Thermo King TracKing Telematics Retrofit 3G to 4G TKV5 Installation guide

Brand: Thermo King

Model: TracKing Telematics Retrofit 3G to 4G TKV5

Type: Installation guide

Kits and Components for SB Trailer Units

TKV5

Base Kit

401643

Single Temperature

Kit

401645

Multi-Temperature

Kit

401648

Item Part Number Description

1. 425470 TKV5 Module 1

2. 557011 M5 Nuts 4

3. 554665 M5 Washer 4

4. 927100 Warning Nameplate 1

5. 935888 Connected Nameplate 1

6. 425175 Harness ST 1

7. 425174 Harness MT 1

8. 938508 Mounting Bracket 1 1

9. 513752 Screw, self-drilling 5 5

10. 331371 Grommet 2 2

11. 553019 Screw, 10–32 2 2

12. 550431 Flat washer, #10 2 2

13. 555292 Locking nut, 10–32 2 2

14. 922229 Spacer 2 2

15. 553019 Band wrap 4 4

16. 337070 Gasket 3 3

17. 551699 Clamp 4 4

Installation Instructions

TracKing™Retrofit 3G to 4G TKV5

OOvveerrvviieeww

The existing TK BlueBox module and harness will be removed from the unit and replaced with

the TKV5 module and communication harness. The TKV5 module has an integral antenna so the

existing remote antenna will no longer be required. The antenna can be removed from the unit

or left in place with the cables bundled and secured with band wraps. Because of the integral

antenna, the TKV5 module cannot be installed inside the metal control box, and instead is

remote mounted up inside the condenser section behind the roadside grille. The new harness is

routed from the remote TKV5 module into the rear of the control box.

When replacing BlueBox with TKV5, the module and harness removal should be done last so

existing connections can be used as a guide.

Harness connections and activation procedures for the TKV5 are the same as TK BlueBox. When

replacing prior telematics or doing a new installation, see TK 56689 for harness connections and

configuration procedures.

IImmppoorrttaanntt:: The TK BlueBox contains a Lithium-Ion battery that must be properly disposed of.

See “TTKK BBlluueeBBooxx DDiissppoossaall”” on Page 7.

Figure 1. TKV5 shown installed inside the condenser section behind roadside grille.

RCS1837

Installation Procedures

IImmppoorrttaanntt:: Disconnect all power to the unit before beginning installation.

IInnssttaalllliinngg tthhee MMoodduullee

1. Open roadside panel, roadside grille and control box door. Mark a line approximately 9” to

10” (229–254 mm) up from condenser bottom plate as shown.

2. Position bottom of module mounting plate with marked line and align angled corners where

sheet metal plenum bends away from frame post. This keeps it clear of the closed condenser

grille.

3. Use mounting plate as a drill template and pre-drill three 7/32” holes. This will simplify use of

self-tapping screws to mount.

a. Attach mounting plate using three self-tapping screws.

4. Install module onto mounting plate studs and secure with four M5 nuts and washers.

NNoottee:: Harness shown installed, do not install harness yet.

Figure 2. TKV5 and pass-through locations and mounting plate with TKV5 module shown

installed.

RCS1838-2

9-10 in.

(229-254 mm)

8-9 in.

(229-254 mm)

5. Use 2” hole saw to create a pass-through hole in bottom condenser plate 8-9” forward of the

frame post as shown.

IImmppoorrttaanntt:: Use caution to avoid damaging any underlying harnesses or components when

drilling pass-through hole, and place hole inboard of the grille in its fixed location.

IInnssttaalllliinngg tthhee HHaarrnneessss

6. Inside the control box, use a 2” hole saw to create a pass–through hole for the harness as

shown.

IImmppoorrttaanntt:: Use caution around existing harnesses and be careful to avoid unit battery when

drilling pass-through hole.

7. Install both grommets over the large 35-pin connector of the harness tthheenn route the

connector through the newly added control box hole from the controller side, up through the

lower condenser panel and attach securely to module.

NNoottee:: Install grommets in both pass-through holes oonnllyy aafftteerr harness has been routed and

connected to module.

Figure 3. Pass-through hole location in control box and harness routed out of box shown.

RCS1839

8. Inside the control box, remove the top and bottom controller bolts on the left side and

replace with the supplied 1.5” long 10-32 hardware.

NNoottee:: Photo shows location of controller bolts on outside of control box.

9. Outside the control box, place PVC spacers over each of the 10–32 screws coming out from

the threaded inserts and use these as a harness anchor points with the P-clamp and #10 nut

to secure harness as shown.

a. Also secure harness with supplied P-clamps and self–drilling screws near base of frame

post and near the pass-through hole on the condenser panel.

10.Provide a drip loop as shown.

Figure 4. Longer controller screws shown with clamps to secure harness.

RCS1840

11.Seal the control box pass-through hole by trimming two of the supplied gaskets and

installing as shown.

a. Use the third gasket to seal the top of the pass-through hole in the condenser plate.

Figure 5. Pass-through hole shown properly sealed with supplied gaskets.

RCS1841-1

12.CCoonnnneeccttiinngg tthhee HHaarrnneessss::

• Multi-Temperature Units: Make TKV5 harness connections at controller power and ground

locations and any other connections as required.

• Single Temperature Units: Make TKV5 harness connections at CAN connections and any

other connections as required.

13.Reconnect all power to unit and verify TKV5 operation.

TK BlueBox Disposal

WWAARRNNIINNGG

RRiisskk ooff FFiirree!!!!

LLiitthhiiuumm——IIoonn bbaatttteerriieess ccoonnttaaiinn hhaazzaarrddoouuss mmaatteerriiaallss aanndd ssttoorree aa llaarrggee aammoouunntt ooff eenneerrggyy iinn aa ssmmaallll aammoouunntt ooff

ssppaaccee.. IImmpprrooppeerr ddiissppoossaall ooff LLiitthhiiuumm——IIoonn bbaatttteerriieess ccoouulldd sshhoorrtt aanndd ssppaarrkk aa ffiirree.. TToo pprreevveenntt ffiirreess,, ttaappee

bbaatttteerryy tteerrmmiinnaallss aanndd//oorr ppllaaccee lliitthhiiuumm--IIoonn bbaatttteerriieess iinn sseeppaarraattee ppllaassttiicc bbaaggss aanndd ttaakkee ttoo sseeppaarraattee rreeccyycclliinngg oorr

hhaazzaarrddoouuss wwaassttee ccoolllleeccttiioonn ppooiinnttss..

NNoottee:: If the TK BlueBox module is not part of a 3G-to-4G exchange program, please dispose of

the module properly. This includes removing and properly disposing of the Lithium-Ion

battery and the TK BlueBox module itself.

1. Remove Lithium-Ion battery from TK BlueBox module.

2. Tape battery terminals and/or place lithium-Ion batteries in separate plastic bags.

BBaatttteerryy DDiissppoossaall

• Take Lithium-Ion batteries to separate recycling or hazardous waste collection points.

•DDOO NNOOTT put Lithium-Ion batteries in garbage or recycling bins.

TTKK BBlluueeBBooxx MMoodduullee DDiissppoossaall

• Take the TK BlueBox module to E-Waste hazardous waste collection point.

•DDOO NNOOTT put TK BlueBox module in garbage or recycling bins.

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Thermo King TracKing Telematics Retrofit 3G to 4G TKV5 Installation guide

Thermo King TracKing Telematics Retrofit 3G to 4G TKV5 Installation guide

Thermo King TracKing Telematics Retrofit 3G to 4G TKV5 Installation guide

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