Thermo King UT-1280 User Manual Download

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transport temperature control solutions. Thermo King has been providing transport temperature control solutions

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TK 56373-1-OP

Oct 2016

Operator’s Manual

Truck Edition

UT-1280

October 2016

Revision 0

TK-56373-1-OP

Summary of Contents for UT-1280

Page 1: ...ator is a worldwide leader in sustainable transport temperature control solutions Thermo King has been providing transport temperature control solutions for a variety of applications including trailer...

Page 2: ......

Page 4: ...ed personnel Failure to implement these procedures correctly may cause damage to the Thermo King unit or other property or personal injury Thermo King Corporation and its affiliates shall have no liab...

Page 5: ...anty Coverage 17 Owner s Warranty Responsibilities 17 Manufacturer Explanation Of Emission Control System Warranty Coverage 18 EPA Emission Control System Warranty Statement 20 Responsibilities 21 Lim...

Page 6: ...2 Pretrip Test Considerations 53 Performing a Pretrip Test 53 Starting a Pretrip Test 53 Pretrip Test Results 55 Display Brightness 56 Electric Standby Operation 57 Electric Power Receptacle 57 Loadin...

Page 7: ...ments major and minor should be handled by a Thermo King dealer for four very important reasons They are equipped with the factory recommended tools to perform all service functions They have factory...

Page 8: ...thing clear of fans and belts at all times when the unit is operating or when opening or closing compressor service valves WARNING Exposed coil fins can cause painful lacerations Service work on the e...

Page 9: ...ny additional wiring harnesses to the battery cables as this could cause an electrical fire CAUTION Do not connect other manufacturer s equipment or accessories to the Thermo King unit This could resu...

Page 10: ...standby present a potential electrical hazard DANGER Fluorocarbon refrigerants may produce toxic gases In the presence of an open flame or electrical short these gases are severe respiratory irritants...

Page 11: ...arrival of emergency medical personnel 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 atten...

Page 12: ...ntain belts and fans which can cause severe injuries if hands or clothing become tangled Figure 3 Automatic Start Caution Locations vary depending on model Decals are located near areas that contain m...

Page 13: ...ause severe injuries if hands or clothing become tangled Model 50 Units Electric Standby Figure 5 Electrical Hazard Locations vary depending on model Typically located near power receptacle high volta...

Page 14: ...Safety Precautions 12 Figure 6 High Voltage Caution Located near high voltage box...

Page 15: ...Air induction system must remain intact and receive regular prescribed maintenance Example Air cleaner element replacement at required operation hour interval 2 3 Exhaust System Exhaust system must r...

Page 16: ...ins important engine information Figure 7 Emission Control Label b Engine Family Name as assigned by the California Air Resources Board identifies engine family group by largest displacement within an...

Page 17: ...ion shown in Figure 9 Figure 9 Emission Control Label Location All engine labels and supplementary labels will contain the following information Engine Family Name Displacement Manufacturer The above...

Page 18: ...nt for that part 5 Maintenance Schedule To maintain optimum engine performance and compliance with the California ULG Rules the maintenance schedule must be adhered to Regular scheduled maintenance is...

Page 19: ...ipment ULG engine is defective the part or component will be repaired or replaced by Thermo King Owner s Warranty Responsibilities As the utility equipment ULG engine owner you are responsible for the...

Page 20: ...ler To obtain the phone number of your nearest Thermo King authorized service dealer call the Cold Line at 952 887 2202 2 Warranty Period Any warranted California emission control system part or compo...

Page 21: ...Get Warranty Service Warranty service or repairs shall be provided at all Thermo King authorized service dealers You can generally find dealers in the Yellow Pages of your regional telephone directory...

Page 22: ...art or component repaired or replaced under warranty is warranted for the warranty period During the term of this warranty Thermo King will provide through a Thermo King authorized service dealer or o...

Page 23: ...ty Responsibilities This warranty is subject to the following Thermo King Corporation Responsibilities During the emission warranty period if a defect in material or workmanship of a warranted part or...

Page 24: ...is Operator s Manual or any other manuals provided with the unit Attachments accessory items or parts not authorized for use by Thermo King Improper off road engine maintenance repair or abuse Owner s...

Page 25: ...is provided by the TK380U a three cylinder special clean and silent diesel engine rated at 19 6 continuous horsepower 14 6 kW at 2425 RPM A belt drive system transfers energy to the compressor unit f...

Page 26: ...less Steel Condenser and Evaporator Hardware TK380U Diesel Engine Unit Options TouchPrint Datalogger Door Switch Scissors Field Installation Kit Battery Box Kit Remote Body Mount Box Kit Premium HMI C...

Page 27: ...demand and shuts down the unit when all demands are satisfied The system monitors and maintains the compartment temperature the engine block temperature and battery charge levels at a point where quic...

Page 28: ...emperature 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 Engine...

Page 29: ...Unit Description 27 Unit Component Identification Figure 12 UT 1280 Front View...

Page 30: ...Description 28 1 2 3 4 6 5 1 Accumulator 4 Compressor 2 Receiver Tank 5 Condenser Radiator Coil 3 Filter Drier 6 Fuel Filter Water Separator Figure 13 UT 1280 Components Front and Side Views Panels Re...

Page 31: ...Unit Description 29 2 1 3 AMA756 1 Compressor Pulley 3 Engine Clutch 2 Electric Motor Pulley UT 1280 Components Rear View Panels Removed...

Page 32: ...t Description 30 1 Oil Fill Location 2 Oil Level Dipstick 3 Oil Filter Figure 14 Engine Oil Service Locations 1 2 3 1 Overflow Tank Cap 2 Expansion Tank Cap Figure 15 Expansion Tank Service Locations...

Page 33: ...SR 3 Truck HMI Controller The SR 3 Standard Truck HMI Control Panel consists of a display and nine touch sensitive keys The display is capable of showing numbers and lighting several icons It does not...

Page 34: ...s Shows HMI Control Panel Serial Number and Software Revision Display The display presents information to the operator This information includes setpoint and box temperature hourmeter readings alarms...

Page 35: ...box temperature inside the truck box When this icon is present the lower display is showing the current setpoint When this icon is present the upper display is showing the diesel engine run time When...

Page 36: ...he key has more than one use the primary use is shown first ON Key Pressing the ON Key will turn the unit on Secondary Use When the unit is on pressing this key and the PRETRIP Key at the same time wi...

Page 37: ...is turned on and the Standard Display is shown pressing the DOWN ARROW Key will decrease the setpoint Secondary Use While holding ON Key down with the unit turned on pressing this key will decrease t...

Page 38: ...eturn to high speed operation after a programmed time limit if timer feature is enabled This feature is typically used in noise sensitive areas to reduce unit noise NOTE The HIGH SPEED LOCK OUT Key is...

Page 39: ...system checks only The amber LED may flash while the Pretrip Test is initialized and will glow steady while the Pretrip Test is running When the Pretrip Test is complete the amber LED will turn off I...

Page 40: ...fly shows dashes as the display initializes IMPORTANT If the display flashes on and off continuously when the ON Key is pressed check to make sure the Base Controller On Off switch is in the ON positi...

Page 41: ...unit operation The unit shuts down immediately and the display goes blank To start the unit again press the ON Key shown in Figure 22 Figure 22 ON Key The Standard Display The Standard Display is the...

Page 42: ...TER Key must be pressed to confirm and load the new setpoint If the setpoint is changed using the UP ARROW Key and DOWN ARROW Key the setpoint display will begin to flash 10 seconds after the last pre...

Page 43: ...completed Figure 26 Alarm Icon and Setpoint Notice that the setpoint has returned to the old setpoint of 35 F 1 6 C and the Alarm Icon has lighted indicating that Alarm Code 127 Setpoint Not Entered i...

Page 44: ...or the engine to run NOTE If the unit is equipped with optional Electric Standby there may be some additional prompts before the engine will start See STARTING THE ELECTRIC MOTOR on the following page...

Page 45: ...is feature can be changed using the Guarded Access Menu See the Guarded Access Unit Configuration Menu Diesel to Electric Auto Switch Enabled feature in Section 3 of the Diagnostic Manual for details...

Page 46: ...l not automatically switch to Diesel mode This is primarily designed to prevent unauthorized diesel engine starts when the truck is indoors or on a ferry where engine operation is strictly prohibited...

Page 47: ...or Manually Switching from Electric Mode to Diesel Mode 4 Press the Standard Truck HMI Control Panel ON Key again to clear Alarm Code 91 Check Electric Ready Input and turn the unit back on in Diesel...

Page 48: ...en 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 automatic...

Page 49: ...is turned on unit will switch to low speed operation and the amber LED indicator will glow No further high speed operation is allowed until this feature is turned off or the High Speed Lockout Timer...

Page 50: ...ill enter a defrost cycle and the amber LED next to the DEFROST Key will glow Figure 34 DEFROST Key IMPORTANT During the defrost cycle the box temperature will rise toward 50 F 10 C This is normal and...

Page 51: ...larm the Alarm Icon and the display will flash on and off and the unit will shut down Figure 36 Alarm Icon Displaying Alarm Codes Alarms are displayed by simultaneously pressing and holding the ON Key...

Page 52: ...to the Standard Display about 30 seconds after all alarms have been cleared Figure 39 Standard Display Important Alarm Notes All alarms must be viewed before any of the alarms can be cleared If an al...

Page 53: ...verifies unit operation The PRETRIP Key allows either a Full Pretrip Test or an Engine Running Pretrip Test to be initiated by the operator Pretrip Test Conditions The current unit settings are saved...

Page 54: ...o heat in low speed is checked Report Test Results The test results are reported when the Pretrip Test is completed If the Pretrip Test fails alarm codes will exist to direct the technician to the sou...

Page 55: ...ning a Pretrip Test on a truck loaded with sensitive cargo monitor the load temperature during the test as normal temperature control is suspended during pre trip operation Always perform Pretrip Test...

Page 56: ...rmal when the Pretrip Test is halted before completion Starting a Engine Running Pretrip Test The Engine Running Pretrip Test must be started with the unit running Turn the unit on and clear all alarm...

Page 57: ...Alarm occurs The amber Pretrip Test LED will turn off at the completion of the test but the Alarm Icon will remain lit This indicates that one or more Check Alarm conditions occurred during the Pretr...

Page 58: ...d to allow for changing ambient light conditions The choices available to the operator are HIGH MEDIUM and LOW To change the display brightness press and hold the ON key then press the UP ARROW Key to...

Page 59: ...electric power is desired See Starting the Electric Motor in the Unit Operation chapter of this manual Electric Power Receptacle The electric power receptacle is used to connect the unit to an approp...

Page 60: ...floor channels which could block the air return creating isolated areas in the load that are warmer than the desired temperature 4 Pre cool the cargo compartment Adjust the setpoint to the desired car...

Page 61: ...re If the load is too hot or too cold make a final notation on the manifest 3 While inspecting to see that the cargo is loaded properly make sure the evaporator inlets and outlets are not blocked 4 Cl...

Page 62: ...nt length of time on road b The unit is in defrost or has just completed defrost NOTE You can cancel defrost by turning the unit off then restarting the unit c The evaporator is plugged with frost Ini...

Page 63: ...cover of this manual for referral NOTE If the temperature in the compartment is not within the desired temperature range repeat the Enroute Inspection every 30 minutes until the compartment temperatu...

Page 64: ...9 7 liters 11 5 quarts 10 9 liters Fill to full mark on dipstick Oil Type API Classification CI 4 or better ACEA Rating E3 or better for Europe Oil Viscosity 14 F to 122 F 10 C to 50 C SAE 15W 40 Synt...

Page 65: ...Saturn General Motors Dex Cool Caterpillar ELC Detroit Diesel POWERCOOL Plus CAUTION Do not add GREEN or BLUE GREEN conventional coolant to cooling systems using RED Extended Life Coolant except in a...

Page 66: ...ew belts should be tensioned cold and tensioned cold again after 10 hours of unit operation Belt Tension No on TK Gauge P N 204 427 Engine Electric Motor 75 5 Compressor Electric Motor 75 5 Electric M...

Page 67: ...Battery Charging System 12 volt 120 amp brush type Thermo King alternator Fuses Fuse Size Function F2 15A Power to On Off Switch F3 40A Fuel Sol Pull In Starter Circuit F4 None 2A No Fuse All Bosch a...

Page 68: ...Main Fuse 2 Circuit F25 7 5A HPCO Switch Circuit F26 5A Power to CAN Connector J98 F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators Install fuse F4 for units with Prestoli...

Page 69: ...Load amps Overload Relay Setting amps 208 3 60 12 8 9 1735 31 4 32 230 3 60 12 8 9 1750 28 8 32 460 3 60 12 8 9 1750 14 4 16 Standby Power Requirements Supply Circuit Breaker 200 230 3 50 60 380 460...

Page 70: ...l see the maintenance manual for your unit and to the PreTrip Inspection chapter in this manual After first week of operation Check belt tension Tighten unit mounting bolts Check coolant level Check r...

Page 71: ...eed Listen for unusual noises vibrations etc Change engine oil hot 2000 hrs with bypass filter or synthetic oil Change oil filters Clean and service crankcase breather Drain water from fuel tank and c...

Page 72: ...ours Check and adjust engine speeds Check condition of engine mounts Check restraining mount snubber pre load adjustment Clean and test fuel injection nozzles every 3 000 hours Replace fuel return lin...

Page 73: ...ck throttling valve regulating pressure on defrost Check compressor oil level Check compressor efficiency and pump down refrigeration system Replace dehydrator and check discharge and suction pressure...

Page 74: ...Check battery voltage Inspect clean battery terminals and check electrolyte level Inspect wire harness for damaged wires or connections Check DC battery charging alternator bearings and brushes Inspec...

Page 75: ...heads Inspect tapered roller bearing idlers for leakage and bearing wear noise Check and clean evaporator and condenser coils Clean defrost drains Check all unit and fuel tank mounting bolts brackets...

Page 76: ...nit model and unit serial number in the spaces provided in the following Emergency Cold Line chapter This information is needed to service the unit Figure 45 Engine Serial Number Location Figure 46 Co...

Page 77: ...Serial Number Locations 75 Figure 47 Unit Serial Number Plate Location Figure 48 Laminated Unit Serial Number Plate Figure 49 Refrigerant Type Label...

Page 78: ...nto 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 c...

Page 79: ...hermo King dealer to reach a dealer without success then call the Toll Free Emergency Cold Line Number 888 887 2202 The answering service will assist you in reaching a dealer to get the help you need...

Page 80: ...78 California Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer...

Page 81: ...79 Warranty Terms of the Thermo King Warranty are available on request Please reference document TK 50047 for the Thermo King Self Powered Truck Unit Warranty...

Page 82: ......

Page 83: ...ator is a worldwide leader in sustainable transport temperature control solutions Thermo King has been providing transport temperature control solutions for a variety of applications including trailer...

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