Evacuation Station Operation Manual (TK-40612).

4. Start the vacuum pump and mid-seat the suction service valve, discharge service valve, and receiver tank outletvalve.

5. Install service valve stem caps with seals and tighten them. The valve stems should remain capped while evacuatingthe unit.

6. Evacuate the unit to 500 microns, or the lowest achievable level between 500 and 1,000 microns.

TK 55774-2-IM-EN 63

7. Continue to evacuate the unit for one additional hour after reaching 500 microns, or the lowest achievable levelbetween 500 and 1,000 microns. This insures complete evacuation of the remote evaporators and tubes.

8. Close the Evacuation Station valve nearest the vacuum pump (V1) to isolate the vacuum pump from the system.Turn the vacuum pump off.

9. Observe the micron gauge:

• The system pressure should remain below 2000 microns for 5 minutes.

• If the pressure does not hold, check for leaks (if a leak is suspected) or continue evacuation (if system is not dry).

10. Restart the vacuum pump, open the Evacuation Station valve nearest the vacuum pump (V1) and repeat steps 6, 8,and 9 as required until system pressure remains below 2000 microns for 5 minutes.

11. When system pressure remains below 2000 microns for 5 mites, restart the vacuum pump and open the EvacuationStation valve nearest the vacuum pump (V1)

12. With the vacuum pump running, back seat the suction and discharge service valves. Replace the valve cap, re-closethe Evacuation Station valve nearest the vacuum pump (V1), and stop the vacuum pump.

13. Close valve V4. The unit is ready to charge.

NNoottee:: Do not exercise the service valves with the unit in a deep vacuum unless the vacuum pump is operating.

LLeeaakk CChheecckk,, EEvvaaccuuaattiioonn aanndd CChhaarrggiinngg PPrroocceedduurreess

64 TK 55774-2-IM-EN


TK 55774-2-IM-EN 65

Charge the SystemNNoottee:: The unit must be left in the Evacuation Test.

1. Insure all compartment bulkheads are open. Ceiling mounted bulkheads should not be stored close to theevaporator outlets as this will restrict airflow.

2. Before charging system, make sure refrigerant lines from the gauge manifold to refrigerant supply bottle have beenevacuated or purged, the suction and discharge service valves are back seated, and receiver tank outlet valve is stillopen.

3. Set refrigerant supply bottle for liquid. Open gauge manifold hand valve and add a partial charge of R-404A throughthe receiver tank outlet valve. Add 14 lb (6.4 kg) to a unit with one remote evaporator. Add 15 lb (6.8 kg) to a unitwith two remote evaporators. Do not add more than this. The remainder of charge will be added through suctionservice valve while unit is running.

4. Close gauge manifold hand valve.

5. Back seat (close) the receiver tank outlet valve.

6. Exit Evacuation Test by turning unit Off and then back On

7. Turn all zones On and set all zone set points for lowest possible temperature to insure that all zones run in Coolmode. Allow unit to start.

8. Front seat suction service valve and allow compressor to pump down to 1 to 3 psi (7 to 21 kPa). Stop the unit.

9. Remove evacuation manifold hoses from receiver tank outlet valve, discharge service valve, and suction servicevalve. Replace and tighten service port and valve stem caps on receiver tank outlet valve.

10. Attach gauge manifold (with refrigerant supply bottle still connected) to compressor. Attach low side gauge tosuction service valve. Mid-seat suction service valve. Attach high pressure gauge on to discharge service valve.Open discharge service valve to monitor discharge pressure.

11. Turn unit On, turn all zones On (with all zone set points set to the lowest possible temperature), and allow unit tostart.

12. Observe suction pressure and slowly open gauge manifold hand valve to allow liquid refrigerant to flow into suctionservice valve. Control liquid flow so suction pressure increases 20 to 25 psi (138 to 172 kPa). Maintain a dischargepressure of 325 to 400 psi (2241 to 2758 kPa).

13. Add refrigerant until ball in receiver tank sight glass rises to middle of sight glass, then close gauge manifold handvalve. Make sure liquid level does not rise above top of sight glass.

14. Continue to operate unit and monitor sight glass until all compartment temperatures are at or below 0 F (-18 C).

15. Check position of ball in receiver tank sight glass. If liquid level has dropped, add liquid refrigerant until levelstabilizes near middle of sight glass. Do not exceed recommended refrigerant charge for unit model.

16. Close hand valve on refrigerant supply bottle.

17. Back seat discharge service valve.

18. Open both hand valves on gauge manifold.

19. Front seat suction service valve and allow compressor to pump down to 1 to 3 psi (7 to 21 kPa). Stop the unit.

20. Remove gauge line from suction service valve and cap service port.

21. Remove gauge line from discharge service valve and cap service port.

22. Back seat suction service valve and cap valve stem.

23. Cap valve stem on discharge service valve.

24. Secure all gauge lines to gauge line anchors.


66 TK 55774-2-IM-EN

Installing Cap Plugs and Evaporator Covers

IImmppoorrttaanntt:: Cap plugs are provided to plug the two evaporator mounting access holes located directly above the drainpan. These plugs must be installed to prevent water in the drain pan from spilling out of these holes andinto the cargo area.

1. Install CCAAPP PPLLUUGGSS - 2 per evaporator.

2. Install SSIIDDEE CCOOVVEERRSS onto evaporator and secure with screws.

3. Install FFRROONNTT CCOOVVEERR into support channel of evaporator and secure with screws.

4. Install RREEAARR CCOOVVEERR into support channel of evaporator and secure with screws.

Figure 1. Install Cap Plugs and Evaporator Covers

3

4

1

RCS1003-3

2

TK 55774-2-IM-EN 67

NNootteess

68 TK 55774-2-IM-EN

DE Critical Installation Requirements

All center-partition (longitudinally split trailer) installations are unique due to the splitting of the air supply outlets andair supply returns. Because of this, the following DE critical installation requirements must be followed.

IImmppoorrttaanntt:: Before installing the bulkhead, check for gaps under the evaporator from the trailer front wall opening beingcut too big. Any gaps under the center of the evaporator mmuusstt be sealed with an air-block to prevent airloss. See illustration.

The following details are ccrriittiiccaall to this installation:

• BBeeffoorree installing the DE specific bulkhead, confirm there are no air gaps directly under the bottom of the evaporatoras a result of the trailer front wall opening being to big.If a gap is found it must be sealed properly with an air-block.

• UUnniitt BBuullkkhheeaadd - The special DE specific bulkhead mmuusstt be installed and sealed properly to ““sspplliitt”” the aaiirr ssuuppppllyyrreettuurrnnss for each compartment. Contact your Thermo King Dealer for details.

• CCeenntteerr PPaarrttiittiioonn - The center partition mmuussttbe installed and sealed properly to ““sspplliitt”” the aaiirr ssuuppppllyy oouuttlleettss foreach compartment.

• RReeaarr CCoommppaarrttmmeenntt BBuullkkhheeaadd - At least one rear compartment bulkhead must always be installed with a frozencompartment.

• AAiirr GGaappss - All air gaps mmuussttbe properly sealed with foam insulation or caulking.

BBuullkkhheeaaddss aanndd CCeenntteerr PPaarrttiittiioonn IInnssttaallllaattiioonn

1. Install the DE specific bulkhead onto the rear of the unit. Contact your Thermo King Dealer for details.

2. Center Divider Partition must have a tight seal along the floor and ceiling of the trailer and to the back of the unit. Allair gaps must be sealed completely with foam insulation or caulking.

3. At least one rear compartment bulkhead must always be installed with a frozen compartment.

TK 55774-2-IM-EN 69

DDEE CCrriittiiccaall IInnssttaallllaattiioonn RReeqquuiirreemmeennttss

70 TK 55774-2-IM-EN

Unit Check List

UUNNIITT CCHHEECCKK LLIISSTT

☐ BEFORE installing the unit, visually inspect it for any damage. If any damage appears, file claim with delivery carrier.

☐ Install the fuel tank, fuel lines and unit as outlined in the Thermo King Installation Manual.

☐ Add 20 gallons (minimum) of ultra-low sulfer diesel fuel to the tank.

BBEEFFOORREE SSTTAARRTTIINNGG TTHHEE UUNNIITT

☐ Check battery and battery cable installation.

☐ Inspect fuel line routing checking for rubbing, chaffing or laying on hot surfaces.

☐ Visually inspect the unit for the following: Loose or improperly fitting bolts, brackets, hardware, hose connections,and hose routing.

☐ Inspect all wiring connections and routing.

☐ Check defrost drain hoses and kazoos.

☐ Check unit mounting hardware for tightness.

☐ Check compressor and engine mounts.

☐ Install refrigeration gauge manifold. (Multi-Temp units only)

☐ Check engine oil level.

☐ Check condenser and evaporator section for cleanliness and signs of refrigerant leaks.

☐ Check front bulkhead and air chute if equipped.

MMUULLTTII--TTEEMMPP UUNNIITTSS ((RREEMMOOTTEE EEVVAAPPOORRAATTOORRSS))

☐ Check evaporator(s) sections for cleanliness.

☐ Leak test interconnecting tubing.

☐ Check for damage, loose or missing bolts, and hardware on remote evaporator(s).

☐ Check for proper installation of drain tubes, drain kazoos and drain tube heater wires.

☐ Check for properly routed refrigerant lines wiring harnesses for remote evaporator(s). Check for properly routedharnesses for remote controller.

☐ Check for proper installation of remote evaporator guards if equipped.

☐ Check remote harness wiring plugs in the host evaporator.

☐ Check wiring, connections, and terminals in the remote evaporator(s).

☐ Check compartment bulk head(s) for proper fit if equipped.

SSTTAARRTT AANNDD RRUUNN UUNNIITT ((OOnn MMuullttii--TTeemmpp uunniittss,, ssttaarrtt oonnllyy tthhee hhoosstt uunniitt))

☐ Check for proper oil pressure, coolant temperature, oil, fuel, or coolant leaks.

☐ Check alternator charge.

☐ Cycle the unit and ensure the unit functions in the correct modes and the mode indicators are working.

☐ Confirm engine speeds at normal engine running temperature. High Speed and Low Speed per maintenancemanual. Check @70° F (21 C) box temperature and 70° F (21 C) ambient.

☐ Set for continuous run with thermostat set point at 32 F (0 C) and run the unit to 32 F (0 C).

☐ Observe and record refrigerant operating pressures in relation to ambient and box temperatures.

☐ Verify the readings above are correct for the conditions.

☐ When box reaches 32 F (0 C) check calibration of thermostat, thermometer and data logger.

☐ Run unit for 30 minutes at 32 F (0 C). During this period check for correct cycling.

☐ Reset thermostat to 50 F (10 C).

☐ Check throttling valve while in the heat cycle.

☐ Check operation of Modulation system if equipped.

TK 55774-2-IM-EN 71

☐ For Single Temp units perform a controlled check of the refrigerant level. For Multi-temps check the charge permulti-temp unit procedures.

MMUULLTTII--TTEEMMPP UUNNIITTSS

☐ Install the compartment bulk head(s) if equipped.

☐ Check for correct rotation of remote evaporator fans.

☐ Check for correct cycling and operation of remote evaporator fans.

AALLLL UUNNIITTSS

☐ Initiate and check defrost operation and termination. Check operation and adjustment of damper door and remotefans. Each zone on multi-temp units must be checked for proper operation.

☐ Set the unit for Cycle Sentry Operation.

☐ Check for proper operation of all door switches.

☐ Remove the compartment bulk head(s) if equipped.

☐ Set the unit for continuous run. SSeeee iimmppoorrttaanntt nnoottee bbeellooww.. Choose a setpoint opposite of ambient temperature.Continue to run the unit with the trailer doors open. Operate the unit until 10 (minimum of 6) hours are shown onthe engine run time hourmeter to verify complete break in of the engine.

IImmppoorrttaanntt:: Eco Pulldown Mode must be disabled to allow the engine to run at continuous high speed operationduring engine break-in. The default setting is Eco Pulldown enabled. Refer to TT750 regarding disablingthe Eco Pulldown Mode feature in Guarded Access Programmable Features Menu. After engine break-inis completed, return the programmable feature to Eco Pulldown enabled.

☐ Run Pre-trip.

EELLEECCTTRRIICC SSTTAANNDDBBYY OOPPEERRAATTIIOONNAALL CCHHEECCKKSS

☐ Test AC electrical contacts and connections by connecting to AC power and running.

☐ Check for correct electric motor rotation.

☐ Check compressor clutch operation.

☐ Cycle thermostat and check for correct modes of operation.

☐ Power source not available to test AC.

SSTTOOPP UUNNIITT

☐ On multi-temp units, leak test interconnecting tubing.

☐ Check and readjust all belt tensions using TK belt gauge 204-1903 or equivalent frequency tool.

☐ Check for oil, fuel, coolant, refrigerant, and exhaust leaks.

☐ Check engine oil and coolant level.

☐ Check entire unit for loosened hardware and fittings.

☐ Check and adjust all skin, door and panels for correct alignment and operation.

☐ Complete the commissioning registration process.

☐ Release unit.

UUnniitt CChheecckk LLiisstt

72 TK 55774-2-IM-EN

Evaporator Dimensions and Weights

TK 55774-2-IM-EN 73

EEvvaappoorraattoorr DDiimmeennssiioonnss aanndd WWeeiigghhttss

74 TK 55774-2-IM-EN

NNootteess

TK 55774-2-IM-EN 75

NNootteess

Thermo King – by Trane Technologies (NYSE: TT), a global climate innovator – is a worldwide leader in sustainabletransport temperature control solutions. Thermo King has been providing transport temperature control solutionsfor a variety of applications, including trailers, truck bodies, buses, air, shipboard containers and railway cars since1938. 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 specificationswithout notice. We are committed to using environmentally conscious print practices.

TK 55774-2-IM-EN 01 Aug 2018

Supersedes TK 55774-2-IM-EN (September 2015) ©2020 Trane Technologies

trailer edition precedent™ - thermo king...©2020tranetechnologies tk55774-2-im-en introduction...

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