Domestic Refrigerated Container (DRC)
85 Gallon Aluminum Fuel Tank
Installation Instructions
These instructions are written exclusively for, and are limited to, the installation of the 85 gallon
aluminum fuel tank (P/N 12-1047), positioned directly under a Thermo King Precedent C-600 RR,
S-600 RR, S-600M RR, SB-230 RR or SB-330 RR refrigeration unit, and mounted onto the front wall
of a Domestic Refrigerated Container (DRC) that was designed and built to meet the requirements
specific to this application. All other installations are the responsibilities of the installer.
DANGER: All fuel tank mounting requirements detailed in this document must be met to correctly
and safely install the 85 gallon tank onto the DRC. Failure to comply to these requirements could
result in severe damage to equipment, injury or death!
WARNING: The front wall of the Domestic Refrigerated Container (DRC) must be structurally
strong enough to support the combined weight of a Thermo King refrigeration unit, the 85 gallon
aluminum fuel tank with mounting hardware, and the full capacity of diesel fuel. Consult your
DRC manufacturer for details regarding your specific installation.
.
Weight of Refrigeration Unit
Weight of
85 Gallon
Aluminum Fuel
Tank and
Mounting Straps
Weight of
Full Capacity
Diesel Fuel
329 liters
(87 gallons)
Total Weight
Refrigeration unit, fuel
tank, mounting
brackets and 329 liters
(87 gallons) diesel fuel
Precedent C-600 RR / S-600 RR
w/SmartPower 12hp/230V
w/SmartPower 12/19 hp/460V
842 kg (1857lbs.)
946 kg (2086 lbs)
962 kg (2121 lbs.)
Precedent S-600M RR
w/SmartPower 12hp/230V
w/SmartPower 12/19 hp/460V
820 kg (1808 lbs.)
920 kg (2030 lbs.)
937 kg (2065 lbs.)
1166.5 kg (2571,7 lbs.)
1266.5 kg (2792.2 lbs.)
1283.5 kg (2829.6 lbs.)
SB-230 RR or SB-330 RR
742 kg (1635 lbs.)
1088.5 kg (2399.7 lbs.)
48.5 kg (107 lbs.)
298 kg (657 lbs.)
TK 55875-4-IM (Rev. 4, 01/15) Copyright© 2014 Thermo King Corp. Minneapolis, MN, USA
1188.5 kg (2620.2 lbs.)
1292.5 kg (2849.5 lbs.)
1308.5 kg (2884.7 lbs.)
IMPORTANT DRC and 85 GALLON FUEL TANK REQUIREMENTS
IMPORTANT: Using the wrong fuel system fittings may void your engine warranty! All Thermo
King supplied fuel line fittings (except fuel line connector) are nickel plated brass for
Precedent units.
•
DO NOT use fuel fittings (main body) made of brass, copper, zinc, zinc plated or
galvanized steel where it would make direct contact with flowing diesel fuel. Diesel fuel
flowing through these types of fittings allows those metals to leach into the fuel forming
deposits on the injector tips which fouls them prematurely.
•
Fuel fitting nuts, compression sleeves, and fuel line connectors made of brass are
acceptable because diesel fuel does not flow across their surfaces.
•
Do not use PTFE (Polytetrafluoroethylene) thread sealing tape on the fuel fittings in a
Precedent unit. PTFE tape may allow strands into the fuel system that could plug up the
tight clearance fuel injectors causing failures.
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 Administration specifications (title 49, paragraph
393.67). A plugged or restricted fuel tank air vent can result in premature damage to the fuel
pump and could also cause severe damage to the fuel tank. NEVER remove or install any other
component in place of the fuel tank air vent.
•
DRC must have four 1/2-13 nuts installed securely into the front vertical wall with spacing as
shown. See Figure 1.
•
DRC must have two mounting plates with four 1/2-13 nuts installed onto the front lower horizontal
member as shown. The mounting plates must be positioned directly over the lower structural
members of the DRC with the nuts aligned with the tank strap mounting bar studs. See Figures 1,
2, 3 and 4.
•
DRC must have a provision that allows access to the fuel tank drain plug. See Figures 2 and 5.
•
Fuel tank must rest on two 1/2” thick rubber mounting pads with two tank hold down straps
positioned directly over each pad. See Figure 2 and 3.
•
Fuel tank must be centered on DRC frame so there is clearance below the refrigeration unit to
access the fuel fill spout. See Figure 2.
•
DRC must be designed to accept the fuel tank and Thermo King refrigeration unit and not interfere
with the operating functions of the container. See Figure 5.
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RELEASED 27/Jan/2014
Figure 1: DRC Requirements
3
RELEASED 27/Jan/2014
Figure 2: DRC Requirements
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RELEASED 27/Jan/2014
Figure 3: DRC Requirements
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Figure 4: Mounting Plate Assembly
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RELEASED 27/Jan/2014
Figure 5: 85 Gallon Fuel Tank
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85 Gallon Aluminum Fuel Tank Components
98-8588 KIT COMPONENTS
(Items 1-9)
Item
P/N
Description
Qty.
1.
NSS
Bar, tank strap mounting
1
2.
NSS
Pad, rubber mounting
2
3.
NSS
Strap, tank w/rubber strips
4
4.
NSS
Bolt, 1/2-13 x 2.00” long
4
5.
NSS
Washer, flat 1/2”
12
6.
NSS
Washer, lock 1/2”
8
7.
NSS
Nut, hex 1/2-13
4
8.
NSS
Bolt, 1/2-13 x 5.50” long
4
9.
NSS
Nut, locking 1/2-13
4
Tank and UFLS Sold Separately
10.
12-1047
Tank, aluminum 85 gallon rectangle tank
1
11.
40-1213
Ultrasonic Fuel Level Sensor (UFLS)
1
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INSTALLATION PROCEDURES
1. Fuel Tank Strap Mounting Bar - Install the mounting bar (studs facing towards the front) to the
front wall of the DRC with four 1/2-13 x 2.00 in. long bolts, 1/2 in. lock washers, and 1/2 in. flat
washers.
•
Torque hardware to 81 N•m (60 ft-lb.).
2. Rubber Pads - Wipe the base plates on the container clean where the fuel tank will sit and install
the two self-adhesive rubber pads.
3. Fuel Tank - Install the fuel tank with the pre-installed rubber pads on the tank facing towards the
rear.
•
Center the fuel tank being sure it is resting evenly on the two rubber pads (installed previously)
onto the base plates.
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4. Tank Straps - Install the L-end of each tank strap onto the studs of the mounting bar with 1/2 in.
flat washers and 1/2 in. locking nuts.
•
Hand tighten the hardware.
5. Align each tank strap end mount with the holes in the lower strap mounting plates:
•
Insert 1/2-13 x 5.5 in.long bolts with 1/2 in. flat washers through each strap end mount, than
install a secondary 1/2 in. nut. This nut will be a jam nut.
•
Position 1/2 in. lock washers over the mounting plate holes and thread the bolts into the
mounting plates.
IMPORTANT: Rubber strips must be in place on the tank straps to prevent the metal
straps from chaffing the aluminum tank.
•
Tighten the bolts once to 20 N•m (15 ft-lbs) and stop. Tighten the jamb nut securely
•
The straps and rubber strips should only be snug enough to the tank to keep it from moving.
IMPORTANT: Do not over tighten the bolts or damage to the tank and strap mounting bar
will result!
Jam Nut
10
FUEL LINE INSTALLATION
DANGER: Leaking fuel lines could cause a fire resulting in death or serious injury! All
fuel lines must be tight and leak free!
DANGER: Do not route fuel lines with battery cables or electrical wires, as this could
cause a fire!
IMPORTANT: Using the wrong fuel system fittings may void your engine warranty!
See “IMPORTANT DRC and 85 GALLON FUEL TANK REQUIREMENTS” on page 2.
6. Route the 3/8'' FUEL SUPPLY line from the fuel pump to the fuel tank fitting:
•
The supply line when installed into the tank must be no higher than 25.4 mm (1.00 in.) from the
bottom of the tank. Determine this length and cut the supply line.
•
Cut the end of the supply line at a 45 degree angle and slide on the fuel line fittings.
•
Insert the supply line into the fuel pickup fitting until it is 25.4 mm (1.00 in.) from the bottom of
the tank then tighten the fuel line fitting securely.
7. Route the 1/4'' FUEL RETURN line from the fuel filter to the fuel tank:
•
Cut the return line to the appropriate length and slide on the fuel line fittings.
•
Install the line onto the fuel return fitting and then tighten the fuel line fitting securely.
8. Remove the plastic cap from the fuel vent and point the outlet to the rear of the container.
ULTRASONIC FUEL LEVEL SENSOR (UFLS)
Interconnect Harness Installation and Routing
DANGER: Do not route electrical wires with fuel lines as this could cause a fire!
IMPORTANT: All electrical connections of the UFLS harness must be made with the supplied crimp and
solder style connectors with separate heat shrink tubing. DO NOT burn the heat shrink. If the heat
shrink is burnt, charred, or has bubbles from overheating, the wire connections must be removed and
redone correctly.
1. Attach the interconnect harness to the fuel sensor wires located inside the control box.
Connections inside
Control Box
BLACK to FUELN-01
WHITE to FUEL-01
GREEN to 8F-01
•
•
•
•
•
Slide supplied heat shrink tubing onto each wire and position them away from joint:
Connect each wire with wire connector and crimp securely.
Solder wires to wire connectors with a soldering gun.
Slide heat shrink tubing over each wire connector and applying heat with a heat gun.
Secure harness inside the control box with tie bands.
2. Route the harness to the fuel tank using the trailer’s harness conduit or chase to avoid interference
with fifth wheel plate area.
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UFLS Harness Connections
3. Cut the interconnect harness to length and splice wires to the fuel sensor’s leads.
Connections at
Sensor
BLACK to BLACK
WHITE to YELLOW
GREEN to RED
•
•
•
•
Slide supplied heat shrink tubing onto each wire and position them away from joint:
Connect each wire with wire connector and crimp securely.
Solder wires to wire connectors with a soldering gun.
Slide heat shrink tubing over each wire connector and applying heat with a heat gun.
4. Secure any exposed harness with clamps.
IMPORTANT: This is a “Solid State” fuel level sensor and the controller must be programmed
accordingly to enable the fuel level feature.
Connections at
Sensor
BLACK to BLACK
WHITE to YELLOW
GREEN to RED
Connections inside
Control Box
BLACK to FUELN-01
WHITE to FUEL-01
GREEN to 8F-01
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PROGRAMMING THE CONTROLLER FOR FUEL LEVEL
NOTE: These procedures can also be done through OptiSet™
1. Turn off the engine. (Guarded Access Menu is not available if the engine is running.)
2. Go to the Guarded Access Menu.
3. Scroll down to and select the Unit Configuration.
4. Scroll down to and select Fuel Level Sensor.
The choices are: NONE, SOLID STATE or FLOAT
•
UFLS STYLE - scroll to SOLID STATE by pressing + key then YES key.
•
FLOAT STYLE - scroll to FLOAT by pressing + key then YES key.
•
Fuel Level Percent will now be in the gauge menu.
•
The unit is now programed, press the exit key.
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