Thermo King HK-430 HO, Installation Manual

Page 1: ...Installation Manual Trailer Edition HK 430 and HK 430 HO Diesel Heating Units TK 55186 2 IM Rev 0 09 11...

Page 2: ...Installation Manual Trailer Edition HK 430 and HK 430 HO Diesel Heating Units TK 55186 2 IM Rev 0 09 11 Copyright 2011 Thermo King Corp Minneapolis MN U S A Printed in U S A...

Page 3: ...2 Release History Released Rev 0 09 11...

Page 4: ...for informational purposes only Thermo King makes no representations warranties express or implied with respect to the information recommendations and descriptions contained herein Information provid...

Page 5: ...Light Opening Dimensions Option 17 Battery Selection Guide 18 Group 31 Battery Dimensions 19 Uncrating and Installing the Unit 20 Installing the Remote HMI 22 Installing the Fuel Tank Aluminum 22 dia...

Page 6: ...ols to the OFF position before servicing the unit WARNING Make sure all mounting bolts are tight and are of correct length for their particular application WARNING Never drill holes in the unit unless...

Page 7: ...ries to the Thermo King unit This could result in severe damage to equipment and void the warranty CAUTION Set all unit electrical controls to the OFF position before connecting battery cables to the...

Page 8: ...4 Tape Measure 5 Mechanics Tools 6 Lifting Device 7 Two Forged Eyebolts 1 2 13 UNC 8 Work Platform Recommended 9 Torque Wrench NOTE Equipment such as torque wrenches should be in good working conditio...

Page 9: ...1 25 OD Screw 10 Screw 1 4 20 Screw Torx T 25 FUEL LINE KIT Hose 1 4 OD x 40 ft Hose 3 8 OD x 40 ft Eyelet fitting 1 4 Eyelet Fitting 3 8 Sleeve Fitting 1 4 Sleeve Fitting 3 8 Nut Fitting 1 4 Nut Fit...

Page 10: ...9 BLANK PAGE...

Page 11: ...gned and built for these applications DANGER The front wall of the trailer or container must be structurally strong enough to support the weight of the HK 430 or HK 430 HO unit WEIGHTS Thermo King HK...

Page 12: ...11 Trailer Container Requirements...

Page 13: ...ree from rivets or bolt heads and flat within 6 5 mm 25 in All mounting bolts must be square with the front wall and securely fastened to the trailer wall in such a manner to allow the mounting nuts b...

Page 14: ...13 Mounting Bolt Specifications and Installation Requirements...

Page 15: ...14 Unit Dimensions...

Page 16: ...15 HMI Remote Mount Dimensions...

Page 17: ...16 Status Light Dimensions Option Corner Mount Version Surface Mount Version...

Page 18: ...17 Flush Mount Status Light Opening Dimensions Option NOTE Dimensions shown will accommodate the Surface Mount Standard Display version only...

Page 19: ...N 203 731 Threaded Stud P N 203 730 SAE Post 925 CCA Wet Cell Thermo King ReliaMax 925N P N 203 733 Threaded Stud P N 203 732 SAE Post 1150 CCA Dry Cell AGM Thermo King EON P N 203 550 Threaded Stud P...

Page 20: ...19 Group 31 Battery Dimensions Lug Connections Threaded Stud Connections...

Page 21: ...unit with the gasket surface facing the trailer opening 8 Secure the collar to the rear of the unit with appropriate hardware and tighten securely 9 Unbolt and remove the lifting plates from the coll...

Page 22: ...21 Uncrating and Installing the Unit...

Page 23: ...sure will be damaged 3 Secure the harness to the trailer wall with the supplied clamps and self tapping screws Flush Mount Installation NOTE Installer to provide a recessed pocket in the trailer wall...

Page 24: ...23 Installing the Remote HMI Surface Mount Installation Flush Mount Installation Recessed pocket shown installer provided...

Page 25: ...commends the fuel tank be mounted 203 2 mm 8 00 in under the trailer as shown Otherwise the OEM or installer is responsible to ensure the fuel tank position meets or exceeds DOT or Federal Highway reg...

Page 26: ...r other crossmember spacing refer to TK 54238 2 IM Non standard crossmember spacing of 9 15 and 16 also requires Kit 701658 90 399 Tank can be mounted on either side of trailer NOTE Location of mounti...

Page 27: ...rdware to 42 N m 31 ft lb 3 Install each hanger assembly facing each other as shown onto the hanger brackets with 1 2 13 screws washers and locking nuts Torque the hardware to 81 to 88 N m 60 65 ft lb...

Page 28: ...27 Installing the Fuel Tank Aluminum 22 dia 30 50 Gallon Option Open Style Bracket Orient Tank Vertically NOTE Location of mounting holes may change if other trailer options are added...

Page 29: ...tank and mounting bracket assembly onto the trailer or container is to be supplied by the installer and must be 1 2 13 UNC rolled thread Medium Carbon Steel Grade 5 or better with Zinc Plate and Dich...

Page 30: ...29 Installing the Fuel Tank Aluminum L Shaped 65 Gallon Option...

Page 31: ...and locking nuts Verify the rubber strips are properly installed on the mounting straps and straps are aligned with the strap guides on the top of the tank Leave the nuts finger tight on the threads...

Page 32: ...nstalling the Fuel Tank Aluminum L Shaped 65 Gallon Option Mounting Strap with T bolts and Rubber Pad Mounting Bracket with 711 mm 28 00 Rubber Pad Support Strap with 635 mm 25 00 Rubber Pad Strap Gui...

Page 33: ...to be supplied by the installer and must be 1 2 13 UNC rolled thread Medium Carbon Steel Grade 5 or better with Zinc Plate and Dichromate finish All mounting hardware must be properly installed and t...

Page 34: ...33 Installing the Fuel Tank Steel Rectangle 65 Gallon Option...

Page 35: ...e upper and lower holes of the L brackets with the supplied 1 2 washers and locking nuts Verify the rubber pads and strips are properly positioned on the L brackets and straps to prevent any metal to...

Page 36: ...35 Installing the Fuel Tank Steel Rectangle 65 Gallon Option...

Page 37: ...line connectors provided in installation kit cut end of fuel line at a 45 degree angle and insert into fuel pickup tube until it is 38 1 mm 1 50 in from the bottom of the tank and tighten securely 3 R...

Page 38: ...37 Installing the Fuel Pump and Fuel Lines FUEL FILTER LOCATED INSIDE UNIT FUEL PUMP LOCATED OUTSIDE TRAILER FOR UNDER CHASSIS FUEL TANKS...

Page 39: ...fitting of the fuel pump Side inlet fitting on the fuel pump to the fuel tank fitting Tighten all fuel line fittings securely 5 FUEL RETURN Route fuel line from Return line fitting from the fuel filt...

Page 40: ...39 Installing the Fuel Pump and Fuel Lines FOR NOSE MOUNTED L SHAPED and RECTANGLE SHAPED 65 GALLON FUEL TANKS FUEL FILTER LOCATED INSIDE UNIT FUEL PUMP LOCATED INSIDE HK UNIT Supply Return...

Page 41: ...and drill the four mounting holes using a 3 16 drill Mount the status light in position with the supplied rivets 2 Route harness as shown allowing a drip loop to prevent water from migrating into the...

Page 42: ...41 Installing the Remote Status Light Option...

Page 43: ...ical shorting 4 Install negative battery cable on negative battery post second to minimize accidental electrical shorting 5 Close and secure unit door CAUTION Set all electrical controls to the OFF po...

Page 44: ...43 Installing the Battery...

Page 45: ...el tank properly installed Fuel lines properly routed and fuel fittings tightened securely Bulkhead properly designed and installed Battery secured correctly and all connections clean and tight Remote...

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