Trane Thermo King SPECTRUM T-1090 Installation Manual Download Page 84

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TK 56701-1-IM-EN

Battery Connections

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e:: Thermo King units are designed for one 12 volt, group 31 battery. The battery must be suitable for deep cycling,

heavy duty, and rated with a minimum of 95 amp/hr.

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Refer to the illustration on the following page for battery cable and fuse installation details.

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1. At the unit, locate the large black cable marked P

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2. FOLLOW THE INSTALLATION INSTRUCTIONS (TK 56239).

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3. Route and connect the fuel pump harness to the fuel pump.

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4. At the unit, locate the large black cable marked N

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5. All harnesses and battery cables should be neatly routed and secured with provided clamps.

6. Install battery box cover securely (if applicable).

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7. Attach supplied nameplate near the battery the unit is connected to (vehicle’s battery or battery box).

Summary of Contents for Thermo King SPECTRUM T-1090

Page 1: ...Revision C August 2020 T TK K 5 56 67 70 01 1 1 1 I IM M E EN N Self Powered Truck Edition Multi Temperature Systems T 1090 SPECTRUM Series Installation Manual ...

Page 2: ...ty y M Ma an nu uf fa ac ct tu ur re er r s sh ha al ll l h ha av ve e n no o l li ia ab bi il li it ty y t to o a an ny y p pe er rs so on n o or r e en nt ti it ty y f fo or r a an ny y p pe er rs so on na al l i in nj ju ur ry y p pr ro op pe er rt ty y d da am ma ag ge e o or r a an ny y o ot th he er r d di ir re ec ct t i in nd di ir re ec ct t s sp pe ec ci ia al l o or r c co on ns se eq q...

Page 3: ...ensions and Weights 18 Unit Lifting Bar Dimensions 22 HMI Controller Dimensions 27 Standby Power Receptacle Dimensions OPTION 28 R Re eq qu ui ir re ed d T To oo ol ls s 3 30 0 C Co on nd de en ns si in ng g U Un ni it t I In ns st ta al ll la at ti io on n C Co om mp po on ne en nt ts s 3 32 2 I In ns st ta al ll li in ng g C Co on nd de en ns si in ng g U Un ni it t 3 34 4 Unit Mounting Bolt Req...

Page 4: ...o or ra at to or r I In ns st ta al ll la at ti io on n C Co om mp po on ne en nt ts s 5 56 6 Basic S 2 and S 3 Installation Components 56 Two and Three Zone S 2 or S 3 Installation Components 58 Two Zone S 2 S 2 Installation Components 60 I In ns st ta al ll li in ng g E Ev va ap po or ra at to or rs s 6 62 2 Ceiling Preparation 62 Mounting Stud or Bolt Requirements 62 S 2 or S 3 Evaporator Insta...

Page 5: ...e er rs s 8 83 3 B Ba at tt te er ry y C Co on nn ne ec ct ti io on ns s 8 84 4 A Au ux xi il li ia ar ry y E El le ec ct tr ri ic ca al l A Ac cc ce es ss so or ri ie es s 8 86 6 TracKing OPTION 86 S Sy ys st te em m L Le ea ak k C Ch he ec ck k P Pr ro oc ce ed du ur re es s 8 87 7 Set up Unit 87 Leak Check the System 87 System Evacuation 89 System Charging 91 C Co om mm mi is ss si io on ni in ...

Page 6: ...io on n r re es su ul lt ti in ng g i in n s su uf ff fo oc ca at ti io on n a an nd d p po os ss si ib bl le e d de ea at th h D DA AN NG GE ER R R Ri is sk k o of f I In nj ju ur ry y K Ke ee ep p y yo ou ur r h ha an nd ds s c cl lo ot th hi in ng g a an nd d t to oo ol ls s c cl le ea ar r o of f f fa an ns s a an nd d o or r b be el lt ts s w wh he en n w wo or rk ki in ng g o on n a a u un n...

Page 7: ...citation to restore breathing if necessary Stay with victim until emergency personnel arrive F Fr ro os st t B Bi it te e 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 R RE EF FR RI IG GE ER RA AN NT T O OI IL L E Ey ye es s Immediately flush with large amounts of water for at lea...

Page 8: ... le e s st te ee el l c cr ra at te es s c ca an n b be e d da an ng ge er ro ou us s E Em mp pt ty y s st te ee el l c cr ra at te es s c ca an n b be e s st ta ac ck ke ed d a a m ma ax xi im mu um m o of f t tw we el lv ve e 1 12 2 h hi ig gh h f fo or r s st to or ra ag ge e F Fo or rk kl li if ft ts s m mu us st t h ha av ve e t th he e r ra at te ed d c ca ap pa ac ci it ty y t to o s sa af ...

Page 9: ...um mp p a an nd d f fu ue el l l li in ne es s s sh ho ou ul ld d b be e i in ns st ta al ll le ed d a a s sa af fe e d di is st ta an nc ce e a aw wa ay y f fr ro om m t th he e e ex xt tr re em me e h he ea at t g ge en ne er ra at te ed d b by y t th he e v ve eh hi ic cl le e s s D Di ie es se el l P Pa ar rt ti ic cu ul la at te e F Fi il lt te er r D DP PF F o or r e ex xh ha au us st t s sy...

Page 10: ...h h f fu ue el l l li in ne es s t to o b ba at tt te er ry y c ca ab bl le es s o or r e el le ec ct tr ri ic ca al l h ha ar rn ne es ss se es s T Th hi is s h ha as s t th he e p po ot te en nt ti ia al l t to o c ca au us se e a a f fi ir re e a an nd d c co ou ul ld d c ca au us se e s se er ri io ou us s i in nj ju ur ry y o or r d de ea at th h W WA AR RN NI IN NG G H Ha az za ar rd d o of ...

Page 11: ...one tube kit if evaporators are mounted in the back of the zone I Im mp po or rt ta an nt t T 1090 SPECTRUM units should not be configured with more than six 6 total evaporator fans Emission control software will restrict capacity performance if unit is configured with more than six 6 fans N NO OT TE ES S 1 S 2 evaporators 902673 include mounting hardware kit 800628 2 S 3 evaporators 902674 includ...

Page 12: ... rt ta an nt t Your forklift must be rated for the combined weight of the self powered truck unit and the steel crate See table below UNIT MODEL UNIT WEIGHT approximate STEEL CRATE WEIGHT TOTAL WEIGHT OF UNIT WITH STEEL CRATE T 590 Model 30 T 590 SmartPower Model 50 413 kg 910 lbs 441 kg 973 lbs 236 kg 520 lbs 649 kg 1430 lbs 677 kg 1493 lbs T 690 Model 30 T 690 Model 30 MAX T 690 SmartPower Model...

Page 13: ...aining channels for shipment 2 Fold down front and rear supports by sliding locking rings U UP P until they rest on tab then fold each support member down flat 3 Crate is now ready to return Figure 1 Returnable Create Components Shown RCS1098 2 1 2 3 4 5 9 7 6 8 1 Rear Support Member 6 Locking Rings X4 2 Mounting Posts X2 7 Twist Locks X2 3 Retaining Channels X2 8 Mounting Post Secured to Retainin...

Page 14: ...eights while lifting a 236 kg 520 lb crate When returning crates they should be stacked no more than eight 8 high I Im mp po or rt ta an nt t Eight 8 crates 236 kg 520 lbs 1 887 kg 4 160 lbs Be sure your forklift is rated for this amount of weight Figure 2 Crates Shown Stacked for Return Maximum Eight 8 High R Re et tu ur rn na ab bl le e S St te ee el l C Cr ra at te e I In nf fo or rm ma at ti i...

Page 15: ...090 SPECTRUM 450 mm 17 7 in 919 mm 36 2 in 323 mm 12 7 in 1888 mm 74 4 in 691 mm 27 2 in 153 mm 6 0 in RCS1134 2 N No ot te e Top of unit to be mounted flush with top of cargo box when possible UNIT MODEL 30 MODEL 50 SmartPower T 1090 SPECTRUM 883 lbs 400 kg 992 lbs 450 kg ...

Page 16: ...4 T 890 T 1090 and T 1090 SPECTRUM Units RCS1077 4 593 mm 23 4 in 593 mm 23 4 in 328 mm 12 9 in 749 mm 29 5 in 762 mm 30 0 in 1 2 1 Service Area Dimensions with Top Screen Option 2 Service Area Dimensions with Top Cover Option D Di im me en ns si io on ns s ...

Page 17: ...69 in 4x Ø 15 9 mm 0 625 in 394 0 mm 15 5 in 151 9 mm 5 98 in 182 8 mm 7 20 in 180 7 mm 7 11 in 87 2 mm 3 43 in 316 0 mm 12 44 in 91 5 mm 3 60 in 102 0 mm 4 02 in 173 9 mm 6 85 in 431 8 mm 17 0 in 1 2 1 Top of unit to be mounted flush with top of cargo box when possible 2 Note this upper curbside mounting hole is 38 mm 1 5 in lower than previous T Series units D Di im me en ns si io on ns s ...

Page 18: ...mm 7 63 in 635 2 mm 25 01 in 57 9 mm 2 28 in 35 4 mm 1 39 in 181 3 mm 7 14 in 988 0 mm 38 90 in 700 0 mm 27 56 in 751 0 mm 29 57 in 106 6 mm 4 20 in 17 7 mm 0 70 in 48 9 mm 1 93 in 298 7 mm 11 76 in 465 3 mm 18 32 in 541 6 mm 21 32 in 67 4 mm 2 65 in 1 4 5 6 2 3 111 1 mm 4 37 in 43kg 95 lbs 4 1 2 3 5 6 D Di im me en ns si io on ns s ...

Page 19: ...9 in 181 3 mm 7 14 in 988 0 mm 38 90 in 700 0 mm 27 56 in 751 0 mm 29 57 in 106 6 mm 4 20 in 17 7 mm 0 70 in 635 2 mm 25 01 in 751 0 mm 29 57 in 1513 3 mm 59 58 in 127 1 mm 5 00 in 48 9 mm 1 93 in 298 7 mm 11 76 in 465 3 mm 18 32 in 541 6 mm 21 32 in 67 4 mm 2 65 in 1 4 5 6 2 3 111 1 mm 4 37 in 43 kg 95 lbs X 2 1 4 2 3 5 6 4 5 6 D Di im me en ns si io on ns s ...

Page 20: ...7 63 in 181 3 mm 7 14 in 988 0 mm 38 90 in 106 6 mm 4 20 in 700 0 m 27 56 in 17 7 mm 0 70 in 1094 0mm 43 07 in 978 2 mm 38 51 in 127 0 mm 5 00 in 1 4 5 6 2 3 48 9 mm 1 93 in 298 6 mm 11 76 in 465 4 mm 18 32 in 541 6 mm 21 32 in 67 4 mm 2 65 in 111 1 mm 4 37 in 52 kg 115 lbs RCS194 2 1 2 3 4 5 6 D Di im me en ns si io on ns s ...

Page 21: ... in 988 0 mm 38 90 in 106 6 mm 4 20 in 2199 2 mm 86 58 in 978 2 mm 38 51 in 700 0 m 27 56 in 17 7 mm 0 70 in 1094 0 mm 43 07 in 1094 0mm 43 07 in 978 2 mm 38 51 in 127 0 mm 5 00 in 1 4 5 6 2 3 48 9 mm 1 93 in 298 6 mm 11 76 in 465 4 mm 18 32 in 541 6 mm 21 32 in 67 4 mm 2 65 in 111 1 mm 4 37 in 52 kg 115 lbs X 2 1 2 3 4 5 6 4 5 6 D Di im me en ns si io on ns s ...

Page 22: ...MO KING S PRIOR WRITTEN PERMISSION 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 THERMO KING UPON COMPLETION OF THE WORK FOR WHICH THEY HAVE BEEN PROVIDED OR UPON ANY EARLIER REQUEST NOTES 1 USE THREE FORGED CLEVIS AND PINS TO ATTACH LIFTING CHAINS 2 EACH AS...

Page 23: ... 3 2 1 SIZE DWG NO REV D CODE IDENT NO 88 1 96 75 2 90 1 00 1 00 2 00 3 00 2 00 3 00 4 00 5 00 3E45668 SHEET 2 OF 5 SCALE 0 375 REAR MEMBER SCALE 0 375 7 9 54 2 3 5 THICK 50 5 0 3 5 27 1 2 5 2X 75 25 1 50 20 534 2 1 4 0 2 5 534 2 1 4 0 2 5 2X 58 2X 58 1 00 25 10 1 00 2 40 D Di im me en ns si io on ns s ...

Page 24: ...C D 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 SIZE DWG NO REV D CODE IDENT NO 3E45668 SHEET 3 OF 5 SCALE 0 375 FRONT MEMBER SCALE 0 375 THICK 50 5 0 2 4 2 5 2X 75 7 5 2 5 1 0 2 5 1 0 8 85 11 45 8 85 11 45 5 0 4X n 534 5 0 4X n 534 2X 122 21 1 23 6 21 1 D Di im me en ns si io on ns s ...

Page 25: ... 8 7 6 5 4 3 2 1 SIZE DWG NO REV D CODE IDENT NO 1 00 2 00 1 00 2 00 3 00 4 00 88 1 96 3E45668 SHEET 4 OF 5 SCALE 0 500 CENTER MEMBER SCALE 0 50 THICK 50 5 0 2X 58 4 0 R1 25 30 3 75 2 90 534 8 2 5 3 4 4X n 534 8 2 5 3 4 18 35 3 00 15 15 31 7 5 00 2 40 1 00 1 00 D Di im me en ns si io on ns s ...

Page 26: ...A B C D A B C D 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 SIZE DWG NO REV D CODE IDENT NO 3E45668 SHEET 5 OF 5 SCALE 0 375 CUTOUT PATTERN FOR CENTER AND REAR MEMBERS 1 00 2 00 3 00 1 00 2 00 3 00 4 00 5 00 2 40 2 90 1 96 5 00 1 00 1 00 88 75 D Di im me en ns si io on ns s ...

Page 27: ...Dimensions Figure 15 Premium and Basic HMI Controllers Shown RCS1080 2 189 0 mm 7 44 in 44 0 mm 1 73 in 11 0 mm 0 43 in 60 0 mm 2 36 in ON OFF 189 0 mm 7 44 in 60 mm 2 36 in 60 0 mm 2 36 in 11 0 mm 0 43 in D Di im me en ns si io on ns s ...

Page 28: ...orth American and International Model Receptacles Shown RCS1078 2 59 7 mm 2 35 in 114 3 mm 4 50 in 99 3 mm 3 91 in 125 0 mm 4 92 in 144 0 mm 5 67 in 78 0 mm 3 00 in 90 0 mm 3 54 in 45 0 mm 1 77 in 75 0 mm 2 95 in 90 0 mm 3 54 in 75 0 mm 2 95 in D Di im me en ns si io on ns s ...

Page 29: ...TK 56701 1 IM EN 29 PAGE INTENTIONALLY BLANK D Di im me en ns si io on ns s ...

Page 30: ... Tubing Cutter 12 Refrigerant Oil 13 Torch Set 14 Mechanics Tools 15 Manifold Set 16 Evacuation Station 17 Reclaiming Station 18 Refrigerant and Scale 19 Dry Nitrogen 20 Tap and Die Set 21 Battery Charger 22 Electronic Leak Detector 23 Tubing Brushes 24 Scotch Brite Pads 25 Lifting Bar Thermo King design with forged links clevises and pins 26 Work Platform recommended 27 Torque Wrench 28 Mechanica...

Page 31: ...TK 56701 1 IM EN 31 Figure 17 Required Tools Shown ABA580 1 1 7 13 2 3 4 5 6 8 11 14 15 17 27 28 25 15 9 35 10 12 18 16 19 20 40 AMP 21 22 23 24 26 R Re eq qu ui ir re ed d T To oo ol ls s ...

Page 32: ...ings 6 Insulated Clamps 7 Clamp 8 Exhaust Pipe Extension 9 Check Valve 10 Terminal Lug 3 8 2 AWG 11 Terminal Lug 3 8 red 12 Fuel Pump 13 Fuel Pump Mounting Bracket 14 Screw 1 4 20 15 Lock Nut 1 4 20 16 Fuel Pickup Tube Assembly 17 Clip 18 Fuse In line 60 Amp 19 Flat Washer 10 20 Screw 10 21 Screw 8 22 Washer 8 23 DIN Bracket 24 Washer 2 OD 25 Premium HMI Harness Adapter 26 HMI In Cab Mounting Brac...

Page 33: ...ing Unit Installation Components Shown 10 11 12 13 1 5 3 4 2 9 6 7 8 19 20 21 22 16 17 18 14 15 23 24 25 26 RCS1082 1 27 28 29 C Co on nd de en ns si in ng g U Un ni it t I In ns st ta al ll la at ti io on n C Co om mp po on ne en nt ts s ...

Page 34: ...o on ns s c ca an n d da am ma ag ge e e eq qu ui ip pm me en nt t Unit mounting bolts are installer supplied and must meet the following requirements Bolt Size and Thread Pitch 1 2 13 UNC Full Thread Grade SAE Grade 5 ISO 8 8 Finish Zinc Dichromate Cadmium Plated Length The length of each of the four mounting bolts protruding from the front wall of the cargo box is shown in the illustration Three...

Page 35: ...g From Cargo Box Single Temperature Shown Multi Temperature same RCS1145 1 2 3 4 Required Bolt Length Protruding From Cargo Box 1 72 mm 2 8 in 2 46 mm 1 8 in 3 46 mm 1 8 in 4 46 mm 1 8 in I In ns st ta al ll li in ng g C Co on nd de en ns si in ng g U Un ni it t ...

Page 36: ...ame locations and tighten securely 3 Install M12 forged lifting eyebolt washers and locking nut installer supplied into the front balance point location and tighten securely I Im mp po or rt ta an nt t Installer supplied lifting eyebolts must be forged steel 12 mm 1 75 pitch with a minimum thread length of 20 5 mm 0 80 in long Substitutions are not acceptable 4 Use an overhead hoist and 3 point li...

Page 37: ...al ll la at ti io on n M Me et th ho od d on the next page N No ot te e Do not install any compressible washers or other materials between the unit and the truck 1 Position condensing unit into cargo box opening Do not pull on the drain hoses or electrical wires during the installation 2 From inside the cargo box insert four 4 correct length mounting bolts with four 4 2 00 OD flat washers supplied...

Page 38: ...drain hoses or electrical wires during the installation a Apply blue thread locker to all four 4 mounting studs or T bolt threads b Install one 1 washer 555234 and one 1 hex nut 550287 installer supplied onto each threaded stud or T bolt c Tighten the nuts evenly and then torque to 81 4 N m 60 ft lb I Im mp po or rt ta an nt t A minimum of 2 thread pitches must extend beyond the surface of the nut...

Page 39: ...he two 2 supplied retaining clips and self tapping screws as shown N No ot te e Lower retaining clip should be positioned in a 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 Figure 24 Oil Drain Hose Shown Secured Under Unit ...

Page 40: ... er r 1 Choose an appropriate location to mount the USB Download Port that provides for safe and easy access for connecting the USB Flash Drive 2 Position the Download Port as shown and attach securely to the truck box with four TEK screws or rivets 3 Provide a drip loop and secure harness to truck box with clamps and TEK screws or rivets Figure 25 Typical Installation Shown RCS1130 1 ...

Page 41: ...nd drill three 13 mm 500 in holes into truck box 2 Insert rubber blind nuts supplied into each hole 3 Attach receptacle with 1 4 x 20 mounting hardware supplied and tighten securely 4 Secure harness to cargo box with clamps and screws supplied I In nt te er rn na at ti io on na al l M Mo od de el ls s N No ot te e Installer to supply mounting hardware and blind nuts for International model recepta...

Page 42: ...troller harness from unit to inside cab I Im mp po or rt ta an nt t Route and secure controller harness to prevent rubbing chafing or making contact with sharp moving or hot components Allow excess length harness for tilt cab applications Supplied rubber grommets must be used when routing harness through sheet metal holes 3 P Pr re em mi iu um m H HM MI I C Co on nt tr ro ol ll le er r S St ta an ...

Page 43: ...label on the fuel inlet fill spout stating ULTRA LOW SULFUR FUEL ONLY Verify label is present If not present order label 93 1184 and install on tank Reference 40 CFR 1039 104 e 1039 135 I IM MP PO OR RT TA AN NT T I IN NS ST TA AL LL LA AT TI IO ON N T TI IP PS S BEFORE drilling any holes check for internal baffles inside the tank PRIOR to installation remove protective caps from ends of pickup tu...

Page 44: ...9 104 e 1039 135 I IM MP PO OR RT TA AN NT T I IN NS ST TA AL LL LA AT TI IO ON N T TI IP PS S BEFORE drilling any holes check for internal baffles inside the tank PRIOR to installation remove protective caps from ends of pickup tubes DO NOT apply any type of sealant material to the fuel pickup tube assembly Doing so will result in plugged fuel lines N No ot te e Use a magnet grease or special hol...

Page 45: ...ing and routing fuel lines a Fuel lines must be routed in split loom protective sleeving with no kinks or sharp bends b Rubber grommets must be used when routing fuel lines through sheet metal c All fuel lines must be secured with provided clamps 2 S Su up pp pl ly y L Li in ne e from tank to pump Install fuel line from fuel pickup supply fitting to fuel pump IN fitting 3 S Su up pp pl ly y L Li i...

Page 46: ...e components are installed correctly and the unit operates as designed Evaporator Locations Refer to the illustration below Best airflow is achieved when an evaporator is installed an equal distance from each wall It is recommended that moving bulkheads are not allowed closer than 1219 mm 48 00 in or one pallet from the evaporator outlet Minimum clearance from bottom of evaporator to top of cargo ...

Page 47: ...45 angle Drains should be 267 mm 10 50 in from evaporator to cargo box ceiling Cargo Wall Drain Tubes Refer to the illustration below 1 Drain tubes must be 25 mm 1 00 in ID and made of Chlorinated Polyvinyl Chloride CPVC material 2 Drain tubes must be installed inside cargo box wall 3 Drain tubes must exit bottom of cargo box wall with no kinks or obstructions and allow condensate to drain freely ...

Page 48: ...use 35 silver solder When tightening ORS tubing connections always use a backup wrench to hold the backside of the ORS fitting to prevent the refrigeration tube from twisting Torque ORS fittings on the condenser to proper specifications Insulation should be added to all segments of suction and hot gas tubes All refrigeration tubes should be routed neatly in a wall or ceiling trough Secure all tubi...

Page 49: ...h Refrigeration tubes should be secured by clamps every 600 mm 24 00 in inside the trough Electrical harness should be secured by clamps or tie bands every 600 mm 24 00 in inside the trough Insulate all hot gas and suction refrigeration tubes inside the trough Trough covers are recommended to protect refrigeration tubes and electrical harnesses from damage Figure 33 Refrigerant Tubing and Electric...

Page 50: ...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 I In ns st ta al ll la at ti io on n P Pr ro oc ce ed du ur re es s 1 Pull resistance...

Page 51: ...1148 7 Pull resistance wire through interconnecting drain tube as far as possible and make sure it is not bunched up D De et ta ai il l V VI II I 8 Insert other resistance wire into other drain Tee connector and as shown D De et ta ai il l V VI II II I I Im mp po or rt ta an nt t At no time should resistance wires from one side of the drain pan overlap the resistance wires from the other side 9 At...

Page 52: ...ck trailer wall drain and pull it as far down wall drain as possible D De et ta ai il l X XI I XI X RCS1150 I Im mp po or rt ta an nt t Only one resistance wire should be installed in the wall defrost drain tube Only the resistance wire from the drain tube closest to the wall should be installed in the trailer drain tube See illustration below RCS1151 1 E Ev va ap po or ra at to or r I In ns st ta...

Page 53: ... 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 the fit by pulling on the tube s to insure that it will not pull out of the fitting To disconnect the tube from the fitting press the collet into the fitting Hold the collect in place and pull the tube out The fitting can be re used Clean any burrs off the...

Page 54: ...ded to plug the two evaporator mounting access holes located directly above the drain pan These plugs must be installed to prevent water in the drain pan from spilling out of these holes and into the cargo area I Im mp po or rt ta an nt t Always install cap plugs after installing the evaporator s Figure 36 Two Cap Plugs Per Evaporator Required ABA369 1 E Ev va ap po or ra at to or r I In ns st ta ...

Page 55: ...the condensing unit and the remote evaporators until ready to connect the tubing Condensing Unit Slowly remove the ORS caps from the hot gas liquid and suction lines at rear of the condensing unit to release the nitrogen holding charge Remote Evaporators Slowly remove the solder caps from the hot gas liquid and suction lines at rear of each evaporator to release the nitrogen holding charge Figure ...

Page 56: ...a at to or rs s 1 Pre Bent Liquid Hot Gas and Suction Tubes 2 Pre Formed Drain Hose 3 4 ID 3 Hose Clamp 4 Water Drain Pipe 5 Water Drain Elbow 6 Terminal Fork Connectors 7 Terminal Ring Connectors 8 Refrigerant Oil 9 Mounting Spacers 3 sizes 10 Locking Nuts 1 2 13 11 Flat Washer 1 2 12 Flat Washer 3 8 13 Locking Nut M10 1 5 14 Cap Plugs 15 Tubing Clamps 16 Screws 1 4 20 17 Flat Washers 1 4 18 Lock...

Page 57: ... and S 3 Installation Components Shipped with all S 2 and S 3 evaporators 7 9 8 10 11 1 3 5 2 6 4 13 16 14 12 15 19 18 17 ABA233 1 O I L 20 21 E Ev va ap po or ra at to or r I In ns st ta al ll la at ti io on n C Co om mp po on ne en nt ts s ...

Page 58: ... o or r 8 80 01 12 28 80 0 b ba as se ed d o on n t th he e i in ns st ta al ll la at ti io on n c co on nf fi ig gu ur ra at ti io on n 1 ORS Pre bent Tubes 2 ORS Adapters 3 O rings 4 Check Valves 5 Copper Elbows 6 Copper Tee s 7 Tube Insulation 8 Insulated Clamps 9 Steel Clamps 10 Self Drilling Screws 11 Washers 12 Band Wraps 13 Terminal Socket Pins 14 Remote Evaporator Harnesses E Ev va ap po o...

Page 59: ...ure 39 Evaporator Installation Components Two and Three Zone S 2 or S 3 Installations 7 9 8 10 11 1 3 5 2 6 4 13 14 12 RCS1209 E Ev va ap po or ra at to or r I In ns st ta al ll la at ti io on n C Co om mp po on ne en nt ts s ...

Page 60: ... K Ki it t 8 80 00 03 37 72 2 f fo or r a a S S 2 2 S S 2 2 i in ns st ta al ll la at ti io on n c co on nf fi ig gu ur ra at ti io on n 1 Copper Elbows 2 Copper Tee s 3 Terminal Fork Connectors 4 Terminal Ring Connectors 5 Check Valve 6 Tee Assembly Liquid Line 7 Tee Assembly Hot Gas Line 8 Insulated Clamps 9 Evaporator Interconnect Harness E Ev va ap po or ra at to or r I In ns st ta al ll la at...

Page 61: ...1 IM EN 61 Figure 40 Evaporator Installation Components Two Zone S 2 S 2 Installations 7 9 8 1 3 5 2 6 4 RCS1210 E Ev va ap po or ra at to or r I In ns st ta al ll la at ti io on n C Co om mp po on ne en nt ts s ...

Page 62: ...ll mounting studs or bolts Mounting Stud or Bolt Requirements R Re ef fe er r t to o t th he e i il ll lu us st tr ra at ti io on n o on n t th he e f fo ol ll lo ow wi in ng g p pa ag ge e The 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 fini...

Page 63: ...TK 56701 1 IM EN 63 Figure 41 Typical Evaporator Installations Shown AFC51 AFC51 1 2 2 3 3 1 1 4 I In ns st ta al ll li in ng g E Ev va ap po or ra at to or rs s ...

Page 64: ...t come with the condensing unit Oil and install new O rings supplied in kit Clean all threads on ORS fittings prior to installation Apply refrigerant oil to the O rings only D DO O N NO OT T A AP PP PL LY Y O OI IL L T TO O T TH HE E O OR RS S F FI IT TT TI IN NG G T TH HR RE EA AD DS S Each zone needs to have a separate suction line with a check valve installed as close as possible to condensing ...

Page 65: ...copper fittings in the illustration are shown in the table below Item Description P N 1 Tee 1 1 8 in x 7 8 in x 7 8 in 558968 2 90 Elbow 7 8 in x 7 8 in 553326 3 90 Elbow 3 8 in x 3 8 in 552876 4 Tee 3 8 in x 3 8 in x 3 8 in 553251 5 90 Elbow 1 2 in x 1 2 in 558812 6 Tee 1 2 in x 1 2 in x 1 2 in 552296 R Re ef fr ri ig ge er ra at ti io on n T Tu ub bi in ng g C Co on nn ne ec ct ti io on ns s ...

Page 66: ... 1 Z O N E 2 3 8 TUBE 7 8 TUBE 1 2 TUBE The copper fittings in the illustration are shown in the table below Item Description P N 1 90 Elbow 7 8 in x 7 8 in 553326 2 Tee 1 2 in x 1 2 in x 1 2 in 552296 3 Tee 3 8 in x 3 8 in x 3 8 in 553251 R Re ef fr ri ig ge er ra at ti io on n T Tu ub bi in ng g C Co on nn ne ec ct ti io on ns s ...

Page 67: ...lied in kit Clean all threads on ORS fittings prior to installation Apply refrigerant oil to the O rings only D DO O N NO OT T A AP PP PL LY Y O OI IL L T TO O T TH HE E O OR RS S F FI IT TT TI IN NG G T TH HR RE EA AD DS S Each zone needs to have a separate suction line with a check valve installed as close as possible to condensing unit N No ot te e Remove internal components of valves before so...

Page 68: ... the illustration are shown in the table below Item Description P N 1 Tee 1 1 8 in x 1 1 8 in x 7 8 in 559517 2 Tee 1 1 8 in x 7 8 in x 7 8 in 558968 3 90 Elbow 7 8 in x 7 8 in 553326 4 90 Elbow 3 8 in x 3 8 in 552876 5 Tee 3 8 in x 3 8 in x 3 8 in 553251 6 90 Elbow 1 2 in x 1 2 in 558812 7 Tee 1 2 in x 1 2 in x 1 2 in 552296 R Re ef fr ri ig ge er ra at ti io on n T Tu ub bi in ng g C Co on nn ne...

Page 69: ... E 1 Z O N E 2 S S 7 8 TUBE 7 8 TUBE 1 2 TUBE 3 8 TUBE The copper fittings in the illustration are shown in the table below Item Description P N 1 90 Elbow 7 8 in x 7 8 in 553326 2 Tee 1 2 in x 1 2 in x 1 2 in 552296 3 Tee 3 8 in x 3 8 in x 3 8 in 553251 R Re ef fr ri ig ge er ra at ti io on n T Tu ub bi in ng g C Co on nn ne ec ct ti io on ns s ...

Page 70: ...plied in kit Clean all threads on ORS fittings prior to installation Apply refrigerant oil to the O rings only D DO O N NO OT T A AP PP PL LY Y O OI IL L T TO O T TH HE E O OR RS S F FI IT TT TI IN NG G T TH HR RE EA AD DS S Each zone needs to have a separate suction line with a check valve installed as close as possible to condensing unit N No ot te e Remove internal components of valves before s...

Page 71: ...ings in the illustration are shown in the table below Item Description P N 1 Tee 1 1 8 in x 1 1 8 in x 7 8 in 559517 2 Tee 1 1 8 in x 7 8 in x 7 8 in 558968 3 90 Elbow 7 8 in x 7 8 in 553326 4 90 Elbow 3 8 in x 3 8 in 552876 5 Tee 3 8 in x 3 8 in x 3 8 in 553251 6 90 Elbow 1 2 in x 1 2 in 558812 7 Tee 1 2 in x 1 2 in x 1 2 in 552296 R Re ef fr ri ig ge er ra at ti io on n T Tu ub bi in ng g C Co o...

Page 72: ... in S 7 8 TUBE 1 2 TUBE 3 8 TUBE The copper fittings in the illustration are shown in the table below Item Description P N 1 90 Elbow 7 8 in x 7 8 in 553326 2 90 Elbow 1 2 in x 1 2 in 558812 3 90 Elbow 3 8 in x 3 8 in 552876 R Re ef fr ri ig ge er ra at ti io on n T Tu ub bi in ng g C Co on nn ne ec ct ti io on ns s ...

Page 73: ...s at the back of condensing unit D De et ta ai il l A A 2 Attach the 2 pin connectors FM1 CH1 and FM2 CH to the correct Zone One or Two mating connectors at the back of the condensing unit D De et ta ai il l A A ZONE ONE ZONE TWO FM1A CHF 1 FM1B CHF 2 FM2A CHF 3 FM2B CHF 4 3 Route each harness to the terminal block of the correct Zone One or Two evaporator a Cut wires HGS SLS LLS FM1 FM2 SC DH CH1...

Page 74: ... or S 3 Evaporators 600 mm 24 in 1 2 CTN CTP A B C DTP DTN A B C RTP RTN 7 mm 0 25 in S 2 or S 3 HGS SLS LLS DH FM1 FM1 FM2 FM2 FM3 FM3 SOL SOL SC SC FM1 FM2 CH1 CH HGS SLS LLS DH SC A C B 4 3 4 ABA226 2 1 2 W Wi ir re e C Co on nn ne ec ct ti io on ns s ...

Page 75: ... length strip 7 mm 0 25 in from ends and attach ring terminals onto CH1 and CH wires and forked terminals on all others b Connect wires HGS SLS LLS DH FM1 FM2 and SC to each terminal block D De et ta ai il l B B c Connect wires CH1 and CH to the ground stud of each evaporator D De et ta ai il l B B 4 Attach the sensor connectors to the mating connectors located in the correct Zone One or Two evapo...

Page 76: ...SOL SOL SC SC CH1 CH CH 7 mm 0 25 in HGS SLS LLS DH SC FMA 2 FMB 2 CH HGS SLS LLS DH SC FMA 2 FMB 2 FM1 FM2 HGS SLS LLS DH SC S 2 S 2 1 2 CTN CTP A B C DTP DTN A B C RTP RTN A C 4 B 5 3 6 HGS SLS LLS DH FM1 FM1 FM2 FM2 FM3 FM3 SOL SOL SC SC 7 mm 0 25 in 7 1 2 FIRST EVAP SECOND EVAP FM1 W Wi ir re e C Co on nn ne ec ct ti io on ns s ...

Page 77: ... or Three mating connectors at the back of condensing unit D De et ta ai il l A A 2 Attach the 2 pin connectors FM1 CH1 and FM2 CH to the correct Zone One Two or Three mating connectors at the back of the condensing unit D De et ta ai il l A A ZONE ONE ZONE TWO ZONE THREE FM1A CHF 1 FM1B CHF 2 FM2A CHF 3 FM2B CHF 4 FM3A CHF 5 FM3B CHF 6 3 Route each harness to terminal block of correct Zone One Tw...

Page 78: ...or Three Zone Systems 600 mm 24 in ABA228 1 1 2 CTN CTP A B C DTP DTN A B C RTP RTN 7 mm 0 25 in S 2 HGS SLS LLS DH FM1 FM1 FM2 FM2 FM3 FM3 SOL SOL SC SC FM1 FM2 CH1 CH HGS SLS LLS DH SC A C 4 B 3 5 1 2 W Wi ir re e C Co on nn ne ec ct ti io on ns s ...

Page 79: ...es su ul lt t i in n a a f fi ir re e Refer to Drain Hose Resistance Wire Installation Guide p 50 for complete details I Im mp po or rt ta an nt t D DO O N NO OT T C CU UT T R RE ES SI IS ST TA AN NC CE E W WI IR RE ES S Drain Hose Requirements For the condensate drain system to operate correctly the drain hose s must be properly seated on tube fittings before mounting to evaporator slope down con...

Page 80: ...drain hose and insert entire length of one resistance wire into each wall drain tube 5 Connect each drain hose to each wall drain tube using a short piece of plastic drain hose and clamps as required 2 3 3 m m 9 1 6 i n 5 4 4 RCS1154 1 4 4 E Ev va ap po or ra at to or r D Dr ra ai in n H Ho os se e I In ns st ta al ll la at ti io on n ...

Page 81: ...all drain tube 267 0 mm 10 5 in RCS1156 W Wa al ll l M Mo ou un nt te ed d C Ch ha an nn ne el l A Ap pp pl li ic ca at ti io on ns s Insert entire length of resistance wire into plastic drain hose Feed plastic drain hose down through wall channel until it exits the bottom of truck Confirm resistance wire is not balled up in wall drain channel 267 0 mm 10 5 in RCS1157 E Ev va ap po or ra at to or ...

Page 82: ...d into a wall drain RCS1158 F Fr ro on nt t D Dr ra ai in n H Ho os se e A Ap pp pl li ic ca at ti io on ns s Install drain T fittings to allow drain tube to exit the front of evaporator insert entire length of one resistance wire into each drain hose and route hose out front of cover to wall drain RCS1155 E Ev va ap po or ra at to or r D Dr ra ai in n H Ho os se e I In ns st ta al ll la at ti io ...

Page 83: ... pan from spilling out of these holes and into the cargo area 1 Install C CA AP P P PL LU UG GS S 2 per evaporator 2 Install S SI ID DE E C CO OV VE ER RS S onto evaporator and secure with screws 3 Install F FR RO ON NT T C CO OV VE ER R into support channel of evaporator and secure with screws 4 Install R RE EA AR R C CO OV VE ER R into support channel of evaporator and secure with screws Figure ...

Page 84: ...arge black cable marked P PO OS S a Route cable to battery cut to proper length and add supplied battery cable lug b D DO O N NO OT T connect to battery yet I In n L Li in ne e F Fu us se e I In ns st ta al ll la at ti io on n 2 FOLLOW THE INSTALLATION INSTRUCTIONS TK 56239 F Fu ue el l P Pu um mp p H Ha ar rn ne es ss s I In ns st ta al ll la at ti io on n 3 Route and connect the fuel pump harnes...

Page 85: ... Figure 52 Battery and Fuel Pump Connections Shown RCS1085 3 10 00 254mm 50 12mm 50 12mm 12 00 305mm SPLICE WIRES TOGETHER AS SHOWN BELOW RCS399 RCS400 RCS401 RCS402 B Ba at tt te er ry y C Co on nn ne ec ct ti io on ns s ...

Page 86: ...ical system of a T 590 T 690 T 890 or T 1090 series units equipped with SR 3 controllers and Tier 4 engines unless approved by Thermo King TracKing OPTION Units equipped with the factory installed TracKing option requires additional procedures to activate the system See TracKing Cellular Installation Manual TK 56186 for activation procedures ...

Page 87: ...either the Language Display or the Alarms Display press and hold the unlabeled soft key and the EXIT key for 5 seconds e The Maintenance Hourmeter Menu will appear Press the NEXT key as required to show the Evacuation Mode Menu f When the Evacuation Mode Menu is shown press the SELECT key g The unit will stay in Evacuation Mode until the battery voltage falls below a minimum voltage or the EXIT ke...

Page 88: ...88 TK 56701 1 IM EN Figure 53 Leak Check the System RCS1152 1 4 1 2 3 2 S Sy ys st te em m L Le ea ak k C Ch he ec ck k P Pr ro oc ce ed du ur re es s ...

Page 89: ...ot seal can be corrected by installing valve stem covers see step 6 6 If step 5 was successful close valve V2 to isolate thermistor Open suction discharge and receiver service valves to port Install brass and steel valve stem covers with sealing washers on service valves and tighten Let vacuum pump continue to operate 7 After 5 minutes of evacuation open valve V2 to access thermistor and micron ga...

Page 90: ...on Shown 2 3 4 5 6 8 7 RCS1159 1 1 Legend for Evacuation and Charging Diagram 1 V 4 5 Two Stage Vacuum Pump 2 V 3 6 To AC Power 3 V 2 7 Micron Gauge 4 V 1 8 Thermistor S Sy ys st te em m L Le ea ak k C Ch he ec ck k P Pr ro oc ce ed du ur re es s ...

Page 91: ...ve 7 Set both zones to HIGH SPEED COOL through the HMI Service Test Mode 8 Observe the suction pressure and slowly open the low side gauge manifold valve to allow liquid refrigerant to flow into the compressor suction service valve 9 Control the liquid flow so the suction pressure increases approximately 20 psi 138 kPa 10 Maintain a discharge pressure of at least 300 psig 2068 kPa while adding ref...

Page 92: ...g Shown 2 3 4 5 6 8 7 RCS1160 1 1 Legend for Evacuation and Charging Diagram 1 V 4 5 Two Stage Vacuum Pump 2 V 3 6 To AC Power 3 V 2 7 Micron Gauge 4 V 1 8 Thermistor S Sy ys st te em m L Le ea ak k C Ch he ec ck k P Pr ro oc ce ed du ur re es s ...

Page 93: ...s form is also available online at Thermo King ReqDirect By completing the Commissioning Form the i in ns st ta al ll le er r confirms the installation was done per Thermo King s Installation Manual and the unit operates as it should Commissioning Forms should be completed for all unit installations and retained by the i in ns st ta al ll le er r FORMS ARE LOCATED ON NEXT THREE PAGES ...

Page 94: ...94 TK 56701 1 IM EN Figure 56 Page 1 of 3 Shown RCS1105 1 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s ...

Page 95: ...TK 56701 1 IM EN 95 Figure 57 Page 2 of 3 Shown RCS1106 1 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s ...

Page 96: ...96 TK 56701 1 IM EN Figure 58 Page 3 of 3 Shown RCS1107 1 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s ...

Page 97: ...the form the s se el ll le er r confirms the unit operates as it should PDI Forms should be completed for all unit sales and retained by the s se el ll le er r Completing both the Commissioning and the Pre Delivery Forms helps assure Thermo King equipment is installed with the highest degree of quality reliability and durability to meet or exceed the expectations of our customers resulting in tota...

Page 98: ...98 TK 56701 1 IM EN Figure 59 Page 1 of 2 Shown RCS1108 1 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s ...

Page 99: ...TK 56701 1 IM EN 99 Figure 60 Page 2 of 2 Shown RCS1109 1 C Co om mm mi is ss si io on ni in ng g a an nd d P PD DI I F Fo or rm ms s ...

Page 100: ...ers truck bodies buses air shipboard containers and railway cars since 1938 For more information visit www thermoking com or www tranetechnologies com Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice We are committed to using environmentally conscious print practices TK 56701 1 IM EN 31 Aug 2020 S...

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