Thermo King UT-Series User manual

Copyright© 2018 Thermo King EMEA
Printed in Ireland
UT-Series
UT-800, UT-1200, UT Spectrum
TK 60652-OP (Rev. 3, 04-18)

Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no
representations or warranties, express or implied, with respect to the information, recommendations
and descriptions contained in this manual and such information, recommendations and descriptions
should not be regarded as all-inclusive or covering all contingencies. In the event you have any
questions or require further information, please contact your local Thermo King dealer.
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to
implement these procedures correctly may cause damage to the Thermo King unit or other property or
personal injury.
The manufacturer, Thermo King Corporation, assumes no responsibility for any act or action taken on
the part of the owner or operator in the repair or operation of the products covered by this manual that
are contrary to the manufacturer’s printed instructions. No warranties expressed or implied, including
warranties arising from cause of dealing or usage or trade, are made regarding the information,
recommendations, and description contained herein. The manufacturer is not responsible and will not
be held liable in contract or in tort (including negligence) for any special, indirect or consequential
damages, including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product, its mechanical failure or the failure of owner/operator to heed
caution and safety decals strategically located on the product.

4
Software Licence
The product includes software that is licensed under a non-exclusive, non-sub-licensable, terminable
and limited license to use the software as installed on the product for its intended purpose. Any
removal, reproduction, reverse engineering, or other unauthorized use of the software is strictly
prohibited. Hacking the product or installing unapproved software may void the warranty. The owner or
operator shall not reverse engineer, decompile, or disassemble the software, except and only to the
extent that such activity is expressly permitted by applicable law notwithstanding this limitation. The
product may include third party software separately licensed as specified in any documentation
accompanying the product or in an about screen on a mobile application or website that interfaces with
the product..

Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . . 6
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 6
Battery Installation and Cable Routing . . . . . . . . . . . . . 7
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . . 9
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Do Not Use Ether Starting Aids . . . . . . . . . . . . . . . . . 12
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . 14
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Thermo King Scroll Compressor . . . . . . . . . . . . . . . . . 14
HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Premium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
CYCLE-SENTRYTM Start-Stop Controls . . . . . . . . . .16
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
DAS - Data Acquisition System . . . . . . . . . . . . . . . . . .16
Electric Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Engine Compartment Components . . . . . . . . . . . . . . .18
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .18
Manual Pretrip Inspection . . . . . . . . . . . . . . . . . . . . .22
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . .25
Unit Operating Instructions Premium HMI Controller . .25
Operating the TSR-3 Controller . . . . . . . . . . . . . . . . . .28
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Loading and Enroute Inspections . . . . . . . . . . . . . .30
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .30
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . .32

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . 42
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Maintenance Inspection Schedule . . . . . . . . . . . . . . 45
Inspection and Service intervals . . . . . . . . . . . . . . . . . 45
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 47
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . 48

Introduction
3
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this manual
will be time well spent.
Performing pre-trip checks and enroute inspections on a regular
basis will minimize on-the-road operating problems. A regular
maintenance program will also help to keep your unit in top
operating condition. If factory recommended procedures are
followed, you will find that you have purchased the most efficient
and dependable temperature control system available.
All service requirements, major and minor, should be handled by a
Thermo King Dealer for these very important reasons:
• They have factory trained and certified technicians
• They have genuine Thermo King replacement parts
• They are equipped with the factory recommended tools to
perform all service functions
• The warranty on your new unit is valid only when the repair
and replacement of component parts is performed by an
authorized Thermo King Dealer.
IMPORTANT: This manual is published for informational purposes
only and the information furnished herein should not be considered
as all-inclusive or meant to cover all contingencies. If more
information is required, consult your Thermo King Service
Directory for the location and telephone number of the local dealer.
Customer Satisfaction Survey
Let your voice be heard!
Your feedback will help improve our manuals. The survey is
accessible through any internet-connected device with a web browser.
Scan the Quick Response (QR) code or click or type the web
address to complete the survey:
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Introduction
4
Emergency Assistance
Thermo Assistance is a multi-lingual communication tool
designed to put you in direct contact with an authorized
Thermo King dealer.
Thermo Assistance should only be contacted for
breakdown and repair assistance.
To use this system, you need the following information before
you call: (phone charges will apply)
• Contact Phone Number
• Type of TK Unit
• Thermostat Setting
• Present Load Temperature
• Probable Cause of Fault
• Warranty Details of the Unit
• Payment Details for the Repair
Leave your name and contact number and a Thermo Assistance
Operator will call you back. At this point you can give details
of the service required and the repair will be organized.
Please note that Thermo Assistance cannot guarantee payments
and the service is designed for the exclusive use of refrigerated
transporters with products manufactured by Thermo King
Corporation.
BEA261

Introduction
5
General Inquires and Unit
Maintenance
For general inquiries please contact your local Thermo King
dealer.
Go to www.europe.thermoking.com and select dealer locator
for your local Thermo King dealer.
Or refer to the Thermo King Service Directory for contact
information.

Safety Precautions
6
Safety Precautions
Thermo King recommends that servicing be done only by a
Thermo King dealer. However, you should be aware of several
safety practices. This chapter gives basic safety precautions for
working with Thermo King units and describes the safety
stickers on your unit that you should be familiar with.
General Safety Practices
Automatic Start/Stop Operation
This unit is capable of automatic operation and could start at
any time without warning.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating
with the doors open.
WARNING: Exposed coil fins can cause painful
lacerations. Service work on the evaporator or
condenser coils should be done by a certified Thermo
King technician.
WARNING: Do not apply heat to a closed cooling
system. Before applying heat to a cooling system,
drain it. Then flush it with water and drain the water.
Antifreeze contains water and ethylene glycol. The
ethylene glycol is flammable and can ignite if the
antifreeze is heated enough to boil off the water.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.

Safety Precautions
7
Battery Installation and Cable
Routing
WARNING: Improperly installed battery could result
in a fire or explosion. A Thermo King approved
battery must be installed and properly secured to the
battery tray.
WARNING: Improperly installed battery cables could
result in fire or explosion. Battery cables must be
installed, routed and secured properly to prevent
them from rubbing, chaffing or making contact with
hot, sharp or rotating components.
CAUTION: Do not connect other manufacturer’s
equipment or accessories 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
battery to prevent unit from starting unexpectedly and
causing personal injury.
CAUTION: Always wear protective clothing, gloves
and eye wear when handling and installing batteries.
Battery acid can cause serious burns when exposed to
eyes or skin. If battery acid contacts skin or clothing,
wash immediately with soap and water. If acid enters
your eye, immediately flood it with running cold
water for at least twenty minutes and get medical
attention immediately.
CAUTION: Always cover battery terminals to prevent
them from making contact with metal components
during battery installation. Battery terminals
grounding against metal could cause the battery to
explode.

Safety Precautions
8
Refrigerant
Although fluorocarbon refrigerants are classified as safe, use
caution when working with refrigerants or in areas where they
are being used.
NOTE: These warnings refer to servicing of the unit.
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
NOTE: These warnings refer to servicing of the unit.
DANGER: Fluorocarbon refrigerants can produce
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.

Safety Precautions
9
First Aid
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid–Refrigerant Oil
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Safety Decals and Locations
Service
The Service decal is located inside the Control Box Door. This
decal gives you the information to access/download your unit
operator manual, but also the safety icons associated with your
unit. These safety icons are directly associated with the
information within this chapter. You can see the explanations
for these icons starting from “General Safety Practices” on
page 6. See “Service Decal” on page 10
NOTE: This decal only contains symbols of warning for the
service of the unit.

Safety Precautions
10
Figure 1: Service Decal
Operation
The Operation decal is located in an appropriate position near
your in-cab controller or rear remote controller (if fitted). This
decal gives you the information to access/download your unit
operator manual
Figure 2: Operation Decal
Condenser and Evaporator Fans
Locations vary depending on model. Decals are located near areas
that contain fans which can cause severe injuries if hands or
clothing become tangled.

Safety Precautions
11
Figure 3: Fan Warning
Refrigerant
Refrigerant decal located on unit frame.
F Gas decal indicates that this equipment Contains fluorinated
greenhouse gases.
BEN217
WARNINGWARNING
CAUTION FAN
ATTENTION VENTILATEUR
ACHTUNG VENTILATOR
ATTENZIONE VENTILATORE
CUIDADO VENTILADOR
CUIDADO HELICE
CAUTION FAN
ATTENTION VENTILATEUR
ACHTUNG VENTILATOR
ATTENZIONE VENTILATORE
CUIDADO VENTILADOR
CUIDADO HELICE
SWITCH UNIT TO OFF BEFORE SERVICING
ARRESTARE L'UNITÀ PRIMA DEGLI INTERVENTI DI SERVIZIO
ARRÊTER LE GROUPE AVANT DE PROCÉDER À L'ENTRETIEN
VOR WARTUNG EINHEIT ABSCHALTEN
PARAR LA UNIDAD ANTES DE HACERLE EL SERVICIO
DESLIGUE A UNIDADE ANTES DE EXECUTAR SERVIÇO
ARRESTARE L'UNITÀ PRIMA DEGLI INTERVENTI DI SERVIZIO
VOR WARTUNG EINHEIT ABSCHALTEN
PARAR LA UNIDAD ANTES DE HACERLE EL SERVICIO
DESLIGUE A UNIDADE ANTES DE EXECUTAR SERVIÇO
UNIT MAY START AUTOMATICALLY AND CAN CAUSE
SEVERE INJURY. SWITCH UNIT TO "OFF" BEFORE SERVICING.
LE GROUPE EST EN FONCTIONNEMENT AUTOMATIQUE
AVANT INTERVENTION METTRE L'INTERRUPTEUR.
DU CIROUPE SUR ARRET.
MASCHINE KANN AUTOMATISCH STARTEN UND
VERLETZUNGEN VERURSACHEN.
VOR WARTUNG EINHEIT ABSCHALTEN.
AVVIO E ARRESTO AUTOMATICO DEL MOTORE. SPEGNERE
L'UNITÀ PRIMA DEGLI INTERVENTI DI SERVIZIO.
MARCHA/ PARO AUTOMATICO
PARAR LA UNIDAD ANTES DEHACERLE EL SERVICIO.
A UNIDADE PODE INICIAR AUTOMATICAMENTE E CAUSAR
FERIMENTO GRAVE. DESLIGUE A UNIDADE ANTES DE
EXECUTAR SERVIÇO.
UNIT MAY START AUTOMATICALLY AND CAN CAUSE
SEVERE INJURY. SWITCH UNIT TO "OFF" BEFORE SERVICING.
LE GROUPE EST EN FONCTIONNEMENT AUTOMATIQUE
AVANT INTERVENTION METTRE L'INTERRUPTEUR.
DU CIROUPE SUR ARRET.
MASCHINE KANN AUTOMATISCH STARTEN UND
VERLETZUNGEN VERURSACHEN.
VOR WARTUNG EINHEIT ABSCHALTEN.
AVVIO E ARRESTO AUTOMATICO DEL MOTORE. SPEGNERE
L'UNITÀ PRIMA DEGLI INTERVENTI DI SERVIZIO.
MARCHA/ PARO AUTOMATICO
PARAR LA UNIDAD ANTES DEHACERLE EL SERVICIO.
A UNIDADE PODE INICIAR AUTOMATICAMENTE E CAUSAR
FERIMENTO GRAVE. DESLIGUE A UNIDADE ANTES DE
EXECUTAR SERVIÇO.
BEN501
R 452A
REFRIGERANT TYPE / GWP = 2140
COMPRESSOR OIL TYPE
203-513
POLYOL ESTER ISO 35
932223
F-GAS
GWP
>150
Kyoto Protocol !

Safety Precautions
12
Do Not Use Ether Starting Aids
Figure 4: Do Not Use Ether Starting Aids
(Near Engine)

Unit Description
13
Unit Description
General Information
The UT-Series unit is a microprocessor based transport
temperature control system that uses the TSR-3 Truck HMI
microcontroller to manage system functions.
The unit is under-mounted, diesel powered cooling and heating
system designed for straight trucks. It is designed for use with
chlorine free R-404A/R-452A refrigerant. Remote evaporators
are used to control temperatures in up to three individual cargo
compartments.The basic models provide the following:
Cooling and hot gas heating on engine operation and electric
standby operation.
Figure 5: Front View

Unit Description
14
Diesel Engine
Engine power for the UT-Series unit is provided by the TK376,
a three cylinder, clean and quite diesel engine. The UT-1200
and UT SPECTRUM are rated at 19.6 continuous horsepower
(14.6 kW) at 2425 RPM whereas the UT-800 is rated at 19.0
horsepower (14.2 kW) at 2200 RPM. A belt drive system
transfers energy to the compressor, unit fans and alternator.
ELC (Extended Life Coolant)
ELC (Extended Life Coolant) is standard equipment. The
maintenance interval for ELC is five years or 12,000 hours. A
nameplate on the coolant expansion tank identifies units with
ELC. The new engine coolant, Chevron Extended Life
Coolant, is RED in color instead of the previous GREEN or
BLUE-GREEN colored conventional coolants.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
Clutch
The centrifugal clutch engages fully at 600 ± 100 RPM on
engine operation, constantly turning the compressor, alternator,
and fans at both high and low speed. The clutch isolates the
engine from the belt drive system during electric standby
operation.
Thermo King Scroll Compressor
The UT-1200, UT SPECTRUM and UT-800 feature the
reliable TKO Scroll 6.0 hp compressor..
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to cooling
systems using “RED” Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.

Unit Description
15
HMI Control Panel
Standard
The Standard HMI Control Panel (Human/Machine Interface)
is used to operate the unit and display unit information. The
Control Panel is typically located in the vehicle driver's
compartment and communicates with the base controller using
a connection on the interface board.
Figure 6: Standard HMI Control Panel
Premium
The Premium Truck HMI (Human/Machine Interface) Control
Panel is available as an option on TSR-3 applications. It is used
to operate the unit, display unit information and access all
TSR-3 Maintenance and Guarded Access Menus. The Control
Panel is typically located in the vehicle driver's compartment
and communicates with the base controller using a connection
on the interface board.
Figure 7: Premium HMI Control Panel
Figure 8: Premium HMI Control Panel - Spectrum

Unit Description
16
CYCLE-SENTRYTM Start-Stop
Controls
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy. When CYCLE-SENTRY Mode
is selected the unit will start and stop automatically to maintain
setpoint, keep the engine warm and the battery charged. When
Continuous Mode is selected, the unit starts automatically and
runs continuously to maintain setpoint and provide constant
airflow.
Defrost
Frost will gradually build up on the evaporator coils as a result
of normal operation. Periodically this frost must be melted to
prevent a loss of cooling and airflow.
Defrost is accomplished by passing hot refrigerant gas through
the evaporator coil, thus melting the frost (or ice). Melted frost
drains out of the unit onto the ground through the drain tubes.
The defrost damper closes during defrost to prevent warm air
from entering the cargo area. The optional electric heater strips
are also energized in defrost during electric standby operation.
Defrost can be initiated at any time the evaporator coil
temperature is below 42 F (5.5 C).
There are two methods of defrost initiation:
TSR/TSR-3 Microprocessor Controller
The Microprocessor Controller is programmed to
automatically initiate timed and forced defrost cycles. The
TSR/TSR-3 uses temperature sensors to determine if forced
defrost is required.
Manual Defrost
Manual Defrost allows the operator to initiate a defrost cycle
by pressing the Defrost key. See “Initiating a Manual Defrost
Cycle.”
DAS - Data Acquisition System
NOTE: (Optional )
The DAS (Data Acquisition System) monitors and records the
temperatures of (up to) six additional sensors. The sensors are
independent from the microprocessor controller and are