UT-Series

UT-800, UT-1200, UT Spectrum

TK 60652-OP (Rev. 3, 04-18)

Copyright© 2018 Thermo King EMEA

Printed in Ireland
 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.
 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..

4
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Premium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
CYCLE-SENTRYTM Start-Stop Controls . . . . . . . . . .16
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . . 6 DAS - Data Acquisition System . . . . . . . . . . . . . . . . . .16
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 6 Electric Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Battery Installation and Cable Routing . . . . . . . . . . . . . 7 Engine Compartment Components . . . . . . . . . . . . . . .18
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .18
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Manual Pretrip Inspection . . . . . . . . . . . . . . . . . . . . .22
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . . 9
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . .25
Do Not Use Ether Starting Aids . . . . . . . . . . . . . . . . . 12 Unit Operating Instructions Premium HMI Controller . .25
Operating the TSR-3 Controller . . . . . . . . . . . . . . . . . .28
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . 14
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Loading and Enroute Inspections . . . . . . . . . . . . . .30
Thermo King Scroll Compressor . . . . . . . . . . . . . . . . . 14 Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .30
HMI Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 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

Introduction
There is nothing complicated about operating and maintaining IMPORTANT: This manual is published for informational purposes
your Thermo King unit, but a few minutes studying this manual only and the information furnished herein should not be considered
will be time well spent. as all-inclusive or meant to cover all contingencies. If more
information is required, consult your Thermo King Service
Performing pre-trip checks and enroute inspections on a regular
Directory for the location and telephone number of the local dealer.
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 Customer Satisfaction Survey
followed, you will find that you have purchased the most efficient Let your voice be heard!
and dependable temperature control system available. Your feedback will help improve our manuals. The survey is
All service requirements, major and minor, should be handled by a accessible through any internet-connected device with a web browser.
Thermo King Dealer for these very important reasons:
Scan the Quick Response (QR) code or click or type the web
• They have factory trained and certified technicians address to complete the survey:
• They have genuine Thermo King replacement parts http://irco.az1.qualtrics.com/SE/?SID=SV_2octfSHoUJxsk6x
• 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.

3
Introduction

Emergency Assistance Please note that Thermo Assistance cannot guarantee payments
and the service is designed for the exclusive use of refrigerated
Thermo Assistance is a multi-lingual communication tool transporters with products manufactured by Thermo King
designed to put you in direct contact with an authorized Corporation.
Thermo King dealer.
BEA261
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.

4
 Introduction

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.

5
Safety Precautions

Safety Precautions
Thermo King recommends that servicing be done only by a
WARNING: Do not apply heat to a closed cooling
Thermo King dealer. However, you should be aware of several
system. Before applying heat to a cooling system,
safety practices. This chapter gives basic safety precautions for
drain it. Then flush it with water and drain the water.
working with Thermo King units and describes the safety
Antifreeze contains water and ethylene glycol. The
stickers on your unit that you should be familiar with.
ethylene glycol is flammable and can ignite if the
General Safety Practices antifreeze is heated enough to boil off the water.

WARNING: Keep hands and loose clothing clear of

fans and belts at all times when the unit is operating
Automatic Start/Stop Operation
with the doors open. This unit is capable of automatic operation and could start at
any time without warning.

WARNING: The unit can start at any time without

WARNING: Exposed coil fins can cause painful warning. Press the OFF key on the control panel and
lacerations. Service work on the evaporator or place the microprocessor On/Off switch in the Off
condenser coils should be done by a certified Thermo position before inspecting or servicing any part of the
King technician. unit.

6
 Safety Precautions

Battery Installation and Cable CAUTION: Always wear protective clothing, gloves
Routing and eye wear when handling and installing batteries.
Battery acid can cause serious burns when exposed to
WARNING: Improperly installed battery could result eyes or skin. If battery acid contacts skin or clothing,
in a fire or explosion. A Thermo King approved wash immediately with soap and water. If acid enters
battery must be installed and properly secured to the your eye, immediately flood it with running cold
battery tray. water for at least twenty minutes and get medical
attention immediately.
WARNING: Improperly installed battery cables could
CAUTION: Always cover battery terminals to prevent
result in fire or explosion. Battery cables must be
them from making contact with metal components
installed, routed and secured properly to prevent
during battery installation. Battery terminals
them from rubbing, chaffing or making contact with
grounding against metal could cause the battery to
hot, sharp or rotating components.
explode.
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.

7
Safety Precautions

Refrigerant Refrigerant Oil

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

WARNING: Fluorocarbon refrigerants evaporate

rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.

8
 Safety Precautions

First Aid Ingestion: Do not induce vomiting. Immediately contact

local poison control center or physician.

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

9
Safety Precautions

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.

Figure 1: Service Decal

10
 Safety Precautions

Refrigerant
WARNING CAUTION FAN
Refrigerant decal located on unit frame.

R 452A
CAUTION FAN
ATTENTION VENTILATEUR
ATTENTION VENTILATEUR
ACHTUNG VENTILATOR
ACHTUNG VENTILATOR

932223
ATTENZIONE VENTILATORE
ATTENZIONE VENTILATORE
F-GAS
CUIDADO
CUIDADOVENTILADOR
VENTILADOR GWP
>150
CUIDADO HELICE
CUIDADO HELICE Kyoto Protocol !

UNIT MAY START AUTOMATICALLY AND CAN CAUSE

SEVERE INJURY. SWITCH UNIT TO "OFF" BEFORE SERVICING.
SWITCH UNIT TO OFF BEFORE SERVICING
REFRIGERANT TYPE / GWP = 2140
LE GROUPE EST EN FONCTIONNEMENT AUTOMATIQUE

203-513
AVANT INTERVENTION METTRE L'INTERRUPTEUR.
ARRÊTER LE GROUPE
DU CIROUPE AVANT DE PROCÉDER À L'ENTRETIEN
SUR ARRET.
MASCHINE KANN AUTOMATISCH STARTEN UND
VOR WARTUNG
VERLETZUNGEN EINHEIT ABSCHALTEN
VERURSACHEN.
VOR WARTUNG EINHEIT ABSCHALTEN.
ARRESTARE L'UNITÀAUTOMATICO
AVVIO E ARRESTO PRIMA DEGLIDELINTERVENTI
MOTORE.DI SERVIZIO
SPEGNERE
L'UNITÀ PRIMA DEGLI INTERVENTI DI SERVIZIO.
PARAR LA
MARCHA/ UNIDAD
PARO ANTES DE HACERLE EL SERVICIO
AUTOMATICO

POLYOL ESTER ISO 35

PARAR LA UNIDAD ANTES DEHACERLE EL SERVICIO.
ADESLIGUE A UNIDADE
UNIDADE PODE ANTES
INICIAR DE EXECUTAR SERVIÇO
AUTOMATICAMENTE E CAUSAR
FERIMENTO GRAVE. DESLIGUE A UNIDADE ANTES DE
EXECUTAR SERVIÇO.

BEN217 COMPRESSOR OIL TYPE

Figure 3: Fan Warning BEN501

F Gas decal indicates that this equipment Contains fluorinated

greenhouse gases.

11
Safety Precautions

Do Not Use Ether Starting Aids

Figure 4: Do Not Use Ether Starting Aids

(Near Engine)

12
Unit Description

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

13
Unit Description

Diesel Engine NOTE: The use of 50/50% pre-mixed ELC is recommended

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

14
Unit Description

HMI Control Panel 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
Standard on the interface board.
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 7: Premium HMI Control Panel

Figure 6: Standard HMI Control Panel

Premium Figure 8: Premium HMI Control Panel - Spectrum

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

15
Unit Description

CYCLE-SENTRYTM Start-Stop Defrost can be initiated at any time the evaporator coil
temperature is below 42 F (5.5 C).
Controls There are two methods of defrost initiation:
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy. When CYCLE-SENTRY Mode TSR/TSR-3 Microprocessor Controller
is selected the unit will start and stop automatically to maintain
setpoint, keep the engine warm and the battery charged. When The Microprocessor Controller is programmed to
Continuous Mode is selected, the unit starts automatically and automatically initiate timed and forced defrost cycles. The
runs continuously to maintain setpoint and provide constant TSR/TSR-3 uses temperature sensors to determine if forced
airflow. defrost is required.

Manual Defrost
Defrost
Manual Defrost allows the operator to initiate a defrost cycle
Frost will gradually build up on the evaporator coils as a result
by pressing the Defrost key. See “Initiating a Manual Defrost
of normal operation. Periodically this frost must be melted to
Cycle.”
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 DAS - Data Acquisition System
drains out of the unit onto the ground through the drain tubes. NOTE: (Optional )
The defrost damper closes during defrost to prevent warm air
The DAS (Data Acquisition System) monitors and records the
from entering the cargo area. The optional electric heater strips
temperatures of (up to) six additional sensors. The sensors are
are also energized in defrost during electric standby operation.
independent from the microprocessor controller and are

16
Unit Description

normally located in the truck box to monitor load temperatures. Standard Features
DAS data can be downloaded through a serial port to an IBM®
PC compatible computer. WinTrac™ 4.8 (or higher) software The following features are standard equipment on units
is used to view and analyze the data. Brief reports can be equipped with Electric Standby.
printed on a microprinter connected to the serial port.
Automatic Diesel/Electric Selection
Electric Standby The unit will automatically switch to electric operation when a
power cord is connected and the standby power is switched
The Electric Standby option allows the unit to be operated on On.
either the diesel engine or external electric power. During
Electric Standby operation, power to the unit is supplied by an
electric motor connected to a high voltage power source.
Overload Relay
Check the unit for proper power source ratings. The overload relay is self-resetting.

Electric Power Receptacle Hot Gas Heat

The electric power receptacle is used to connect the unit to an Hot gas heat is utilized on all units.
appropriate electric power source for electric standby
operation. Turn the unit OFF before connecting or Automatic Phase Correction
disconnecting the power cord.
The control system features two motor contactors. This allows
correct motor rotation regardless of phase rotation on the
incoming power.

17
Unit Description

Optional Features Engine Oil Dipstick

The following features are available as an option on units Use the engine oil dipstick to check the engine oil level.
equipped with Electric Standby.
CAUTION: Make sure the engine is turned off before
• Autoswitching attempting to check the engine oil.

Engine Compartment
Components Receiver Tank Sight Glass
The receiver tank sight glass is used to assist in checking the
amount of refrigerant in the system.
Coolant Expansion Tank
The coolant level and temperature are monitored by the base
controller. If the coolant temperature becomes too high or the
Compressor Oil Sight Glass
level becomes too low, an alarm will occur. The compressor oil sight glass is used to check the relative
level of compressor oil in the compressor sump.
The engine must have antifreeze protection to -34 C (-30 F).
Check and add coolant in the expansion tank as needed.

WARNING: The unit can start at any time without

Unit Protection Devices
warning. Press the OFF key on the control panel and High Pressure Cutout Switch (HPCO): This normally
place the microprocessor On/Off switch in the Off closed switch monitors the discharge pressure at the
position before inspecting any part of the unit. compressor. It opens on high discharge pressure to shut the unit
down to prevent damage.

18
Unit Description

Engine Oil Pressure Switch/Sensor: The engine oil

pressure switch/sensor is located on the filter head above the
bypass oil filter. Engine oil pressure should rise immediately
on starting. If engine oil pressure drops below 10 ± 2 psig (69 ±
14 kPa), the switch/sensor signals the microprocessor to stop
the engine.
Preheat Buzzer: The preheat buzzer sounds when the
CYCLE-SENTRYTM system energizes the glow plugs. This
should warn anyone near the unit that the
CYCLE-SENTRYTM system is about to start the diesel
engine.
Coolant Temperature Sensor: This sensor provides an
engine coolant temperature input to the microprocessor. If the
engine coolant temperature is too high, the controller stops the
unit and records an alarm.
Electric Motor Overload Relay: The overload relay
protects the electric standby motor. The overload relay opens
the circuit from the contactor to the electric motor if the motor
overloads for any reason and an alarm will occur. The relay
resets when the alarm code is cleared.
Fuses: Sizes and functions are described in the Specifications
section of this manual.

19
Unit Description

1. Engine Oil Dipstick (on side of engine) 5. Alternator

2. Engine 6. Compressor
3. Coolant Expansion Tank 7. Dehydrator (Filter-Drier)
4. Electric Motor
Figure 9: Main Components in UT-Series Units

20
Unit Description

Pharma
Single temperature units qualified for pharmaceutical
applications under Thermo King protocol. Please follow the
following recommendations:
• To maintain the best temperature management within the
load-space it is recommended to operate with the
following set-point temperatures in the following ranges.
• +20 °C Set-Point for temperature range +15 °C to +25
°C
• +5 °C Set-Point for temperature range +2 °C to +8 °C
• -25 °C Set-Point for temperature below -20 °C
• For optimum temperature management and air
distribution, the refrigeration unit’s continuous operation
mode must be used for all temperature ranges.
• Efficient loading practices and operating procedures have
to be followed to ensure optimum air circulation and
temperature management.

21
Manual Pretrip Inspection

Manual Pretrip Inspection

Before Starting the Unit CAUTION: Turn the engine off before checking the
engine oil level.
Pretrip inspections are an important part of a preventative
maintenance program designed to minimize operating
problems and breakdowns. Perform this pretrip inspection Engine Coolant: Check the coolant level in the overflow
before every trip involving refrigerated cargo. bottle. It should be above the Full Cold line. If necessary, add
coolant to the overflow bottle. The engine coolant should be a
NOTE: Please refer to “Pre-Loading Inspection” on page 36 60/40 mixture and must have antifreeze protection to -34 C
also before commencing your journey. (-30 F). Add coolant if Alarm Code 37 is active. Check and add
NOTE: Pretrip inspections are not intended to take the place coolant to the expansion tank.
of regular maintenance inspections. NOTE: Please see Specifications chapter and “Engine” on
Fuel: Make sure the diesel fuel supply is adequate to page 37 where it is clearly states which coolant types are
guarantee engine operation to the next check point. Allow for allowed to be used in this unit.
maximum fuel consumption of 3.8 Litres (one gallon) per hour
of engine operation. WARNING: Do not remove the expansion tank cap
while the coolant is hot.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is threaded all the way into the oil
Battery: Make sure the battery terminals are tight and free of
pan. Do not overfill.
corrosion.

22
 Manual Pretrip Inspection

NOTE: All truck and trailer units will have a small battery Belts: Make sure belts are in good condition and adjusted to
drain when the unit is off. The battery can be drained even the proper tension. For more information about belt tension,
quicker if there are Aftermarket options or third party devices see the Specifications chapter.
connected to the unit which consume battery power.
Electrical: Check the electrical connections to make sure they
This will cause the battery to become discharged over time. are securely fastened. Wires and terminals should be free of
Apart from the obvious inconvenience of having to charge corrosion, cracks, and moisture.
the battery, it is also liable to damage battery cell material Structural: Visually inspect the unit for leaks, loose or
and cause the life of the battery to be shorter than acceptable. broken parts, and other damage.
Therefore, to ensure the battery remains in optimum Coils: Ensure condenser and evaporator coils are clean and
condition during periods when the unit is not being used, free of debris.
Thermo King strongly recommends to switch on the unit at
least once each week and run for 30 minutes or longer. • Washing with clean water should be sufficient.

Failure to do so may result in warranty for the battery being • The use of cleaning agents or detergents is strongly
rejected. discouraged due to the possibility of degradation of the
construction.
Alternatively, Thermo King offer a solar panel option from
aftermarket which would negate the requirement to switch • If using a power washer, the nozzle pressure should not
off the microprocessor switch during long unit idle periods. exceed 600 psi (41 bar). For the best results, spray the coil
For more information, please contact your local Thermo perpendicular to the face of the coil. The spray nozzle
King dealership. should be kept between 1 inch and 3 inches (25 to 75
millimeters) from the coil surface.

23
Manual Pretrip Inspection

• If necessary to use a chemical cleaner or detergent use a Cargo Box: Check the interior and exterior of the cargo box
cleaner that does not contain any hydrofluoric acids and is for damage. Any damage to the walls or insulation must be
between 7 and 8 on the pH scale. Ensure dilution repaired.
instructions provided by the detergent supplier are
Cargo Doors: Make sure that the cargo doors and weather
followed. In case of doubt about the compatibility of the
seals are in good condition. The doors should latch securely
detergent with the type of materials listed above, always
and the weather seals should fit tightly.
ask the supplier a written confirmation of the
compatibility. Defrost Drains: Check the defrost drain hoses to make sure
they are open.
• Should a chemical cleaner be required, it is
MANDATORY that all components are thoroughly rinsed Remote Evaporators : UT SPECTRUM
with water even if the instructions of the cleaner specify
• Visually inspect Evaporator(s) for damaged, loose, or
that it is a “no rinse” cleaner.
broken parts.
WARNING: Failure to comply with above mentioned
guidelines will lead to a shortened life of the equipment to an • Check also for refrigerant leaks.
indeterminable degree and also may void your warranty. • Check Defrost initiation and termination (including
NOTE: The repeated transportation of meat and fish waste defrost timer) by activating/initiating a manual defrost.
can cause extensive corrosion to the evaporator coils and
evaporator section tubing over time due to ammonia
formation and can reduce the lifespan of the coils.
Appropriate additional measures should be taken to protect
the coils against the aggressive corrosion that can result from
transportation of such products.

24
Operating Instructions

Operating Instructions
Unit Operating Instructions 8 6 7
Premium HMI Controller
The Premium Truck HMI (Human/Machine Interface) Control
Panel is available as an option on TSR-3 Truck applications. It 1 3
is used to operate the unit, display unit information and access
all TSR-3 Maintenance and Guarded Access Menus. The 2 4
Premium HMI Control Panel communicates with the base
controller via the CAN (Controller Area Network) bus. It is
connected to the base controller via CAN Connector J14 on the
interface board. The Premium HMI Control Panel is typically 5
located in the vehicle driver's compartment. It may be installed
in the truck instrument panel using a DIN mounting ring or Premium HMI Control Panel Display
under the instrument panel using an under dash mounting kit. Hard Keys
1. On Key
2. Off Key
3. Defrost
4. High Speed Lockout

25
Operating Instructions

5. Soft Keys
Hard Keys
6. Box Temperature
1. On Key
7. Setpoint
2. Off Key
8. Display
3. Defrost
Figure 10: Premium HMI Control Panel Display 4. High Speed Lockout
5. Zone 1 Soft Keys
6 7 8 6. Box Temperature
7. Setpoints
8. Zone 2 Display
1 3 9. Zone 2 Soft Key
2 4 10. Menu Soft Key

Figure 11: SPECTRUM - Premium HMI Control Panel

Display
5 9 10
The HMI control panel consists of a display and 8
touch-sensitive keys. The display is capable of showing both
text and graphics.

26
Operating Instructions

The keys on the left and right sides of the display are dedicated • Sends a Start of Trip to the ServiceWatch data logger.
single function "hard" keys.
The four keys under the display are "soft" keys. The functions Display
of these soft keys change depending on the operation being The display presents information to the operator. This
performed. If a soft key is active the current key function is information includes setpoint and temperature, unit operating
shown in the display directly above the key. information, gauge readings, temperatures and other
information as selected by the operator.
Controller Features The Standard Display of box temperature and setpoint is
• Displays Box Temperature and Setpoint in Fahrenheit or shown here. The CYCLE-SENTRY Icon in the upper right of
Celsius the display shows the unit is running in CYCLE-SENTRY
(Start-Stop) Mode. The unit has a setpoint of 2 C, and an actual
• Displays Engine Running and Motor Running Hourmeters
box temperature of 2.1 C. The down-pointing arrow at the left
• Changes Setpoint side of the display shows the unit is cooling.
• Indicates Alarm Condition Exists The four keys under the display are termed "soft" keys. The
• Displays and Clears Alarms functions of these keys change depending on the operation
being performed. The function of each soft key is shown by
• Selects and Indicates CYCLE-SENTRY or Continuous labels in the display located directly above each soft key. In
Mode Operation the example shown above, pressing the left soft key accesses
• Selects and Indicates High Speed Lock-Out Operation the SETPOINT and pressing the right soft key accesses the
MAIN MENU. The other two soft keys access the GAUGES
• Initiates and Indicates a Defrost Cycle
menu and SENSORS menu as shown by the labels above the
• Initiates and Indicates a Pretrip Test keys.

27
Operating Instructions

Keys SELECT/EXIT
CLEAR/HELP
Hard Keys HOUR METERS/SENSORS
The keys on either side of the display are dedicated or "hard" GAUGES
keys. Their function always remains the same.

Soft Keys Operating the TSR-3 Controller

Please refer to Profeesor Kool and the “TK Tutor Series” for
Soft Key Description step by step instructions and training on how to use your
The four "soft" keys under the display are multi-purpose keys. Standard or Premium HMI and also “TK Alarm Codes” to help
Their function changes depending on the operation being diagnose any alarms. These can be found at the following link:
performed. If a soft key is active the key function is shown in http://www.europe.thermoking.com/tools/
the display directly above the key. The keys are numbered from NOTE: These are App’s are developed for your Mobile
left to right, with Key 1 on the far left and Key 4 on the far device, please contact your Dealer for desktop applications.
right.

Typical soft key functions:

MENU
NEXT/BACK
YES/NO
+/-

28
Alarm Codes

Alarm Codes
Introduction NOTE: Some alarms (3, 4, 74, 203, and 204) cannot be
cleared in the Alarms Menu, they must be cleared in the
An alarm code is generated when the microprocessor senses an Maintenance Menu or the Guarded Access Menu. Contact
abnormal condition. Alarms direct an operator or service your supervisor or a Thermo King dealer about clearing
technician to the source of a problem. those alarms.
Multiple alarms can be present at one time. All generated IMPORTANT: Always record any Alarm Codes that occur -
alarms will be stored in memory until cleared by the operator. in the order that they occur - as well as any other pertinent
Document all alarm occurrences and report them to the service information. This information is extremely valuable to
technician. service personnel.
NOTE: Please refer to Profeesor Kool and the “TK Tutor NOTE: In some cases alarms cannot be cleared, or cannot be
Series” App for step by step instructions and training on cleared after they have occurred a specified number of times.
Alarm types and how to clear alarms. Please refer to “TK If such is the case, these alarms must be cleared by service
Alarm Codes” App for the most up to date alarms list. These personnel. These are all explained in your Alarm Codes App.
app’s can be found at the following link:
www.europe.thermoking.com/tools/
NOTE: The alarm codes leaflet can also be downloaded from
this site, or from the EMEA user manuals website at
www.emea-user-manuals.thermoking.com/

29
Loading and Enroute Inspections

Loading and Enroute Inspections

This chapter describes pre-loading, post loading, and enroute • Clogged defrost drain tubes
inspection procedures. Thermo King refrigeration units are
• Blocked return air bulkhead
designed to maintain the required product load temperature
during transit. Follow these recommended loading and enroute 5. Verify that the setpoint temperature is correct for your
procedures to help minimize temperature related problems. cargo. Pre-cool the truck as required.
6. Supervise product loading to ensure sufficient air space
Pre-Loading Inspection around and through the load. Airflow around the cargo
must not be restricted.
1. Check the engine oil pressure indicates OK. When first
NOTE: If the warehouse is not refrigerated, operate the
starting a cold engine, the oil pressure may be higher.
unit with doors closed until cargo is ready to be loaded.
2. Pre-cool products before loading. Note any variances on Then turn off the unit, open cargo doors and load cargo.
the manifest. When cargo is loaded, close truck doors and restart the
3. Inspect door seals and vent doors for condition and a tight unit.
seal with no air leakage. The unit can be operated with the cargo box doors open
if the truck is backed into a refrigerated warehouse and
4. Inspect the truck inside and out. Look for: the dock door seals fit tightly around the truck.
• Damaged or loose truck skin and insulation
• Damaged walls, air ducts, floor channels or “T”
flooring

30
 Loading and Enroute Inspections

4
5
6

1. Unit Inspection
2. Good Outside Air Circulation
3. Gaskets Equally Compressed
4. Clear Defrost Drains
5. Tight Doors
6. Good Air Circulation Around Load
7. Cargo at Proper Temperature Prior
7 to Loading
8. Interior and Exterior Walls and
Insulation in Good Condition
8

3
1 2

Figure 12: Loading Considerations

31
Loading and Enroute Inspections

Post-Loading Inspection 4. Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
Post-loading inspections ensure the cargo has been loaded
properly. To perform a post-load inspection: 5. Make sure the setpoint is at the temperature listed on the
manifest.
1. Inspect the evaporator outlets for blockage.
6. If the unit was stopped, restart using the correct starting
2. Turn the unit off before opening the cargo box doors to procedure. See the Operating Instruction chapter in this
maintain efficient operation. manual.
NOTE: The unit can be operated with the cargo box 7. Start a manual defrost cycle 30 minutes after loading. See
doors open if the truck is backed into a refrigerated the Manual Defrost procedure in this manual.
warehouse and the dock door seals fit tightly around the
truck.
3. Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on
the manifest.

CAUTION: Cargo must be pre-cooled to the proper

temperature before loading. The unit is designed to
maintain temperature, not cool an above-temperature
load.

32
 Loading and Enroute Inspections

Enroute Inspections 2. Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
Complete the following enroute inspection every four hours. temperature range. Stop the unit if the compartment
This will help minimize temperature related problems. temperature is not within the desired temperature range on
two consecutive 30 minute inspections, especially if the
Inspection Procedure compartment temperature appears to be moving away
1. Verify setpoint is correct. from the setpoint.

2. Check the return air temperature reading. It should be 3. Immediately contact the nearest Thermo King Dealer or
within the desired temperature range. your company office.

3. Initiate a manual defrost cycle after each enroute 4. Take all necessary steps to protect and maintain proper
inspection. load temperature.

Inspection Troubleshooting
1. If a temperature reading is not within the desired
temperature range, refer to the troubleshooting table on the
following pages. Correct problem as required.

33
Loading and Enroute Inspections

CAUTION: Stop the unit if the compartment

temperature remains higher than the desired
temperature range from the setpoint on two
consecutive 30 minute inspections. Contact the
nearest Thermo King Dealer or your company office
immediately. Take all necessary steps to protect and
maintain proper load temperature.

34
 Loading and Enroute Inspections

Inspection Troubleshooting
Problem Cause Remedy
A return air The unit has not Refer to the load log history. Look for above temperature load records,
temperature had time to cool properly pre-cooled cargo compartment, length of time on road, etc. Correct
reading is not down to correct as required. Continue monitoring return air temperature until the reading is
within desired temperature. within the desired temperature range of the setpoint.
temperature NOTE: Ensure cargo is properly pre-cooled prior to loading onto truck. If 'warm
range of the cargo' is loaded onto truck and reefer is used to cool to setpoint this will result in
setpoint. longer time required to cool down to correct temperature and possibly plugging of
evaporator with frost due to increased humidity in truck compartment.
The unit may have Check the receiver tank sight glass for refrigerant level. If liquid is not
a low refrigerant showing in the receiver tank sight glass, the refrigerant charge may be low.
charge. A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
or has just if the temperature returns to the desired temperature range of the setpoint.
completed a defrost
cycle.
The evaporator is Initiate a manual defrost cycle. The defrost cycle will automatically terminate
plugged with frost. when complete. Continue monitoring the return air temperature until the
reading is within the desired temperature range of the setpoint.

35
Loading and Enroute Inspections

Inspection Troubleshooting
Problem Cause Remedy
Improper air Inspect the unit and cargo compartment to determine if the evaporator fan(s)
circulation in the are working and properly circulating the air. Poor air circulation may be due
cargo compartment. to improper loading of the cargo, shifting of the load, or fan belt slippage.
Correct as required. Continue monitoring return air temperature until
problem is corrected.
The unit did not Determine the cause for not starting. Correct as required. Continue
start automatically. monitoring the return air temperature until the reading is within the desired
temperature range of the setpoint.

36
 Specifications

Specifications

Engine
Model:
UT-1200, UT SPECTRUM, UT-800, Thermo King TK 376U
UT Extreme HIGH Ambient
Fuel Type Diesel Fuel must conform to EN 590
Crankcase and Oil Filter: 11.0 litres, w/ Bypass Oil Filter: 12.1
Oil Capacity
litres.
Fill to full mark on dipstick
Petroleum Multi-grade Oil: API Type CI-4, ACEA Class E3
Oil Type Synthetic Multi-grade Oil (after first oil change): API Type CI-4,
ACEA Class E3

37
Specifications

Engine (Continued)
-10 C to 50 C (14 F to 122 F): SAE 15W-40 (Synthetic)
Recommended oil viscosity based on ambient -15 to 40 C (5 to 104 F): SAE 15W-40
temperature -15 to 40 C (5 to 104 F): SAE 10W-30 (Synthetic or Synthetic
Blend)
-25 to 40 C (-13 to 104 F): SAE 10W-40
-25 to 30 C (-13 to 86 F): SAE 10W-30
-30 to 50 C (-22 to 122 F): SAE 5W-40 (Synthetic)
Below -30 C (-22 F): SAE 0W-30 (Synthetic)
Engine RPM:
UT-1200, UT SPECTRUM, UT Extreme HIGH High Speed 2425 ± 25 RPM
Ambient Low Speed 1625 ± 25 RPM2250 ± 25 rpm

High Speed 2200 ± 25 RPM

UT-800 Low Speed 1450 ± 25 RPM

38
 Specifications

Engine (Continued)
Conventional Coolant: Conventional coolant (antifreeze) is
green or blue-green. GM 6038M or equivalent, low
silicate antifreeze mixture, 50/50 antifreeze/water mixture, not
to exceed 60/40.
CAUTION: Do not mix conventional coolant and ELC. ELC
Engine Coolant Type
(Extended Life Coolant): ELC is red. Units containing ELC have
an ELC nameplate on the expansion tank. Use a 50/50
concentration of any of the following equivalents: Texaco ELC
(7997, 7998, 16445, 16447), Havoline Dex-Cool® (7994, 7995),
Havoline XLC for Europe (30379, 33013), Shell Dexcool® (94040),
Shell Rotella (94041), Saturn/General Motors Dex-Cool®,
Caterpillar ELC, Detroit Diesel POWERCOOL® Plus
CAUTION: Do not use high silicate automobile antifreeze
Check the coolant level in the overflow bottle. It should be
Coolant System Capacity
above the Full Cold line. If necessary, add coolant to the
overflow bottle.
Coolant Expansion Tank Cap Pressure
UT-Series 7 psig (48 kPa)

39
Specifications

Fuses
Fuse Size Function
F2 15A Power to On/Off Switch
F3 40A Fuel Sol Pull-In/Starter Circuit
F4 None No Fuse - All Bosch and Thermo King Alternators
2A 2A Fuse - All Prestolite Alternators
F5 40A Preheat Circuit
F6 15A High Speed Circuits
F7 2A 8XP Circuit - Controller On Feedback to HMI
F8 5A 2A Power to CAN Connector J12
F9 5A 2A Power to CAN Connector J14
F10 10A 8X Power (Install fuse in upper position)
F11 10A Zone 1 LLS
F12 5A CAN Connector J13

40
 Specifications

Fuse Size Function

F13 2A 8FC Circuit (Remote Lights)
F20 2A Alternator Sense
F21 60A Main Fuse (2 Circuit)
F25 7.5A HPCO/Run Circuit
F4 Depending on your unit, this fuse maybe removed, please consult your Dealer for further information.
F10 When fuse F10 is installed in the upper position the On/Off keys on the HMI turn the unit on and off. When fuse
F10 is installed in the lower position the unit will start and run without the HMI control panel.

41
Specifications

Electrical Control System

Low Voltage 12.5 Vdc (nominal)
Voltage Regulator Setting 13.8 to 14.4 volts @ 77 F (25 C).
Battery 12 Volt, AHr Rating - 75 AHrs, 640 Cold Cranking Amps at -18C (ENCCA)
120 amp, (Brush Type) Integral Alternator used with UT-1200, UT SPECTRUM.
Battery Charging
65 amp, (Brush Type) Integral Alternator used with UT-800

Standby Power Requirements

Supply Circuit Breaker:

200-230/3/50-60 (UT-Series unit) 50 amps

All 380-46/3/50-60 (UT-Series unit) 20 amps
Up to 15 m — 10 gauge
Extension Cord Size:
23 m — 8 gauge

42
 Specifications

Refrigeration System
Contact your Thermo King dealer for refrigeration
system service or maintenance.

43
Warranty

Warranty
Terms of the Thermo King Self Powered Truck Unit Warranty
are available on request from your Thermo King Dealer.
Please also refer to TK 61598-2-WA Thermo King EMEA
Limited Warranty for Self Powered Truck Units.

44
 Maintenance Inspection Schedule

Maintenance Inspection Schedule

Pretrip Inspect/Service These Items

Inspection and Service intervals
• Run Pretrip Test (See “Operating the TSR-3
Inspection and Service intervals are determined by the number Controller” on page 28)
of unit operating hours and by the age of the unit. Examples are
shown in the table below. Your Dealer will prepare a schedule • Check fuel supply.
to suit your specific needs. • Check and adjust coolant/engine oil levels.
• Listen for unusual noises, vibrations, etc.
Interim Inspection Complete PM
• Visually inspect unit for fluid leaks. (fuel,
A Service B Service
coolant, oil and refrigerant).
Every 1000 hours or every Every 2000 hours or every
6 months (whichever 24 months (whichever • Visually inspect unit for damaged, loose or
comes first) comes first) broken parts (includes air ducts and
bulkheads if so equipped).
NOTE: For further best practices, please go to
www.europe.thermoking.com/best-practices

45
Maintenance Inspection Schedule

Service Record
Each inspection and service performed should be recorded on
your Dealer Service Record. This may be provided by you
Thermo King Dealer Representative, or you can download one
from the EMEA User Manuals Website.

46
 Serial Number Locations

Serial Number Locations

Serial Number Plate and Location

47
Recover Refrigerant

Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment and limit the potential harm to the ozone layer
that can result from allowing refrigerant to escape into the atmosphere.

We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere.

In addition, service personnel must be aware of Federal regulations concerning the use of refrigerants and the
certification of technicians. For additional information on regulations and technician certification programs,
contact your local THERMO KING dealer.

48