Thermo King T-1000M Installation Manual Download Page 43 | Manualshive

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Installing the Fuel Pickup Tube Into a Plastic Tank

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Summary of Contents for T-1000M

Page 1: ...AP Single Temperature Systems T 580R T 800M and T 1000M with TSR Controller T 680S T 880S T 1080S with SR 3 Controller T 600R T 680R T 800R T 880R T 1000R T 1080R with SR 3 Controller T 1200R EMEIA Only with SR 3 Controller TK 55212 1 IM Rev 4 01 15 ...

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Page 3: ...s T 580R T 800M and T 1000M with TSR Controller T 680S T 880S T 1080S with SR 3 Controller T 600R T 680R T 800R T 880R T 1000R and T 1080R with SR 3 Controller T 1200R EMEIA Only with SR 3 Controller TK 55212 1 IM Rev 4 01 15 Copyright 2011 Thermo King Corp Minneapolis MN U S A ...

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

Page 5: ...3 Installation Manual for T Series Systems ...

Page 6: ...ly 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 Thermo King s warranty shall not apply to any equipment whi...

Page 7: ...s 24 Uncrating the Unit 26 Installing the Unit 28 Installing the Hose Management Caps 30 Installing the Hose Management System OPTION 32 Securing the Oil Drain Hose 34 Securing the Evaporator Drain Hoses 36 Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank 38 Installing the Fuel Pickup Tube Into a Plastic Tank 40 Installing the Steel Fuel Tank 42 Installing the Aluminum Fuel Tank OPTIO...

Page 8: ...frigerant tends to displace air and can cause oxygen depletion which may result in death by suffocation WARNING Always wear goggles or safety glasses Refrigerant liquid refrigeration oil and battery acid can permanently damage the eyes see First Aid under Refrigeration Oil WARNING Keep your hands away from fans and belts when the unit is running This should also be considered when opening and clos...

Page 9: ...m rubbing chaffing or making contact with hot sharp or rotating components WARNING Do not attach fuel lines or any additional wiring harnesses to the battery cables as this could cause an electrical fire CAUTION Set all unit electrical controls to the OFF position before connecting battery cables to the battery to prevent unit from starting unexpectedly and causing personal injury CAUTION Always w...

Page 10: ...ush with the top of the cargo box when possible The top of the evaporator to be positioned 25 4 mm 1 00 in below ceiling The dimension from the top of the cargo box to the evaporator cutout will vary depending on the type of box truck cab tilt clearance etc T 580 through T 880 series units minimum dimension 107 mm 4 25 in ...

Page 11: ...h the top of the cargo box when possible The top of the evaporator to be positioned 25 4 mm 1 00 in below ceiling The dimension from the top of the cargo box to the evaporator cutout will vary depending on the type of box truck cab tilt clearance etc T 1000 through T 1200 series minimum dimension 147 mm 5 75 in ...

Page 12: ...10 Service Area T 580R T 600R T 680R T 680R T 680S T 800M T 800R T 880R T 880S ...

Page 13: ...11 Service Area T 1000M T 1000R T 1080R T 1080S and T 1200R ...

Page 14: ...12 Remote Power Receptacle Dimensions OPTION NORTH AMERICAN MODELS INTERNATIONAL MODELS ...

Page 15: ...13 Battery Box Dimensions OPTION ...

Page 16: ...14 Remote Status Light Dimensions OPTION ...

Page 17: ...15 HMI Controller Dimensions HMI Controller LED Display HMI Controller Graphics Display ...

Page 18: ...p of the evaporator to be positioned 25 4 mm 1 00 in below ceiling Unit mounting location must allow for adequate tilt clearance see Unit Dimensions NOTE The top of the unit to be mounted flush with the top of the cargo box when possible The top of the evaporator to be positioned 25 4 mm 1 00 in below ceiling The dimension from the top of the cargo box to the evaporator cutout will vary depending ...

Page 19: ...n and free of all rivets or head bolts for proper gasket sealing Evaporator to be positioned 25 4 mm 1 00 in below ceiling Unit mounting location must allow for adequate tilt clearance see Unit Dimensions NOTE Existing opening same as RD II TS 500 and TS 600 units and does not require modifications Opening must only be enlarged when changing from a TS 200 TS 300 MD 100 MD 200 MD 300 MD II or KD II...

Page 20: ...77 lbs T 880R 437 kg 963 lbs T 880S 447 kg 985 lbs T 800M 443 kg 977 lbs T 1000M 476 kg 1029 lbs T 1000R 461 kg 1016 lbs T 1080R 453 kg 999 lbs T 1080S 459 kg 1012 lbs T 1200R 475 kg 1046 lbs T 580R 459 kg 1012 lbs T 600R 468 kg 1032 lbs T 680R 462 kg 1018 lbs T 680S 472 kg 1040 lbs T 800R 468 kg 1032 lbs T 880R 462 kg 1018 lbs T 880S 472 kg 1040 lbs T 800M 468 kg 1032 lbs T 1000M 516 kg 1138 lbs ...

Page 21: ...nt lifting bar to safely lift and install units A lifting bar can be made from the drawings provided WARNING All hardware used to assemble the lifting bar must be DIN 931 class 10 9 SAE Grade 8 The use of hardware other than specified may cause personal injury severe damage to the equipment and void the warranty WARNING Use forged clevis and pins forged chain links and forged locking hooks with st...

Page 22: ...SION 1 DISCLOSE NOR USE THIS DRAWING OR THE INFORMATION IN IT EXCEPT AS SPECIFIED ABOVE OR 2 MAKE ANY COPIES OF OR EXTRACTS REVISIONS OR UPDATES FROM THE DRAWING ALL COPIES MUST BE RETURNED TO INGERSOLL RAND UPON COMPLETION OF THE WORK FOR WHICH THEY HAVE BEEN PROVIDED OR UPON ANY EARLIER REQUEST UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INTERPRET DIM AND TOL PER ASME Y14 5M 1994 M GILMA...

Page 23: ... 4 0 2 4 1 75 2X 75 7 5 1 75 1 0 8 85 11 45 5 0 4X 534 1 75 1 0 8 85 11 45 5 0 4X 534 4 0 R1 25 30 3 50 THICK 3 5 2X 75 1 75 4X 534 2X 8 2X 3 4 21 1 21 1 2X 58 2X 122 2X 58 23 6 11 2 17 2 2X 58 31 7 2 1 2 1 9127C30 J SHEET 2 OF 2 SCALE 0 250 SCALE 0 250 REAR MEMBER SCALE 0 250 FRONT MEMBER SCALE 0 150 WELDING DETAIL FRONT MEMBER CENTER MEMBER REAR MEMBER SCALE 0 250 CENTER MEMBER I 2X 2X I I I I I...

Page 24: ...s 1 Safety Glasses 2 Drill 3 Drill Bits 4 Tape Measure 5 Mechanics Tools 6 Lifting Bar New Style Design Required with forged clevis and pins forged connecting links and forged locking hooks 7 Work Platform Recommended ...

Page 25: ...23 Required Tools ...

Page 26: ...Fuel Pump Bracket 10 Screws HH 1 4 20 SS 11 Locking Nuts 1 4 20 SS 12 Fuel Pickup Tube 13 Fuel Line Fittings 14 Clamps 15 Self Tapping Screws 10 HWHSM 16 In Line Fuse Holder 17 Fuse 60 amp 18 Terminal Connector Splice 19 Heat Shrink Sleeving 3 00 20 Terminal Red 3 8 21 Terminal Lug 3 8 22 Cable Ties 23 Muffler Gasket 24 Exhaust Tube Extension 25 Nut Blind 26 HMI Controller 27 HMI DIN Mount 28 Oil ...

Page 27: ...25 Installation Components ...

Page 28: ... eyebolts and slightly raise the unit 5 Remove the eight skid bracket screws securing the unit to the of the crate Detail C 6 Remove the two rear members of the crate and raise the unit from base approximately 304 8 mm 12 0 in Detail C 7 Remove the four mounting bolts securing the two upright members to the unit Detail C The unit is now ready to install WARNING Thermo King requires a 3 point lifti...

Page 29: ...27 Uncrating the Unit ...

Page 30: ...tion kit Torque the mounting hardware to 81 4 N m 60 ft lbs Disconnect and remove the lifting bar NOTE Depending on your particular installation excess threads of the upper roadside unit mounting bolt may need to be cut off to prevent interference with the muffler 4 Reinstall the muffler and the new gasket supplied in kit onto the engine Torque the muffler mounting bolts to 18 4 N m 13 6 ft lbs In...

Page 31: ...29 Installing the Unit ...

Page 32: ...he front exterior wall of the cargo box Roadside Evaporator Drain Hose In Cab Controller Harness Remote Receptacle Power Cable Model 50 Units Only Curbside Cap 2 Route the following items out of the curbside cutout of the bottom pan and down the front exterior wall of the cargo box Curbside Evaporator Drain Hose Coolant Overflow Hoses 2 Fuel Supply and Return Lines 2 Positive and Negative Battery ...

Page 33: ...31 Installing the Hose Management Caps Cutout Guide Marks Front of Unit ...

Page 34: ...ines Positive Battery Cable Unit Control 2 Power Wire Fuel Pump Harness Negative Battery Cable 2 Install the funnel cap into the bottom pan securely 3 Mark a line from the center of the funnel cap down the truck box wall 4 Install two clip assemblies onto each cover with supplied hardware Insure the surface area of the truck box is clean flat and uniform Clean the surface area thoroughly with 50 5...

Page 35: ...33 Installing the Hose Management System OPTION Front of Unit ...

Page 36: ... Ensure there is no contact and adequate clearance between the oil drain hose and the hose management caps The cutout in the hose management cap should be as large as possible with no sharp edges 3 Lower retaining clip should be positioned in an location easily accessible for servicing the unit Your actual location will depend on the distance between the bottom of unit to top of cab etc ...

Page 37: ...35 Securing the Oil Drain Hose The cutouts in the hose management cap should be as large as possible with no sharp edges ...

Page 38: ...kinks to allow for proper water drainage 1 Route drain hoses from under the unit through the Hose Management Caps and down the front wall of the truck box 2 Secure drain hoses with supplied self tapping screws and clamps 3 Cut off excess drain hose and install a check valve onto each drain hose securely with tie bands ...

Page 39: ...37 Securing the Evaporator Drain Hoses ...

Page 40: ...e hole 3 Cut the end of the pickup tube so approximately 25 mm 1 00 in is above the bottom of the fuel tank 4 Loosen the nut and slide all the parts to the top of the pickup tube assembly 5 Hold the parts in position and slide the assembly into the hole at a slight angle until the bushing is inside the hole 6 Tip the backup washer and slide it through the hole and position it onto the bushing Thre...

Page 41: ...39 Installing the Fuel Pickup Tube Into a Steel or Aluminum Tank ...

Page 42: ...and slide all the parts to the top of the pickup tube assembly 5 Hold the parts in position and slide the assembly into the hole at a slight angle until the bushing is inside the hole 6 Tip the backup washer and slide it through the hole and position it onto the bushing Thread the nut onto the bushing position as needed to facilitate fuel line connections and tighten to 54 Nm 40 ft lb DANGER Diese...

Page 43: ...41 Installing the Fuel Pickup Tube Into a Plastic Tank ...

Page 44: ... 11 16 in drill bit and drill four holes in the frame 2 Install each fuel tank mounting bracket securely onto the truck s frame with two 1 2 13 Grade 5 bolts flat washers and locking nuts Substitutions are not acceptable Torque the bolts to 81 88 N m 60 65 ft lb 3 Install the mounting bands T bolts onto the mounting brackets with flat washers and locking nuts 4 Install the fuel tank into the mount...

Page 45: ...43 Installing the Steel Fuel Tank 1 2 3 4 ...

Page 46: ...ame with two 1 2 13 Grade 5 bolts flat washers and locking nuts Substitutions are not acceptable Torque the bolts to 81 88 N m 60 65 ft lb 3 Install the mounting bands onto the mounting brackets with flat washers and locking nuts Tighten only the lower T bolt to 47 N m 35 ft lb Install the self adhesive rubber strips onto each mounting bracket as shown 4 Install the fuel tank into the mounting ban...

Page 47: ...45 Installing the Aluminum Fuel Tank OPTION 1 2 3 4 ...

Page 48: ...ine into the other fuel line fitting and tighten the fuel line fitting securely 9 Remove the plastic cap from the fuel vent and point the outlet towards the rear of the truck IMPORTANT The factory installed fuel tank air vent must be in place and functional for the Thermo King unit s fuel system to operate correctly and for the fuel tank to remain in compliance with Federal Motor Carrier Safety Ad...

Page 49: ...47 Installing the Fuel Pump and Fuel Lines ...

Page 50: ...viceWatch port that provides for safe and easy access for connecting the download cable The download port can be rotated to fit your particular installation 1 Attach the download port securely to the truck box with four TEK screws 2 Provide a drip loop and secure the harness with supplied clamps and screws ...

Page 51: ...49 Installing the ServiceWatch Remote Download Port ...

Page 52: ...with the supplied 1 4 x 20 mounting hardware and tighten securely 4 Route and secure the harness with supplied clamps and screws International Units Detail B 1 Measure and drill four 9 5 mm 375 in holes into truck body 2 Insert the supplied rubber blind nuts into each hole in truck body 3 Install the receptacle to the truck box with the supplied 10 32 mounting hardware and tighten securely 4 Route...

Page 53: ...51 Installing the Remote Power Receptacle OPTION ...

Page 54: ...ts 2 Provide a drip loop to prevent water from migrating into the Status Light and route the harness towards the bottom of the unit 3 Secure harness to the truck box using the supplied clamps and rivets 4 Remove the bottom pan from the unit and locate the 6 pin connector under the unit near the control box 5 Remove the blank plug and attach the Status Light connector securely 6 Secure excess harne...

Page 55: ...53 Installing the Remote Status Light OPTION ...

Page 56: ...tabs to secure 2 Route the controller harness from the unit to inside the cab and through the mounting sleeve HMI Controller LED Display Insert the controller harness to the mating connector at the rear of the HMI controller until it locks firmly in position Lightly pull on the harness to confirm the harness is locked securely Install the plug cover onto the rear of the controller with the two sup...

Page 57: ...55 Installing the HMI Controller NOTE HMI with LED Display shown HMI with Graphics Display installs the same ...

Page 58: ...use holder enter box 3 DO NOT install protective battery cover This will be installed later CAUTION Battery boxes and covers must be installed securely with proper hardware to prevent them from falling off CAUTION Battery cables must be properly routed and secure to prevent rubbing chafing or making contact with sharp moving or hot components ...

Page 59: ...57 Installing the Battery Box OPTION ...

Page 60: ...r assembly Use battery cable crimper to securely crimp 8 AWG 2 wire and fuse holder together and heat shrink the connection Apply a liberal amount of Superlube to the 60 amp fuse and fuse holder and then install fuse Route the fuse holder terminal along with the positive cable POS into the battery box through the rubber grommet and connect to the POSITIVE terminal of the battery Detail A Fuel Pump...

Page 61: ...59 Battery Connections ...

Page 62: ...must be installed away from traffic i e forklifts or protected from it The door switch and magnet must be installed parallel to each other not perpendicular Long cross hair aligns to long cross hair It is important that a maximum gap of 19 mm 0 75 in is maintained between the door switch and the magnet Shims may be required and must be a non magnetic material aluminum wood plastic etc or the door ...

Page 63: ...61 Installing the Door Switch OPTION Right Angle Mounting Top x Top Mounting Side x Side Mounting ...

Page 64: ...ce harness to a door switch Connect matching wires per the table below RED RED WHITE WHITE BLACK BLACK to each door switch using splice connectors Crimp splice connectors securely and apply heat with a heat gun 3 All harnesses should be installed routed and properly secured to protect from damage 4 Operate unit and verify door switch operation Interface Harness Wiring Door Switch Wiring RED DSP PO...

Page 65: ...63 Installing the Door Switch OPTION Interface Harness Wiring Door Switch Wiring RED DSP POWER RED DSP POWER BLACK CH GROUND BLACK CH GROUND WHITE DS OUTPUT WHITE DS OUTPUT ...

Page 66: ...connected to the Thermo King electrical system is the customer s responsibility Electrical Connection Guidelines Connect the 12 volt load to the 2 terminal J24 on the Base Controller Use J8 Pin 4 to control a 12 volt relay The relay will be energized when the unit is on DO NOT connect ground wires for electrical accessories to the CH terminal J23 on the Base Controller Use independent ground wires...

Page 67: ... Check front bulkhead and air chute if equipped Check damper door bushings and springs MULTI TEMP UNITS REMOTE EVAPORATORS 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 ...

Page 68: ...r 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 Continue to run the unit with the back doors open alternating between high speed cool and heat until at least 6 hours 10 hours preferred are shown on the engine run time hour meter to ensure complete break in of th...

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