Mitsubishi Reefer Tdj430d

MITSUBISHI
TRANSPORT REFRIGERATION UNIT

SERVICE MANUAL
TDJ300D
TDJ430D
'99 · TD-S · 001
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Introduction
This service manual describes the outline and maintenance procedures, etc., of the refrigeration unit, and is
intended to be used by the service personnel of the unit. Read this manual thoroughly before using to ensure
quick and waste-less servicing and to maintain the performance of the refrigeration unit.
• How to read the type
TDJ430D - 2 L 2
Indication of power voltage

[ 2: DC24V
Indication of temperature range
L: For refrigeration
[Inside temperature range: -30 to 25°C]
Indication of compressor operation
1: Vehicle driving engine operation
[ 2: Vehicle driving engine operation and motor operation
Model name
[Example]
TDJ300D - 1 L 2 In this manual, these are shown by abbreviating

as type 1 and type 2.
Type 1 (Type 2)

Safety Precautions
● Read the "Safety Precautions" thoroughly before using inspections and maintenance.
● The precautions described here are classified as " WARNINGS" and " CAUTIONS". Items that could lead to
fatalities or serious injuries during inspection and maintenance are listed as " WARNINGS". Note that even the items
listed as " CAUTIONS" could lead to series results depending on the situation. In any case, important information
related to safety is described, and must be observed.
● The meaning of the symbols used in this manual are as follows.
Never carry out. Always follow the instructions and carry out.
WARNINGS
(1) Never touch the high temperature sections such as the movable sections, exhaust pipe,
and high pressure side piping while the refrigeration unit is operating.
Failure to observe this could lead to burns.
(2) If the refrigerant gas leaks during work, always ventilate the area.
Toxic gas could be generated if the refrigerant gas contacts fire.
(3) According to this manual, securely install the product unit. If it is poorly installed, it will
cause refrigerant leakage, electric shock or fire.
(4) For installation, apply the method which must be sufficiently durable for the weight of
the product unit. If the strength is insufficient or the installation is poor, the product unit will drop
to cause an accident or wound.
(5) Don't change any setting value of the protector or safety device. If any setting value is
changed, the product unit will be punctured or fired.
(6) Don't mix any other refrigerant, air or similar except the specified refrigerant into the
refrigeration cycle.
If it is mixed, the pressure will become abnormally high in the refrigerant cycle, resulting in puncture
or wound.
(7) Do not make modifications.

Making modifications could lead to injuries, electric shocks or fires due to abnormal operation.
CAUTIONS
Before starting the refrigeration unit operation, confirm that the doors and screws for
the outer plates, etc., are completely tightened. Contacting the rotary parts could lead
to injuries.

Contents
1. Characteristics ··········································· 1 10.16 Storage temperature sensor (TH) ············ 18

2. Specification ················································ 2 10.17 Td sensor (Td) ········································· 19
3. General information ································· 4 10.18 Controller ················································· 19
3.1 Controller ··············································· 4 10.19 Drain hose heater (option) ······················· 20
3.2 Drive system ··········································· 4 11. Electric wiring diagram ··························· 21
3.3 Operation control ···································· 4 11.1 Sequence diagram ···································· 21
3.4 Defroster ················································· 4 11.2 Wiring layout drawing ····························· 24
3.5 Protective device ····································· 4 11.3 Explanation of operation ························· 28
4. Name of each component ······················ 5 12. Periodic inspection ··································· 34
5. Adjustment of test operation ················ 6 12.1 Inspection at the time of installation
5.1 Pre-operation inspection ·························· 6 and test run ·············································· 34
5.2 Inspection during operation ····················· 6 12.2 Daily inspection ······································· 34
6. Daily operation ············································ 6 12.3 Monthly inspection ·································· 35
6.1 Description of operation for the 12.4 Six-mouth inspection ······························· 35
controller ·················································· 6 12.5 Bolt tightening table for each section ······ 35
6.2 Other operations ······································· 7 12.6 Caution to be taken at the time of
6.3 Operation of special service switches ······ 7 daily inspection ········································ 36
6.4 Operation sequence ·································· 7 12.7 Caution to be taken at the time of
6.5 Operation of display switches ·················· 8 periodic inspection ·································· 38
6.6 Defrosting operation and manual 12.8 Check sheet (Installation, test run and
defrosting ················································· 8 periodic inspection) ································· 40
7. Loading ··························································· 9 12.9 Pressure table for standard operation ······ 41
7.1 Inspection before loading ························ 9 13. Defect and its cause ································· 42
7.2 Loading procedure ··································· 9 13.1 Diagnosis of defects on refrigerant
7.3 Unloading ················································ 10 system ······················································ 42
7.4 Caution to be taken for the usage ············ 10 13.2 Charging the refrigerant <R404A> ·········· 46
8. Refrigerant piping system ····················· 11 13.3 Diagnosis of defects on electric parts······ 47
8.1 Refrigerant piping system diagram ·········· 11 14. Method to select a model with
8.2 Freezing cycle ········································· 11 jumper cable ················································· 64
9. Control system ············································ 12 15. Refrigerant saturated pressure
10. Description of main parts ······················· 13 table (R404A) ················································ 65
10.1 Compressor ·············································· 13 16. Installation procedure ····························· 66
10.2 Magnet clutch ·········································· 13 16.1 Cautionary points during installation ······ 66
10.3 Heat accumulator ····································· 14 16.2 Cautionary and requested points
10.4 Accumulator ············································ 14 during installation ···································· 67
10.5 Electromagnetic valve ····························· 15 16.3 Reference drawing of installation ············ 71
10.6 Check valve ············································· 15
10.7 Receiver ··················································· 15
10.8 Sight glass ················································ 16
10.9 Dryer ························································ 16
10.10 Condenser fan motor ······························· 16
10.11 Evaporator fan motor ······························· 17
10.12 Multi-function valve ································ 17
10.13 Expansion valve ······································· 17
10.14 Defrost thermostat (DTS) ························ 18
10.15 Dual pressure switch (DPS) ····················· 18

1. Characteristics
We have developed this refrigeration unit based on our long years of accumulation of refrigeration technique.
(1) The refrigeration unit is a compactly arranged and unitized type which can be easily installed and removed because
of a nose-mounted type.
(2) The refrigeration unit can operate in the range of the outside temperature of -5°C ~ 40°C to keep the inside
temperature in the rage of -30°C ~ 25°C. However, it is impossible to keep the inside temperature higher than the
outside temperature.
(3) The unit is easy to operate and capable of making automatic operation by switch.
(4) The refrigeration unit, which has adopted a new controller with a letter display function, can accurately establish a
desired storage air temperature digitally. And also the pre-operation inspection for the unit can be easily made by a
simple button operation, and easy diagnosis of defects will set you at ease in using the unit.
(5) The compressor is operated by the engine of a truck with a belt, and it starts and stops with magnet clutch “ON” and
“OFF”. The magnet clutch becomes “ON” and “OFF” by thermostat.
(6) The evaporator fan with DC motor installed respectively to them perform directly connected operation.
(7) Timer and manual defroster remove frost and always bring refrigeration effect into full play.
(8) New refrigerant R404A which are tender for the environments are employed.
(9) The new multi-function valve is employed. This prevents the refrigerant from returning to the high-pressure control
or compressor, and has a function for excellent start under the different pressure balance. This considerably
improves the capacity in the high temperature range, and makes the pull-down early.
Refrigeration unit
Controller
Power source box

(Type 2 only)
Motor pack
Compressor (Type 2 only)
–1–

2. Specification
(1) TDJ300D
Type
Item TDJ300D - 1L2 TDJ300D - 2L2
Performance
Ambient temperature °C 35
0°C 3490 (3000) 3490 (3000) * [2790 (2400)]
Return air W
temperature (kcal/h)
-18°C 2150 (1850) 2150 (1850) * [1740 (1500)]
Function Cooling
Range of Inside air temperature °C -30 ~ 25
usage Outside air temperature °C -5 ~ 40
Compressor: Belt-driven from a vehicle
engine and belt-driven by
engine
Drive method motor
Condenser fan
Evaporator fan }
Direct drive by direct current motor
Evaporator Condenser Compressor
Model CR2211L-A
Discharge cm3/rev 110
Revolution min-1 600 ~ 3600 * (1420)
Refrigeration oil cm3 Diamond Freeze MA32, 350
Type Aluminum tube, Corrugate fin
Fan Propeller fan, Directly connected to fan motor
Revolution of fan min-1 2100
Fan motor W 75 × 2
Type Copper pipe, Aluminum fin
Fan Centrifugal fan, Directly connected to fan motor
Fan motor W 70 × 2
Type — Totally enclosed fan-cooled 3-phase motor
Motor
3-phase AC220V 60Hz,

Power source —
380V 50/60Hz, 415V 50Hz
Revolution min-1 — 1500/1800 (50/60Hz)
Rated output kW — 2.2
Enclosed refrigerant volume kg R404A : 1.7
Storage air temperature
adjustment °C -30 ~ 25 (Microcomputer controller)
Defroster Automatic defrosting (Timer system)

Dual-pressure switch
[High pressure side] CUT OUT 2.94MPa (30kgf/cm2), CUT IN 2.35MPa (24kgf/cm2)
Safety device [Low pressure side] CUT OUT 0.20MPa (2.0kgf/cm2), CUT IN 0.23MPa (2.3kgf/cm2)
Over current relay 11A (Type 2 only), Fusible plug 95°C, Discharging temperature sensor 135°C
1596 × 666 × 499
Unit size
Refrigeration unit W×H×D

Motor pack mm — 492 × 300 × 385
Refrigeration unit 67
Weight
Compressor 7.3 (Include magnet clutch)

kg
Motor pack — 54
Accessories 11 45
Note: (1) The capacity of refrigeration (performance) shown in the above parenthesis represents case of 60Hz motor drive.
–2–

(2) TDJ430D
Type
Item TDJ430D - 1L2 TDJ430D - 2L2
Performance
Ambient temperature °C 35
0°C 5000 (4300) 5000 (4300) * [4070 (3500)]
Return air W
temperature (kcal/h)
-18°C 2790 (2400) 2790 (2400) * [2210 (1900)]
Function Cooling
Range of Inside air temperature °C -30 ~ 25
usage Outside air temperature °C -5 ~ 40
engine and belt-driven by
engine
Drive method motor
Condenser fan
Evaporator fan }
Direct drive by direct current motor
Evaporator Condenser Compressor
Model CR2318LWR
Discharge cm3/rev 181.2
Revolution min-1 600 ~ 3600 * (1420)
Refrigeration oil cm3 Diamond Freeze MA32, 800
Type Aluminum tube, Corrugate fin
Fan Propeller fan, Directly connected to fan motor
Fan motor W 75 × 2
Type Copper pipe, Aluminum fin
Fan Centrifugal fan, Directly connected to fan motor
Fan motor W 70 × 3
Type — Totally enclosed fan-cooled 3-phase motor
Motor
3-phase AC220V 60Hz,

Power source —
380V 50/60Hz, 415V 50Hz
Revolution min-1 — 1500/1800 (50/60Hz)
Rated output kW — 3.7
Enclosed refrigerant volume kg R404A : 2.1
Storage air temperature
adjustment °C -30 ~ 25 (Microcomputer controller)
Defroster Automatic defrosting (Timer system)

Dual-pressure switch
[High pressure side] CUT OUT 2.94MPa (30kgf/cm2), CUT IN 2.35MPa (24kgf/cm2)
Safety device [Low pressure side] CUT OUT 0.20MPa (2.0kgf/cm2), CUT IN 0.23MPa (2.3kgf/cm2)
Over current relay 15A (Type 2 only), Fusible plug 95°C, Discharging temperature sensor 135°C
1596 × 666 × 499
Unit size
Refrigeration unit W×H×D

Motor pack mm — 570 × 340 × 398
Refrigeration unit 72
Weight
Compressor 7.3 (Include magnet clutch)

kg
Motor pack — 85
Accessories 11 47
Note: (1) The capacity of refrigeration (performance) shown in the above parenthesis represents case of 60Hz motor drive.
–3–

3. General information 3.4 Defroster
In order to prevent the evaporator from being covered

3.1 Controller with frost and reducing its cooling effect, the defrost
timer (it will be established within three hours before
The refrigeration unit employs a new microcomputerized
being shipped out from our factory) operates
controller which has a character display function, and
defrosting.
the desired inside temperature can be accurately and
When defrosting has been completed and temperature
digitally set with the soft touch type switch. Moreover,
of the evaporator has risen, changes to cooling
a trouble can be easily diagnosed.
operation by the defrost thermostat. Also the evaporator
fan stops during the defrosting operation, keeping
3.2 Drive system
warm air from going into the inside.
(1) In case of engine drive from a running vehicle Further when the storage is loaded with watery goods
The refrigeration unit is operated in which the or cooling in the storage is slow, defrosting can be
engine of a running vehicle drives the compressor made by manual operation.
by belt and condenser fan and evaporator fan are
driven by a direct current motor respectively. 3.5 Protective device
After having the ignition switch of its vehicle

The refrigeration unit is protected both by a protective
turned on and the vehicle started, the refrigeration
device (dual pressure switch) which stops the unit when
unit can be operated with the controller operation
discharging pressure of the compressor becomes
switch "ON".
unusually high and the dissolving plug which
(2) In case or motor drive (Type 2) discharges refrigerant when the pressure becomes
The refrigeration unit is equipped with a motor higher due to fire, etc.
drive besides engine drive from a running vehicle Also these devices will stop the refrigeration units
and can be operated by the power supply (standard when discharging temperature of the compressor
specification, 3-phase AC 220V 60Hz, 380V becomes unusually high due to leakage of refrigerant,
50/60Hz, 415V 50Hz) at a garage, truck terminal, etc. When the unit has been abnormally stopped by the
ferry boat, etc. protective device (except fusible plug), an abnormal
It can be operated with the controller operation indication lamp will display its abnormality.
switch "ON" after connecting three-phase power
source to an outlet of the power source box.
3.3 Operation control
When a storage air temperature is higher than the

temperature established by the thermostat, it starts
cooling operation with the magnet clutch of the
compressor connected, and when the storage air
temperature has been lowered to the temperature
established by the thermostat, the magnet clutch will be
disconnected and the fan stops together with the
compressor, which in turn stops cooling operation. The
evaporator does not stop but continues to operate.
–4–

4. Name of each component
(1) Refrigeration unit
(2) Controller
Alarm lamp Defrost switch
(red)
Defrost indication lamp
Digital display Alarm switch
(orange)
Operation indication lamp
Temperature setting (green)
switches
Operation switch
Hours switch
Display indication lamp
Hours indication lamp (green)
(green) Display switch
(3) Compressor (4) Motor pack (only for type 2)

(a) TDJ300D
Discharge Suction
service valve service valve Compressor
Magnet clutch
(b) TDJ430D (5) Power source box (only for type 2)
Discharge Suction
service valve service valve
Limit switch
Fuses
Alarm indication lamp

Manual reset button (Motor overcurrent relay
(For motor overcurrent relay) active indicator)
Power source
Magnet clutch Power source outlet indication lamp
–5–

5. Adjustment of test operation 6. Daily operation
5.1 Pre-operation inspection 6.1 Description of operation for the controller
(1) Check the seal going through the board of 3 Alarm lamp
(red)
2 Defrost switch
4 Digital display 2 Defrost indication lamp

3 Alarm switch
refrigeration unit. (orange)
5 Temperature setting 1 Operation indication lamp
switches (green)
(2) Check if the clamp of the tubing is adequate.
C Buzzer (built-in)
1 Operation switch
(3) Check if the drain hose is connected properly and 6 Hours switch
7 Display indication lamp
6 Hours indication lamp (green)
the clamp is proper. (green) 7 Display switch
(4) Check the belt for looseness, degree of parallel

Description of operation for the controller
(Coming out of the interline) and flaw.
Name Operation
(5) Check if components such as compressor, pully,
1 Operation switch The switch starts or stops the
belt, tubing and wiring are touching each other. (ON/OFF) refrigeration unit.
(6) More tightening of fixing bolts for the following 2 Operation The lamp (green) is lit when the
indication lamp operation switch is on.
units.
3 Defrosting switch The switch turns on the forcible
• Refrigeration unit defrosting operation.
4 Defrosting
• Compressor and bracket
indication lamp
The lamp (orange) is lit when
defrosting is in operation.
• Magnet clutch 5 Alarm switch When the alarm lamp lights or blinks,
• Tension pulley and bracket press the switch, and all faults which
occur will be indicated as the code on
• Fan motor and fan
the digital display unit.
(7) Check the electric wiring for mis-wiring and the 6 Alarm lamp When a fault occurs, the alarm lamp
(red) lights and blinks.
clamp for properness.
7 Digital display The in-container temperature,
(8) Check the wiring terminal for looseness and the incontainer preset temperature, fault
display code and integrated operation
covering of wiring for flaw. time are displayed according to the
switches.
(9) Check the refrigerant system for gas leakage (oil
8 Temperature The switch changes the incontainer
leakage). setting switches preset temperature.
9 Hours switch The switch makes the working time
(10) Check electric wiring for grounding and defective
(operation hours) of the evaporator
insulation. (Type 2 only) fan displayed.
0 Hours indication Press the hours switch, and the lamp
lamp (green) will come on.
5.2 Inspection during operation A Display switch When the refrigeration unit stops,
press this switch, and the incontainer
(1) Check the compressor, magnet clutch, motor, fan temperature will be displayed on the
digital display unit for 5 seconds.
and tubing for abnormal sound and vibration. Moreover, when the refrigeration unit
runs, press this switch, and the
(2) Check the refrigerant sight glass for color and incontainer temperature will be
degree of flashing. displayed if the preset temperature,
fault code or integrated operation
(3) Check the compressor and magnet clutch for start time is displayed in the display unit.
B Display Press the display switch, and the
and stop due to the thermostat.
indication lamp lamp (green) will come on.
(4) Check refrigeration (indication by temperature C Buzzer Buzzer prevents improper start.
(Type 2 only) Keeping the power code for motor
display and high and low pressure).
drive connected, turn the vehicle
(5) Check the defroster for operation. ignition key to "ON", and the buzzer
integrated in the controller will sound
(6) Check the dual pressure switch for operation. to stop the refrigeration unit.(Even if
the refrigeration unit stops, the buzzer
(7) Check the motor for drive (Type 2 only) and will sound.
buzzer with ignition switch "ON".
–6–

6.2 Other operations (2) How to display the fault history
1 Press the display switch and alarm switch together
When the refrigeration unit stops (power is supplied),
for 4 seconds, and max. 5 faults which have
the following operations are ready.
occurred will be displayed with the codes in
(1) Change of inside-container preset temperature sequence from the newest one.
DISPLAY ▲ ··· To higher temperature 2 When the fault history is displayed, press the
e
▼ ··· To lower temperature alarm switch and temperature setting switch ▼
After pressing "display switch", press the switch together for other 4 seconds, and the fault history
▲ or ▼ , and the inside-container preset will be cleared.
temperature will be displayed on the digital (3) How to change the defrost timer setting
display unit in the blinking mode to select the 1 Press the display switch and defrost switch
inside-container temperature setting mode. together for 4 seconds, and the preset temperature
Continuously press the switch, and the preset will be displayed.
temperature will vary. 2 Press the defrosting switch together with the
▲ ··· To higher  Every push of the switch temperature setting switch ▲ or ▼ , and the
temperature  changes the temperature defrosting time will be changed in the range of 1
▼ ··· To lower
temperature
 by 1°C.
to 6 hours.
(Continuously press the switch ▲ or ▼ , and the

6.4 Operation sequence
temperature will continue varying.)
5 seconds after the finger is released from the (1) In case of engine drive from a running vehicle
switch, the inside-container temperature will be 1 Start the engine which drives the car.
displayed.
2 Turn the operation switch to "ON".
Then, the digital display unit will go out after (When the operation switch comes "ON", the
other 5 seconds. Thus, it will be completely set. operation lamp (green) will come on.)
(2) Integrated operation time 3 Setting of inside-container temperature
DISPLAY e HOURS Press either temperature setting switch ▲ or ▼ ,
and the inside-container setting temperature on the
After pressing "display switch", press "hours digital display unit will blink to indicate the
switch", and the integrated operation time will be inside-container temperature setting mode.
displayed on the digital display unit.
Keep the switch pressed as it is, and the setting
5 seconds after the finger is released, the inside temperature will vary.

container temperature will be displayed. Then, the ▲ ··· To higher Every push of the switch
digital display unit will go out after other 5 temperature  changes the temperature
seconds. ▼ ··· To lower
temperature
 by 1°C.
Thus, it will be completed.
(Continuously press the switch ▲ or ▼ , and the
6.3 Operation of special service switches temperature will continue varying.)
Keep the temperature setting switch pressed, and
When the operation switch is "off", the following
release the finger from the switch when the
operation is ready.
temperature indicated on the digital display unit
(1) How to clear the evaporator operation time reaches the inside container pressure temperature
1 Press the display switch. (transportation temperature).
2 Press the hours switch and temperature setting After 5 seconds, the digital display unit will return
switch ▼ together for 4 seconds, and it will be to display the inside-container temperature. Thus,
cleared. the inside-container temperature setting mode will
be completed.
–7–

Since the controller is provided with the function Since the controller has the function to
 
(memory function) which memorizes the  memorize the temperature which was set during 
temperatures preset in the refrigeration unit up to  last operation of the refrigeration unit, press 
 
now, check the preset temperature by pressing  either temperature setting switch once ▲ or ▼
either temperature setting switch ▲ or ▼ one  to check the memorized temperature for 
time for the assurance's sake.
 caution's sake.

4 Stopping 4 Stopping
• To turn it "OFF", press the operation switch • Press the operation switch again to turn it to
again and the refrigeration operation will be "OFF", and cooling operation will be stopped.
stopped. • Turn the operation switch to "OFF", and the
• Turn the operation switch to "OFF", and the operation indication lamp and digital display
operation indication lamp and digital display will go out.
unit will go out. Note: 1) Before disconnecting the receptacle of the
Note: Before turning the ignition switch of the car to motor drive power supply, be sure to turn the
"OFF", be sure to turn the operation switch of the operation switch of the refrigeration switch to
refrigeration unit to "OFF". "OFF".
(2) Motor driven type (Type 2 alone) 2) Don't start or stop the unit by using the power
1 Turn the ignition switch of the vehicle to "OFF", supply breaker or connecting/disconnecting
and connect the receptacle of the motor drive the power supply plug. Otherwise, it will
power supply to supply electric power. cause an electric circuit trouble or electric
shock.
Note: Before connecting the power supply, make sure
that the operation switch is "OFF". 3) Prevent rain and water from splashing over
the receptacle area of the power box, or it will
2 Press the operation switch to "ON".
cause an electric shock when the motor is
When the operation switch becomes "ON", the
driven.
operation indication lamp will come on. (Green)
3 Inside temperature setting 6.5 Operation of display switches
Press either setting switch ▲ or ▼ , and the inside
set temperature on the digital display unit will be (1) When the refrigeration unit is operating
displayed in the blinking mode with the inside When the preset temperature, fault code or
temperature setting mode selected. integrated operation time is displayed on the
Keep the switch pressed as it is, and the setting digital display unit, it can be returned to the inside-
temperature will vary. container temperature.
▲ ··· To higher  Every push of the switch
(2) When the refrigeration unit is stopped
temperature  changes the temperature  Press the display switch, and the inside-container
▼ ··· To lower  by 1°C.  temperature will be displayed on the digital
temperature  
(Continuously press the switch ▲ or ▼ , and the  display unit. At this time, press the following
 switch, and the selected content will be displayed. 
temperature will continue varying.)
• Single push of ▲ or ▼ ····Preset temperature
When the temperature indicated on the digital
• ALARM······························Fault code
display unit is brought to a desired inside
• HOURS·······························Operation time
temperature (transportation temperature) by
• DEFROST···························Defrost interval time
pressing the temperature setting switch, release the
finger from the switch.
6.6 Defrosting operation and manual defrosting
After 5 seconds, the digital display will return to
the inside temperature with the temperature setting Defrosting operation is applied to prevent the cooling
mode ended. effect from dropping since the evaporator is frosted.
–8–

The defrost timer (factory-set at every 3 hours at 7. Loading
shipment) will automatically work for automatic
defrosting.
7.1 Inspection before loading
When the delay timer of 1 minute runs out after
defrosting is completed, it will be automatically (1) Clean inside of the storage.
switched into the cooling operation.
(2) Inspect the car side and the refrigeration unit.
At this time, the evaporator fan is stopped to prevent
(3) Establish a storage air temperature.
the warm wind from entering the room.
(4) Before loading, make sure to perform
(1) Method to change the timer setting of defrosting.
cooling operation, and refrigerate the
Though the defrost timer was factory-set at every 3 storage up to an established temperature
hours at shipment, it is adjustable in the range of 1 in advance.
to 6 hours.
First of all, it is necessary to refrigerate a storage
1 Turn the operation switch to "OFF". in order to transport and deliver goods properly.
2 Press both display switch and defrost switch Under the blazing sun in midsummer, inside of a
together for 4 seconds, the preset time will be storage may become as hot as 60°C. And so if
displayed. freight is put in it without cooling the storage in
3 The preset time can be changed by pressing the advance, a defect due to improper transportation
temperature setting switch ▲ or ▼ with the temperature will happen.
defrost switch pressed.
(2) Manual defrosting method How to make an effective cooling
operation in advance.
If inside cooling becomes poor since frost sticks to
the evaporator, manual defrosting is possible.
• Operate the refrigeration unit under the shade.
Press the defrost switch during cooling operation.
• In case of engine drive, operate it with engine
• The defrost indication lamp (orange) is lit  running more than 800min-1.
 during defrosting operation. 
  • On Type 2, make pre-cooling operation done by
• The operation indication lamp is lit during 
the motor drive.
 defrosting operation. (Green) 
(5) Check the sight glass during operation
It will automatically return to the cooling
and confirm that there is no bubbling and
operation when defrosting is complete. (It can not
that the checking color is green.
be manually returned to OFF.)
 After 60 minutes, it will be automatically 
 
 returned to the cooling operation with the 
 defrost forced ending timer (integrated). 
7.2 Loading procedure
(1) Load a refrigerator freight truck with the

goods which have been cooled to an
established air temperature in advance by
some other cooling device.
(Never load anything hot and warm in the truck
because it will only cause overloading operation to
the refrigeration unit.)
(2) Perform loading by stopping the refrigeration
unit and in a short time, if possible.
–9–

(3) Load so as to allow cool air circulating every Remarks: Operation procedure operate the unit for about
corner of the storage. 15 minutes, After switching "ON" and "OFF"
To circulate cold wind, the clearance between the repeat at intervals of several seconds.
cargo and room wall must be 30mm or more on In case of driving engine operation type operate by
both sides and the following values on the rear idling condition.
side, front side and floor except the blow-out area (4) The display indication of the controller may flicker
from the ceiling evaporator. due to wireless (wireless of both our manufactured
vehicles and other makes). If a wireless in installed
in our vehicle, disconnect it.
(5) Regarding the power source and voltage of motor
drive:
• In case of standard specification, set up the
power volume which allows a rush voltage on
the refrigeration unit side to be able to secure
more than 180V when the motor is started.
• Motor specification
The values in ( ) are applicable for TDJ430D. Standard specification 3-phases AC 220V 60Hz,
(4) Make the upper side of the load as flat as can be. 380V 50/60Hz, 415V 50Hz
(5) After loading, operate the refrigeration unit. • In case of using commercial power source, a
measure to cope with electric leakage for power
7.3 Unloading supply circuit is required.
(6) Washing
(1) Perform unloading after stopping the
• When washing a vehicle, be careful not to splash
refrigeration unit.
water directly to the electric equipments inside
(2) Opening the door of the storage once will make the refrigeration unit.
the inside temperature going up momentarily, so
• When cleaning the condenser and evaporator
open and close the door quickly so as to not let the
coil, never make a high pressure washing by a
cool air out.
high pressure washing machine as it crushes the
(3) When loading and unloading, make sure to use a fin. Also never make a steam washing as it
curtain in order to keep outside air from coming in increases pressure inside of the units unusually
and cool air going out. and is dangerous.
7.4 Caution to be taken for the usage
(1) In case of using a refrigerator freight truck as a

refrigerator for a long time consecutively, make
the entire indoor temperature as high as a plus
degree and melt the ice completely.
(2) Operate the refrigeration unit more than 15
minutes once in 3 or 4 days even if the unit is not
used for a long period of time.
(3) Avoid using only either the engine of a truck or the
motor of a unit for long. If one of them is not
going to be used for long, make sure to operate
either of them more than 15 minutes once in every
3 or 4 days.
– 10 –

8. Refrigerant piping system
8.1 Refrigerant piping system diagram
Multi-function valve
Refrigeration unit
Discharge hose
To vehicle’s compressor
Suction hose
Accumlator
Motor pack
(Type 2 only)
8.2 Freezing cycle (Type 2 only)
(1) Refrigeration cycle

Dual pressure switch Dryer Liquid injection electromagnetic valve
Receiver Sight glass Multi-function valve Heat accumlator
Condenser
fan motor
Evaporator
Condenser
Refrigeration unit
Expansion valve
Defrost electromagnetic
valve (closed)
Evaporator fan motor
Strainer (Suction)
(Discharge)
Accumlator
Conpressor (Engine side)

Engine drive type
(Discharge)
Motor pack
(Suction)
Remarks:
The figure shows an example of Type 2. Compressor
Type 1 is not equipped with motor pack
AC motor
and accumulator. Motor drive type
– 11 –

(2) Defrost cycle
Refrigeration unit
Defrost
electromagnetic
valve (open)
Engine drive type
Motor pack
Remarks:
The figure shows an example of Type 2.
Type 1 is not equipped with motor pack
and accumulator. Motor dirve type
9. Control system
Refrigeration unit
Control box
Controller Power source

box
Compressor
To ignition
switch
Td2 sensor
Motor pack
In case of type2
Td1 sensor
To battery (+) terminal
Fusible link
Ground
On the 1 type, connect it to the battery as it is.
Ground
– 12 –

10. Description of main parts (3) Service valve
The compressor are equipped with a suction
10.1 Compressor service valve and discharge service valve.
(1) TDJ300D
Service valve
Note: When working the pipe for service, finally
connect the suction and discharge pipes of the
CR2211L-A compressor since the refrigerator oil is highly
Name Specification Name Specification liable to absorb water.
Model CR2211L-A Weight 7.3kg
(include magnet
clutch) (4) Lubrication system (TDJ430D)
Volume of 110cm3/rev Lubricating Diamond Freeze Lubrication oil is supplied forcibly to respective
discharge oil MA32
bearings, pistons, tank shaft pins and shaft seals by
Revolution 600 ~ 3600min-1 Amount of
(motor 1420min-1) oil 350cm 3 the oil pump.
(2) TDJ430D
Schematic diagram of lubrication system
10.2 Magnet clutch

CR2318LWR
The magnet clutch is installed in the crank shaft of the
Name Specification Name Specification
Model CR2318LWR Weight 13.5kg compressor, and turns on and off the compressor by
(include magnet indication of the thermostat. When cooling is required
clutch)
it is "ON" and when not required it is "OFF".
Lubricating Compulsory Lubricating Diamond Freeze
method lubrication oil MA32
Volume of 181.2cm3/rev Amount of

discharge oil 800cm3
Revolution 600 ~ 3600min-1

(motor 1400min-1)
– 13 –

10.3 Heat accumulator
While separating liquid refrigerant from gas refrigerant

so as not to let the compressor sucks the liquid
refrigerant, increase capacity of refrigeration by
making a heat-exchange of high temperature liquid
refrigerant and low temperature gas refrigerant.
Magnet clutch
Specification
TDJ300D TDJ430D
Volume 53W 31W
Direction of revolving Right Heat accumulator
Belt used Type B × one each

10.4 Accumulator (type 2 only)
How to determine defective or not defective.
When the battery voltage is applied between the lead Separate liquid refrigerant from gas refrigerant so as
1 and the ground wire of the main body, the not to let the compressor sucks the liquid refrigerant.
compressor will turn if the pulley and the friction plate Here, the refrigerant is designed to flow from U type
stick together (it clinks). tube only to the engine side or motor pack side where
If it will not turn even when voltage is applied, it is the compressor is in operation.
defective. Measure by a tester the continuity between
the lead 1 and a ground of the main body, and it is
normal if there is continuity and defective if no
continuity due to disconnection of the coil. When
sound is heard, it is defective due to wear of the
bearing. If the magnet clutch is defective, replace its
assembly.
Measuring of air-gap
TDJ300D: 0.3 ~ 0.5mm
TDJ430D: 0.3 ~ 0.6mm
Accumulator
– 14 –

10.5 Electromagnetic valve How to determine defective or not defective:
Same as defrost electromagnetic valve.
(1) Defrost electromagnetic valve Refer to "defrost electromagnetic valve".
It is installed in order to flow hot gas into the
evaporator side when defrosting. 10.6 Check valve
It is installed to prevent the refrigerant from flowing

back ward.
Arrow mark
Main valve
Disk
Spring
Check valve
Defrost electromagnetic valve
How to determine defective or not defective:
How to determine defective or not defective:
Make a judgment by the difference of temperature at
When continuity of the lead between 1 and 2 is the inlet and outlet of the check valve and replace it if it
measured, the coil is normal if there is continuity is leaking.
and if not, it is defective.
Before the coil is electrified, the temperature at the 10.7 Receiver
inlet and outlet of refrigerant differs. So if the
temperature becomes the same after the coil is It reserves the refrigerant which has been liquefied by
electrified, the plunger is operating normally. the condenser.
If the temperature differs the plunger is stuck. The receiver has a dissolving stopper which will melt
and discharge the refrigerant in order to prevent a
Easy way to find out the problem:
danger due to unusual high temperature.
When you electrify the coil with your hand
When the stopper has been melted, replace it with a
touching the electromagnetic valve, it is normal if
new one.
your hand feels a shock as the plunger goes up
with a click sound.
(2) Liquid injection electromagnetic valve
It opens when delivery temperature (at the sensor)
of the compressor becomes more than 125°C,
keeping the delivery temperature from becoming
high.
Receiver
Liquid injection electromagnetic valve
– 15 –

10.8 Sight glass
It can judge the circulating amount of refrigerant and

existence of water in the refrigerant.
Dryer
When the dryer is replaced, replace it quickly. Here,

when installing the dryer, pay heed to its direction and
Sight glass install it on the unit with the arrow mark aligned to the
If the refrigerant is short, repair the leaking place and flow of the refrigerant.
then charge gas.
10.10 Condenser fan motor
How to determine existence of water:
Color of a color-check
Moisture amount Revolution Electric current Input

Judgment Refrigerant Refrigerant
temperature 24°C temperature 38°C
2100min-1 3.2A 70W
Green Normal 15 ppm or less 30 ppm or less
Light green Rather 15 ~90 ppm 30 ~140 ppm

abnormal
Yellow Abnormal 90 ppm or more 140 ppm or more
In case of yellow color, it in necessary to vacuum and

replace the dryer.
10.9 Dryer
Moisture and foreign materials are eliminated from the

refrigerant. If the desiccant (molecular sieve) in the
dryer can not remove moisture (the check color of the
sight glass becomes yellow), replace the dryer
assembly. Also if inside of the dryer is clogged during Condenser fan motor
operation, there will be a difference in temperature Remarks: The brush can not be replaced
between the inlet and the outlet, and the outlet side
becomes cool.
– 16 –

10.11 Evaporator fan motor
Revolution Electric current Input
2000min-1 2.92A or less 70W
Multi-function valve
Note: (1) Since the multi-function valve was factory-

set at shipment, don't adjust it at the site.
If the adjusting screw is turned, the setting will
become disturbed to cause a poor operation.
(2) When installing the multi-function valve
and connecting the pipe, don't apply any
shock to the multi-function valve.
Otherwise, it will cause gas leakage or
Evaporator fan motor (Fan assembly) improper operation.
Note: The fan motor is press-fit to the fan.

Replace it as the assembly of the fan.
10.13 Expansion valve
10.12 Multi-function valve The valve detects overheat at the outlet of the
evaporator so that proper amount of refrigerant can
The multi-function valve features the following.
flow into the evaporator, and make an automatic
(1) At the abnormally high pressure, the suction adjustment.
pressure is controlled to allow the unit to operate
When adjusting, turn the adjusting screw at a revolution
without any abnormal stop (high-pressure cutting).
of 1/4 and then 1/2 little by little, and see how much
(2) Since the main valve of the multi-function valve is heated it is.
closed when the unit is stopped, the liquid does not
return. This eliminates a danger of liquid
compression to improve the reliability of the
compressor.
(3) The pressure equalizing hole of the multi-function
valve makes the pressure difference early balanced
soon after the unit is stopped. This will reduce the
starting torque.
Expansion valve
– 17 –

10.14 Defrost thermostat (DTS) Adjustment is impossible.
It detects temperature of the evaporator coil and

indicates an end of defrosting.
Defrost thermostat Dual pressure switch

Judgment whether is proper or not
CUT IN 0 ± 3°C
[High pressure side]
CUT OUT 8 ± 3°C
If there is any continuity when the pressure is
Not adjustable
2.94MPa (30kgf/cm 2) or lower during stop and
How to determine defective or not defective operation, and there is not when the pressure is
Put the defrost thermostat into a household electric 2.94MPa (30kgf/cm2) or higher, it is proper.
refrigerator and check as you look at a thermometer. It [Low pressure side]
is normal if there is continuity under 0°C and no If there is any continuity when the pressure is
continuity above 8°C. 0.20MPa (2.0kgf/cm 2 ) or less during stop and
operation, and there is not when the pressure is
10.15 Dual pressure switch (DPS) 0.20MPa (2.0kgf/cm2), it is proper.
When the delivery pressure becomes excessively high

10.16 Storage temperature sensor (TH)
or low, it is dangerous. So, the dual pressure switch
(normally close type) is activated to stop the The sensor detects a storage temperature in order to
compressor. keep its temperature to an established temperature,
Setting valve MPa (kgf/cm ) 2
keeping the magnet clutch or the relay "ON" and
CUT OUT CUT IN "OFF".
2.94 ± 0.2 2.35 ± 0.2 Setting of storage temperature is made by the
High pressure side (30 ± 2) (24 ± 2) temperature setting switches of the controller.
0.20 ± 0.02 0.23 ± 0.02
Low pressure side (2.0 ± 0.2) (2.3 ± 0.2)
Controller
– 18 –

Storage temperature sensor Td sensor
How to determine defective or not defective How to determine defective or not defective:
(a) Measure continuity by removing the connector at Measure the resistance value by removing the
the edge of temperature detection. connector.
(b) Resistance value at the edge of temperature Resistance value in normal condition
detection in normal condition.
200°C 0.430kΩ 100°C 5.228kΩ
(Unit kΩ)
175°C 0.738kΩ 25°C 80.470kΩ
°C Rmin. Rnom. Rmax.
115°C 3.352kΩ
-30 25.293 26.316 27.376
-20 15.125 15.572 16.031 10.18 Controller
-10 9.342 9.524 9.709
A new controller with a character display function has
0 5.940 6.000 6.060 been adopted, which enables to set digitally a desired
10 3.810 3.882 3.995 storage temperature accurately. In addition to it, pre-
20 2.505 2.573 2.644 operation inspection for the refrigeration unit can be
made by a simple button operation and a diagnosis at
25 2.049 2.113 2.179
the time of the unit being defective can also be made
30 1.687 1.746 1.808
easily.
40 1.163 1.213 1.265
50 0.819 0.860 0.903
(c) If the resistance value is widely out of order,

remove it at the edge of the temperature detection
(with lead) and replace it.
(d) If the above resistance value is normal, check the
controller.
10.17 Td sensor (Td)

Controller
It detects delivery temperature of the compressor and
stops the refrigeration unit or opens the liquid injection Display function
electromagnetic valve. • Operation indication lamp
• If the delivery temperature becomes more than 125°C, • Defrost indication lamp
opens the liquid injection electromagnetic valve in • Alarm lamp
order to lower delivery temperature. • Hours indication lamp
• If the delivery temperature becomes more than 135°C, • Display indication lamp
stops the refrigeration unit.
– 19 –

• Inside-container temperature 

• Fault display  Displayed on
• Inside-container preset temperature  the digital
 display unit.
• Operation times 
• Defrost timer 
Remarks: As to abnormal indication, refer to page 47.
10.19 Drain hose heater (option)
It is electrified when the defrost thermostat is "ON" and

prevent the drain hose from being frozen.
Capacity 6W
Drain hose heater
– 20 –

11. Electric wiring diagram
Wire color codes
11.1 Sequence diagram wire colors are identified by the following color codes.
Code Wire color Code Wire color Code Wire color
(1) TDJ300D-1L2, TDJ430D-1L2
B Black Y Yellow P Pink
W White L Blue V Violet
R Red Br Brown Gy Gray
G Green O Orange Lg Light green
Remarks: Three FM1 (evaporator fan motor) are provided on TDJ430D.
Explanation of mark
SYMBOL NAME SYMBOL NAME

SWUP Temperature setting switch (up) AR1 Thermostat relay
SWDOWN Temperature setting switch (down) AR2 Liquid injection electromagnetic relay
SWALARM Alarm switch AR3 Evaporator fan motor relay
SWDEF Defrost switch AR4 Condenser fan motor relay
SWHOURS Hours switch AR5 Defrost electromagnetic valve relay
SWON/OFF Operation switch
SWDISP Display switch AR7 Drain hose heater relay
PLALARM Alarm lamp F1 Fuse (*1: 15A, *2: 25A)
PLDEF Defrost indication lamp F2 Fuse (10A)
PLHOURS Hours indication lamp F3 Fuse (15A)
PLDISP Display indication lamp
TH Storage temperature sensor FM1 Evaporator fan motor
DPS Dual pressure switch FM2 Condenser fan motor
TD1 Td sensor (engine side) H Drain hose heater (option)
MCL1 Magnet clutch (engine side)
DTS Defrost thermostat
FL Fusible link
BATT Battery SV1 Defrost electromagnetic valve
IG Ignition terminal SV2 Liquid injection electromagnetic valve
*1: TDJ300D
*2: TDJ430D
– 21 –

(2) TDJ300D-2L2
Explanation of mark
SYMBOL NAME SYMBOL NAME SYMBOL NAME

GL21 AC power indication lamp SWUP Temperature setting switch (up) AR1 Thermostat relay
RL21 OCR operation indication lamp SWDOWN Temperature setting switch (down) AR2 Liquid injection electromagnetic relay
F21 Fuse (3A) SWALARM Alarm switch AR3 Evaporator fan motor relay
F22 Fuse (5A) SWDEF Defrost switch AR4 Condenser fan motor relay
AR21 AC-DC transfer relay SWHOURS Hours switch AR5 Defrost electromagnetic valve relay
AR22 Actuator relay SWON/OFF Operation switch
AR23 OCR relay SWDISP Display switch AR7 Drain hose heater relay
PLALARM Alarm lamp F1 Fuse (15A)
LS Limit switch (plug cap) PLDEF Defrost indication lamp F2 Fuse (10A)
MS Electromagnetic switch (with OCR) PLHOURS Hours indication lamp F3 Fuse (15A)
Tr Transformer PLDISP Display indication lamp
D1, 2, 3 Diode TH Storage temperature sensor FM1 Evaporator fan motor
D4, 5, 6 Diode DPS Dual pressure switch FM2 Condenser fan motor
D8, 9 Diode TD1 Td sensor (engine side) H Drain hose heater (option)
C Condenser TD2 Td sensor (motor side) MCL1 Magnet clutch (engine side)
MCL2 Magnet clutch (motor side)
FL Fusible link
M Motor BATT Battery SV1 Defrost electromagnetic valve
– 22 –

(3) TDJ430D-2L2
Explanation of mark
SYMBOL NAME SYMBOL NAME SYMBOL NAME

GL21 AC power indication lamp SWUP Temperature setting switch (up) AR1 Thermostat relay
RL21 OCR operation indiction lamp SWDOWN Temperature setting switch (down) AR2 Liquid injection electromagnetic relay
F21 Fuse (3A) SWALARM Alarm switch AR3 Evaporator fan motor relay
F22 Fuse (5A) SWDEF Defrost switch AR4 Condenser fan motor relay
AR21 AC-DC transfer relay SWHOURS Hours switch AR5 Defrost electromagnetic valve relay
AR22 Actuator relay SWON/OFF Operation switch
AR23 OCR relay SWDISP Display switch AR7 Drain hose heater relay
PLALARM Alarm lamp
LS Limit switch (plug cap) PLDEF Defrost indication lamp F1 Fuse (25A)
MS Electromagnetic switch (with OCR) PLHOURS Hours indication lamp F2 Fuse (10A)
Tr Transformer PLDISP Display indication lamp F3 Fuse (15A)
D1, 2, 3 Diode TH Storage temperature sensor
D4, 5, 6 Diode DPS Dual pressure switch FM1 Evaporator fan motor
D8 Diode TD1 Td sensor (engine side) FM2 Condenser fan motor
C Condenser TD2 Td sensor (motor side) H Drain hose heater (option)
APR Antiphase detection relay DTS Defrost thermostat MCL1 Magnet clutch (engine side)
FL Fusible link
M Motor BATT Battery SV1 Defrost electromagnetic valve
– 23 –

11.3 Explanation of operation (Explanation is made for TDJ300D-2L2)
(1) In case of engine drive
A Cooling operation
1. Start the engine of a vehicle to be run.

2. Turn the operation switch to "ON".
• Operation indication lamp will light. (green)
• AR3 (Evaporator fan motor relay) is energized, and FM1 (evaporator fan motor) is electrified and then the
evaporator fan turns.
3. When storage temperature is more than the established temperature (the thermostat is "ON").
• AR1 (thermostat relay) is energized, and MCL1 (magnet clutch on engine side) is electrified and then the
condenser fan turns.
• AR4 (Condenser fan motor relay) is energized, and FM2 (condenser fan motor) is electrified and then the
condenser fan turns.
4. When storage temperature is less than 0°C, DTS (defrost thermostat) is "ON".
• The defrost timer starts adding up time.
• AR7 (drain hose heater relay) is energized and H (drain hose heater) (option) is electrified.
The above procedures make a cooling operation.
Remarks: If the delivery temperature becomes more than 125°C, AR2 (Liquid injection relay) is energized and
SV2 (Liquid injection electromagnetic valve) is electrified.
[Less than 120°C ······ non-energized]
– 28 –

B Operation of ON-OFF by thermostat during cooling operation.
Remarks: The following shows a diagram
being stopped by thermostat.
1. In case a storage temperature drops (thermostat "OFF") to an established temperature

• AR1 (thermostat relay) is dropped out, and MCL1 (magnet clutch) is disconnected and then the compressor stops.
• AR4 (condenser fan motor relay) is dropped out, and FM2 (condenser fan motor) is disconnected and then the
condenser fan stops.
Remarks: The followings are operating even when the unit has stopped with thermostat "OFF".
(1) The evaporator fan is rotating.
(2) In case the storage temperature is less than 0°C (DTS is "ON".):
• Drain hose heater is electrified.
• Defrost timer adds up time.
(3) Operation indication lamp (green) is on.
2. In case the storage temperature has become more than the established temperature (thermostat "ON")
• AR1 (thermostat relay) is energized, and MCL1 (magnet clutch) is electrified and then compressor turns.
• AR4 (condenser fan motor relay) is energized, FM2 (condenser fan motor) is electrified and then condenser fan
turns.
Storage temperature will be kept at a fixed temperature by repeating the above procedure.
– 29 –

C Defrost operation
1. When defrost switch has been turned on or defrost timer is operating (the timer is built into the controller and is set
in 3 hours for shipment from factory)
• Defrost indication lamp lights. (orange)
• AR3 (evaporator fan motor relay) is dropped out, and FM1 (evaporator fan motor) is disconnected and then
evaporator fan motor stops.
• AR4 (condenser fan motor relay) is dropped out, FM2 (condenser fan motor) is disconnected and then condenser
fan stops.
• AR5 (defrost electromagnetic relay) is energized, and SV1 (defrost electromagnetic valve) is electrified and open.
Defrost operation will start after going through the above procedure.
Remarks: Even if the unit is stopped by thermostat operation, defrost timer will operate or if defrost switch is turned
on, it performers defrost operation.
2. When frost is melted and evaporator coil temperature rises, DTS (defrost thermostat, "ON": 0°C "OFF": 8°C) turns off.
• Defrost indication lamp (orange) turns off.
• AR3 (evaporator fan motor relay) is energized, and FM1 (evaporator fan motor) is electrified and evaporator fan turns.
• AR4 (condenser fan motor relay) is energized, and FM2 (condenser fan motor) is electrified and condenser fan turns.
• AR5 (defrost electromagnetic relay) is dropped out, SV1 (defrost electromagnetic valve) is disconnected and closed.
• AR7 (drain hose heater relay) is dropped out and H (drain hose heater) is disconnected. (It will be electrified
when storage temperature drops and DTS becomes "ON".)
• Defrost timer becomes "OFF". (When storage temperature drops and DTS becomes "ON", it starts adding up time.)
Cooling operation will start after going through the above procedures.
– 30 –

D Operation of protection device
1. DPS (Dual pressure switch) operates ···· The unit • AR 4 (condenser fan motor relay) is de-
stops. energized, FM 2 (condenser fan motor) is
High pressure side disconnected, and the condenser fan motor
OFF : 2.94MPa (30.0kgf/cm ) 2 stops.
ON : 2.35MPa (24.0kgf/cm2) Remarks: (1) When alarm lamp lights, the defects
Low pressure side will be shown on the display when
OFF : 0.20MPa (2.0kgf/cm ) 2 alarm lamp is lit, press the alarm
ON : 0.23MPa (2.3kgf/cm ) 2 switch, and the defects will be
shown on the display.
• The alarm lamp lights (red).
DPS operates ························
• All relays are dropped out.
F1 is blown ····························
2. F1 (fuse) is blown ···· The unit stops.
F2 is blown ····························
F3 is blown ····························
TD operates ··························
3. F2 (fuse) is blown ···· The unit stops. Storage temperature sensor defect
• The alarm lamp lights (red). ·········································
(2) When pressure and temperature
4. F3 (fuse) is blown ···· The unit stops. drops, DPS and TD automatically
• The alarm lamp lights (red). operate again.
• All relays are dropped out. (The light goes out if the operation
5. FL (fusible link) is blown ···· The unit stops. switch is turned "OFF".)
6. TD (Td sensor) operates ···· The unit stops.
("OFF" at compressor delivery temperature 135°C
and "ON" at 125°C)
• AR1 (thermostat relay) is de-energized, MCL1
(magnet clutch) is disconnected, and the
compressor stops.
– 31 –

(2) In case of motor drive
Remarks: As the operation of the thermostat and defrost is the same with that of engine drive, refer to page 29 and 30.
A Cooling operation
1. Turn on the power.

• GL21 (AC power indication lamp) lights.
• AR21 (AC-DC transfer relay) is energized.
(automatic switch-over from engine drive to motor derive.)
2. Turn on the operation switch.
• Operation indication lamp lights (green).
• AR3 (evaporator fan motor relay) is energized, and FM1 (evaporator fan motor) is electrified and evaporator fan
turns.
3. When storage temperature is more than an established temperature (thermostat is "ON"):
• If AR1 (thermostat relay) is energized:
When AR22 (actuator relay) is energized, MS (electromagnetic switch) is energized, which electrifies M (motor)
and the motor turns.
• AR4 (condenser fan motor relay) is energized, and FM2 (condenser fan motor) is electrified and condenser fan
turns.
4. When storage temperature is less than 0°C, DTS (defrost thermostat) is "ON".
• Defrost timer starts adding up time.
• AR7 (drain hose heater relay) is energized and H (drain hose heater) (option) is electrified.
Cooling operation will start after going through the above procedures.
Remarks: If the delivery temperature becomes more than 125°C, AR2 (Liquid injection relay) is energized and SV2
(Liquid injection electromagnetic valve) is electrified.
[Less than 120°C ······ non-energized]
– 32 –

B Operation of protection device
1. OCR (Overcurrent relay) operates ···· The unit stops.

• MS (electromagnetic switch) is dropped out, M (motor) is disconnected and the motor stops.
• AR23 (OCR relay) is energized and RL21 (OCR operation indication lamp) lights.
• All relays drop out because power source to the controller is OFF. For re-start, push OCR manual reset button.
Remarks: As for the procedures except for the above, refer to page 31 as they are the same with those of engine
drive.
– 33 –

12. Periodic inspection (12) Check starting and stopping of compressor,
magnet clutch and fan by thermostat.
Perform the periodic inspection for the items required (13) Cooling operation
on the following period. Check display for temperature indication and
Write down necessary matters to the check sheet on dropping of temperature.
page 40.
(14) Check defrost for operation.
1. Inspection at the time of installation and test run
Check it by turning on manual defrost switch.
2. Monthly inspection
3. Six-month inspection (15) Check DPS (Dual pressure switch) for operation.
CUT OUT (high): 2.94MPa (30kgf/cm2)
12.1 Inspection at the time of installation and test run (low): 0.20MPa (2.0kgf/cm2)
(16) Check power source wiring (ground wire,
(1) Check seals of refrigeration unit at the sections insulation resistance) (Type 2 only)
passing through a van wall. Note:
Check if the sealant is processed for sure and no Insulation resistance measurement method (AC 3-
air goes in. phase circuit only)
(2) Check the tubing clamp for adequacy. Short-circuit the power source terminal (R.S.T or
Make sure tubing does not vibrate during driving. power source plug pin) and measure the insulation
resistance between the short-circuited section and
(3) Check the drain hose for connection and drainage
the grounded section by an insulation resistance
and the clamp for adequacy.
tester.
(4) Check the belt for tension, degree of parallel
(17) Check the motor drive for operation. (Type 2 only)
(stick-out of interline) and scratches.
Hold center of the belt and adjust its bending up to (18) Check the buzzer for buzzing. (Type 2 only)
about 7 ~ 10mm. (19) Check the instruction manual.
(5) Check if the belt is touching another parts such as

compressor, pulley, belt, tubing and wiring. 12.2 Daily inspection
Especially check if abnormal sound is heard from
Refer to page 36 except the following items.
moving parts.
(1) Implement the checking items about the engine to
(6) Check if the mounting bolt is tightened more, if
be run.
the refrigeration unit, compressor, compressor
head, magnet clutch, tension pulley, bracket, fan (2) Confirm that there are no abnormal sound and
motor and fan are properly installed, if the unit is vibration.
deformed or if truck has scraches on the body. (3) Check if anything is touching the movable places.
(7) Check for wrong electrical wiring, clamp, loose (4) Check the compressor belt for tension, wear and
terminal. abnormal sound.
(8) Check the service valve is opened of refrigerant (5) Check if the condenser fan and evaporator fan are
system. turning.
(9) Check refrigerant system, oil and gas leakage, (6) Check if the temperature indication of the display
connection part of tubing and installation of is proper.
functional parts. (7) Check commercial power driving equipment
(10) Abnormal sound and vibration (motor drive)
Check the compressor, magnet clutch, motor, fan • Check the power source cord for damage.
and tubing for abnormal sound and vibration. Check if the power box cover is firmly fixed.
(11) Inspection of sight glass Check to see no water is in the plug receptacle.
Color of the sight glass is to be green and the glass • Check to see the motor is running and if
has to have no excessive bubbles. abnormal sound is heard during operation.
– 34 –

(8) During transportation, look at the display from 12.5 Bolt tightening table for each section
time to time to see if it keeps and established
storage temperature. (1) Standard tightening torques for flare nuts.
Applicable
copper pipe Tightening torque N·m(kgf·cm)
12.3 Monthly inspection
ø 6.35 9.8 ~ 19.6 (100 ~ 200)
(1) Check the belt for looseness, degree of parallel
ø 9.52 19.6 ~ 29.4 (200 ~ 300)
(stick-out of interline) and scraches. (bending of
ø 12.7 29.4 ~ 39.2 (300 ~ 400)
the belt is to be about 7mm ~ 10mm.)
ø 15.88 39.2 ~ 49.0 (400 ~ 500)
(2) Check if anything is touching to another part.
(compressor, pulley, belt, tubing and wiring) ø 19.05 49.0 ~ 58.8 (500 ~ 600)
(3) Clean carefully the refrigeration unit and drain

pipe with soft brush. (2) Tightening torques of general N·m (kgf·cm)
The fins will be deformed or damaged if a hard
Material
brush is used. SS41C S45C SUS304
Note: Head
mark
(a) Never make a high pressure washing with a
v
Thread No mark or 4 or 7 No mark
diameter
high pressure washing machine as it crushes
its fin. 0.6 ~ 1.0 1.0 ~ 1.5 0.8 ~ 1.0
M3
(6 ~ 10) (10 ~ 15) (8 ~ 10)
(b) Never make a steam washing as it raises its
inside pressure unusually high and is 1.0 ~ 1.5 2.0 ~ 3.0 2.0 ~ 2.5
M4
(10 ~ 15) (20 ~ 30) (20 ~ 25)
dangerous.
2.0 ~ 2.5 4.0 ~ 5.0 3.4 ~ 4.4
(4) Check the refrigerant sight glass for color and M5
(20 ~ 25) (40 ~ 50) (35 ~ 45)
degree of flash.
3.5 ~ 4.4 6.9 ~ 8.3 6.4 ~ 7.8
Green = Normal M6
(36 ~ 45) (70 ~ 85) (65 ~ 80)
Yellow = Abnormal (water in it)
8.4 ~ 9.8 17.7 ~ 19.6 16.7 ~ 19.6
Lots of bubbles = Insufficient refrigerant M8
(86 ~ 100) (180 ~ 200) (170 ~ 200)
(Replacement of dryer and refrigerant is needed if
17.0 ~ 19.6 35.3 ~ 40.2 33.3 ~ 38.2
water is in it) M10
(173 ~ 200) (360 ~ 410) (340 ~ 390)
(5) Check refrigeration. (Check temperature indication
29.4 ~ 33.3 59.8 ~ 69.6 56.9 ~ 65.7
on the display and high and low pressure power.) M12
(300 ~ 340) (610 ~ 710) (580 ~ 670)
As to high and low pressure power, refer to page
47.1 ~ 53.0 96.1 ~ 107.9 91.2 ~ 104.9
41. M14
(480 ~ 540) (980 ~ 1100) (930 ~ 1070)
(6) Implement the matters to be taken care of at the 73.5 ~ 84.3 156.9 ~ 176.5 142.2 ~ 165.7
M16
time of periodic inspection as shown on page 38. (750 ~ 860) (1600 ~ 1800) (1450 ~ 1690)
12.4 Six-mouth inspection
(1) Implement the checking items required at the time

of installation-test operation and monthly
checking. (excluding a check for mis-wiring)
(2) Check the relay for contact point.
Correct defective contact point due to short circuit.
(3) Carry out the warning items at the time of periodic
inspection listed on page 38.
– 35 –

12.6 Caution to be taken at the time daily inspection
Instruct users to comply with the following items.
No. Item Contents Care to be taken at the time of operation Anticipated defect Disposition (remarks)
1 Check for gas • Perform this as a daily 1. Amount of refrigerant 1. Insufficient amount of 1. Check for leakage and
leakage inspection as the amount When the amount of refrigerant is short refrigerant repair if any, and then
of refrigerant and water due to gas leakage, there are lots of • Defective refrigeration supply refrigerant.
in the refrigeration can bubbles, and when extremely short, it or no refrigeration 2-1. After recovering
be checked by sight looks white (flashing condition) • Rizing of delivery gas refrigerant and
glass. 2. Existence of water temperature replacing dryer,
It is normal when the check color is 2. Inflow of water vacuumize it and then
green, and abnormal when the color is • Clogging of expansion charge a fixed amount
yellow with more than 140ppm valve of refrigerant.
(refrigerant temperature 38°C) water. • Clogging of receiver 2-2. Check and supply
dryer or dryer amount of the
compressor in the
same way.
2 Washing of • Prevention of dropping of 1. The fin will be crushed if it is washed 1. Stain of condenser coil. 1. Remove and wash stain
condenser coil heat exchange due to directly by high pressure water current. Insufficient operation of of coil as often as
stain of coil So wash it with brush by water current DPS and capacity of possible.
from a hose. refrigeration
3 Painting of the • Disposition for peeling of 1. The rust generated on the painted 1. Hole and crank in panel. 1. When occurrence of rust
body paint on the metal section surface due to a frying stone or scratch, 2. Falling off of panel is confirmed, clean the
of the units which have will develop without being aware of it. affected place by sand
been used for long and Rust in early stage can be well prevented paper in early stage and
for occurrence of rust. from developing by touch up. repair by touch up.
2. Replace the part which
has developed to opening
of hole or crack.
To a servicing shop.
4 Caution to be • When not using for long, 1. When the unit is not used for long, 1. When the compressor is
taken when not decrease the refrigerant operate it about 15 minutes once in not used for long, it will
using for long staying in the compressor every three or four days. hold refrigerant liquid in
and prevent the shaft seal In case of type 2 it, which, when started,
from running out of oil. (Run the engine and motor about 15 will cause lack of
minutes once in every three or four days. lubrication and burning
of the compressor. And
also running out of oil in
shaft seal section may
cause leakage of
refrigerant gas.
5 Caution to be • Do not remove the 1. Do not remove the compressor belt even 1. Though shaft bearings
taken when the compressor belt. if a vehicle is used and the refrigeration are in the condition of
refrigeration is not used for long. being fixed by tension of
unit is not belt, fretting corrosion
used. may be generated on
affected place due to
vibration if a vehicle is
run with belt removed.
6 Caution to be • Preparatory refrigeration, • In case of using a refrigerator truck for 1. Clogging of drain pipe
taken when a keeping load in long instead of a refrigerator, make a due to freezing of
refrigerator refrigeration, in case of storeroom temperature up to plus degree defrosted water or
truck is used using an power-driven once a week and melt the ice frosted. developing of ice due to
instead of a equipment sold at a failure of draining may
refrigerator. market for long instead crush defrost pipe and
of a refrigeration in order cooling coil.
to refrigerate and excess
load at night, prevention
of defroster from troubles
– 36 –

7 How to load 1. Load by giving enough 1. Dimensions shown below are specially 1. It may happen that 1. Larger size load will
into storage space so as to be able to important. temperature become keep storage temperature
secure circulation of uneven at lower and from becoming uneven.
wing in the storage. upper and front and rear 2. Space between both sides
2. When loading and sides of storage. of a load is to be more
unloading with door 2. When the storage door is than 30mm.
open, stop the unit. opened by circulating
wind, cold air in the
room will be replaced by
outside air, which makes
The values in ( )are applicable for the storage temperature
TDJ430D. rise.
– 37 –

12.7 Caution to be taken at the time of periodic inspection
1 Tension of belt • Tension of belt between 1. Use tension meter to adjust belt and 1. Too loose 1. Proper tension
direct coupled type provide with an appropriate tension. • Slipping of belt • Direct coupled type
engine pulley, idle pulley 2. As a new belt becomes stretched in its • Dropping of capacity Bending of 7 ~ 10mm
and clutch pulley early stage, re-fasten the belt after 2. Too tight when pushed by 98N
operating about 10Hr. • Abnormal pulley (10kg) force
3. After that, check and adjust every bearing
100Hr. • Premature wearing of
belt
• Breaking of engine
crank
2 Inspection of a • Disposition of a ground 1. Clamp the ground wire terminal and 1. Many defects which will 1. Confirm at each
ground wire on wire terminal for the unit apply sealer so as not to have its inside cause burning of relay, inspection.
the side of a and vehicle chassis broken during running of a car. Remove etc. 2. Apply sealer to each
vehicle and painting on the side of a vehicle. 2. Breaking of terminal due terminal of wiring
maintenance to its corrosion (except inside of control
and 3. Failure of contact box)
disposition of
harness.
3 Washing • When compressor is 1. Washing inside of refrigerant 1. No refrigeration 1. HCFC141b is a

inside of replaced due to circuit 2. Clogging of expansion refrigerant for washing.
refrigerant compressor accident, (1) Enclose HCFC141b and circulate by valve
circuit and check for refrigerant and another pump. 3. Clogging of dryer
operation for oil stain, And after washing inside circuit, 4. Symptom of compressor
cleaning and *if necessary, wash recover HCFC141b and enclose • In case of burning
inside of the circuit or refrigerant after vacuumizing it. • In case of remaining oil
operate for cleaning. 2. Operation for cleaning having nearly black
(*) In case of item 4 of (1) Replace with a new compressor and color and metal powder
"anticipated defect" after vacuumizing it, charge gas and mixed.
shown on the right perform cooling operation for about • In case of having much
hand column. an hour. (For type L specification, wear and many
perform defrost operation for about scratches on the sliding
15 minutes) surface of cylinder,
(2) After that, recover refrigerant and piston and rod.
replace receiver dryer or dryer. When such symptoms as
Replace oil for compressor and once above have occurred,
again vacuumize and charge gas. same kind of defect may
The above procedures will prevent a happen again soon as it is
compressor from becoming possible that the
defective again. refrigerant circuit is
stained even after
replacing the compressor.
4 Refrigerating • Precaution when using 1. The refrigerating machine oil (Diamond 1. Clogging may occur in 1. Do not use refrigerating
machine oil refrigerating machine oil Freeze MA32) has an extremely high each section if machine oil that has been
for charging to the absorbency, so work quickly when refrigerating machine oil exposed to air for a long
compressor. handling it. exposed to air for a long time.
2. Never use leftover oil. Always dispose time is used.
of it.
3. Dispose of any refrigerating machine oil
in the oil can be used, and store it in a
dry state.
– 38 –

5 Parts sold at a • Care to be taken when 1. Do not use easily parts sold at a market 1. In case of tension pulley 1. Replace them with
market parts sold at a market are by only checking sizes and capacity. bearing, using a bearing genuine parts.
used with different sealing
structure (nonecontat seal
type) will soon bring
about a defect even after
replacing with new one.
2. Using fuse with different
characteristic will give no
protection or cause
erroneous operation.
6 Repair to • Early disposition for 1. Rust will increasingly develop into a 1. Hole or crack in panels 1. Parts which have been
painted place peeling of paint and rust secondary damage if left alone. Make an 2. Fall off of panel developed into having a
to metallic place of the appropriate repair such as touch up after hole or crack are to be
unit removing rust with wire brush, sand replaced in order to
paper, etc., and washing well. prevent and accident of
falling off a running
vehicle.
– 39 –

12.8 Check sheet (Installation, test run and periodic inspection)
Customer’s
Customer signature
Model Delivery date
Refrigeration unit
Serial No. Van maker
Inspection interval Inspection date
Model
Compressor kit
Serial No. Inspection company
Refrigeration
Model
trial operation
unit installation
Vehicle
Installation
company
Every one
Inspector
Every six
Serial No.
months
months
Inspection items Inspection result Remarks

Inspection seal sections of van where refrigeration unit passes through
Inspection for appropriate wiring clamps
Inspection for secure drain hose connections and adequate clamps
Inspection for belt slack, parallelism (alignment), and damage
Inspection for contact with other parts (compressor, pulley, belt, piping, wiring)
Tightening of installation bolts (refrigeration unit, compressor, compressor head,
bracket, magnet clutch, tension pulley, fan motor, fan)
Inspection for incorrect wiring and for adequate clamps
Inspection for electrical wiring terminal looseness, wiring, sheath damage
Relay contact inspection
Cleaning of refrigeration unit and drain discharge ports
Inspection to check that refrigerant system operation valve is open (gauge manifold inspection)
Inspection for refrigerant system gas leaks (oil leaks)
Inspection for abnormal noise and abnormal vibration
(compressor, magnet clutch, motor, fan, piping)
Inspection of refrigerant sight glass color and flushness
Confirmation of compressor and magnet clutch start/stop, and
condenser fan start/stop with thermostat
Cooling inspection (indication of digital display temperature, high/low pressure inspection)
Confirmation of defrosting operation
Confirmation of dual pressure switch operation
Check of motor operation (operation current measurement) (type 2)
Inspection of power wiring (ground wire, insulation defects) (type 2)
Inspection of buzzer sounding (type 2)
Daily inspection Cleaning of condenser coils
Seasonal inspection Refrigeration unit painting
Time Outside temperature ˚C
Item
inspection
Note) Operate the unit until the

Cooling
Room temperature ˚C
High pressure temperature drops to the
MPa (kgf/cm2) designated temperature.
Low pressure
MPa (kgf/cm2)
Remarks
– 40 –

12.9 Pressure table for standard operation
(1) TDJ300D
Compressor revolution 1800min-1
2.7 (28)
Storage
2.5 (26) temperature 0°C
2.4 (24)
2.2 (22)
High pressure
2.0 (20)
1.8 (18)
1.6 (16)
1.4 (14)
1.2 (12)
MPa(kgf/cm2) Storage
1.0 (10) temperature -18°C
0.8 (8)
0.6 (6)
Storage Storage
temperature 0°C temperature -18°C
0.5 (5)
Low pressure
0.4 (4)
0.3 (3)
0.2 (2)
0.1 (1)
MPa(kgf/cm2) 0 (0)
10 15 20 25 30 35 40
Return air temperature by condenser °C

(Outside air temperature)
(2) TDJ430D
Compressor revolution 1800min-1
2.7 (28)
Storage
2.5 (26) temperature 0°C
2.4 (24)
2.2 (22)
High pressure
2.0 (20)
1.8 (18)
1.6 (16)
1.4 (14)
1.2 (12)
MPa(kgf/cm2) Storage
1.0 (10) temperature -18°C
0.8 (8)
0.6 (6)
Storage
temperature 0°C
Storage
temperature -18°C
0.5 (5)
Low pressure
0.4 (4)
0.3 (3)
0.2 (2)
0.1 (1)
MPa(kgf/cm2) 0 (0)
10 15 20 25 30 35 40
Return air temperature by condenser °C

(Outside air temperature)
– 41 –

13. Defect and its cause
13.1 Diagnosis of defects on refrigerant system
(1) Table of defect and cause of refrigerant system
Compressor will not maintain sucking pressure

Defect
Bubble can be seen in sight glass.
Compressor becomes frosted.
No capability of refrigeration
Compressor gives off sound.
Compressor will not suck.
Defrost can not be made.

High pressure is high.
Low pressure is high.

Low pressure is low.
Cause
Overcharge of refrigerant
Shortage of refrigerant
No refrigerant
Return air temperature by condenser is too high.
Clogging of condenser
Return air temperature by condenser is too low.
Air is mixed in refrigeration cycle
Stopping of condenser fan
Clogging of evaporator
Defrost of evaporator is required.
Leakage of compressor delivery valve
Leakage of inlet valve
Excessive circulation amount of refrigeration machine oil
Inadequate tightening of compressor and magnet clutch
Compressor bearing is defective.
Compressor valve plate is broken.
Thermo bulb of expansion valve is defective.
Installation of thermo bulb of expansion valve is defective.
Excessive opening of expansion valve
Excessive closing of expansion valve
Clogging of expansion valve
Liquid back
Low pressure side is clogged.
High pressure side is clogged
– 42 –

(2) Diagnosis by pressure gauge
Standard pressure value
High pressure [Condenser entrance air temperature] + Saturation

Refrigerant pressure of about 14 ~ 16°C
pressure
Low pressure [Cool wind entrance temperature] - Saturation pressure
of about 20°C
With the storage temperature at about 0°C
No. Pressure Main causes
1 Both high and low pressure are too high 1. Excessive refrigerant (Accompanied by backing of liquid)
Take out refrigerant up to a fixed amount.
2. Storage temperature is very high.
2 High pressure is rather low and low pressure is 1. Suction of compressor is defective due to cracking of valve.
too high. (Repair)
3 High pressure is rather high and low pressure is 1. Excessive opening of expansion valve (Adjust).
too high. 2. Contact of expansion valve thermo cylinder to suction pipe is
defective. (Correction)
4 High pressure is almost normal but low pressure 1. Refrigerant is al little short. (Charge refrigerant)
is too low. (Evaporator becomes frosted.) 2. Clogging of receiver dryer or dryer, and expansion valve.
(Replace and adjust)
3. Evaporator fan is defective. (Repair)
5 High pressure is too high but low pressure is 1. Condenser is dirty. (Clean)
almost normal. 2. Amount of wind of condenser is short
3. Outside temperature is high
4. Incompressible gas is mixed in the unit. (Vacuumizing, gas
charge)
5. Fan for condenser is defective. (Repair)
6 Both high and low pressure is too low. 1. Refrigerant is extremely short. (Charge refrigerant)
Expansion valve is making a hissing sound.
2. Outside temperature is low. Excessive amount of wind
– 43 –

(3) Shortage of refrigeration
Cause of defect Disposition
(1) Wind does not come out much

(a) Evaporator coil is frosted. (a) Change operating time of defrost timer. (Type L only)
(b) Operate manual defrosting.
(c) It is normal if defrost is operating, but if defrost electromagnetic valve
(b) Defrost solenoid valve is operating. is operating during cooling operation, Check for it. (Type L only)
(2) There is a chink in the refrigeration van, Check and repair so as to get rid of chink.
which brings in outside air.
(3) A lot of bubbles can been seen in sight Check for gas leakage and supply refrigerant after repair.
glass and refrigerant is reducing.
(4) Condenser coil is stained. Wash by water. However, be careful that fin will be crushed if rubbed by
hard brush
(5) In case the said items (1), (2), (3) and (4) (a) Start engine by connecting a gauge manifold and confirm that
are normal, compressor is operating. Through on the high pressure side shows
(a) Expansion valve is clogged. rather low value, expansion valve, receiver dryer or dryer is clogged
if low pressure side shows lower value than the one shown on page
41.
1) Expansion valve is clogged because water is frozen at the outlet of
expansion valve. So stop operation once, and then after inside ice
being melted, turn compressor again thermostat cylinder in
floating condition. If pressure on low pressure side goes up much
high and after a while pressure lower than the one when operated
normally is shown, it is suspected that water is in the cycle. In case
low pressure gauge will not go up even if thermostat cylinder is
floated, it is suspected that expansion valve is stuck or gas leaks
from thermostat cylinder. (Replace)
2) In case water is in, receiver refrigerant and replace receiver dryer
or dryer. As to vacuumization, use "repeating vacuumization
method", and charge after removing water completely. Also if
receiver dryer or dryer is clogged, low pressure gauge shows lower
pressure than the one when operated normally. And in a extreme
case, tubing followed by receiver dryer or dryer will become
frosted all over. And also in case they are slightly clogged,
temperature differs before and after receiver dryer or dryer.
(Replace)
(b) Expansion valve is opened too much. (b) In case pressure on low pressure side is high and compressor
generates frost at the same time, expansion valve opens too much,
which indicates that refrigerant goes into compressor as liquid
refrigerant. Check for floating of thermostat cylinder. It is suspected
that expansion valve is stuck.
(c) Compressor valve is broken. (c) In case there is little difference of pressure between high and low
pressure, either compressor valve is broken or expansion valve
opens too much. As to excessive opening of valve, determine by (b)
above, and as defective compressor valve, check whether or not the
difference of pressure between high and low pressure is normal with
gauge manifold being connected. In case temperature of condenser
will hardly go up, it is suspected that compressor is not compressed.
(check and repair)
– 44 –

(d) Refrigerant is excessive. (d) It is a little difficult to determine but tendencies are:
1) High pressure gauge indicates high, that is pressure at operation
indicates higher value than high pressure power shown on page
41.
2) No bubble can be seen from sight glass even if compressor is
turned at high temperature. No bubble still can be seen even if
compressor is turned with the door fully opened when outside
temperature is 35°C or more.
(e) Air is mixed in the unit. (e) In case a lot of bubbles can be seen from sight glass and
refrigeration is poor, although high pressure gauge indicates high,
air is mixed. As air is lighter than refrigerant, it gathers at the
highest place of the unit and so air purge can not be made.
It is necessary to vacuumize.
(4) Abnormal sound can be heard
(1) Installation work is defective. Check, repair and increase tightening.
(2) Metallic sound can be heard from inside of Disassemble inside, check and repair or replace.
compressor.
(3) Belt is loose. Put it on again.
(4) Fan is touching. Check and repair.
(5) Compressor liquid is compressed. Check expansion valve and amount of refrigerant.
– 45 –

13.2 Charging the refrigerant <R404A>
1. Use the following procedure to charge the refrigerant.

(1) Operation procedure
Multi-function valve Service valve B

Condenser
fan motor
Service
valve A
HP take-
out tube
HP take-out port C
Discharge operation Suction operation
valve valve D
(2) Evacuation 2 Since the multi-function valve is installed on the

Connect the high pressure side of the gauge system, the pressure is necessary to open the
manifold to the service valve A, and the low main valve. Before running the engine slowly,
pressure side to the compressor suction operation charge 30 to 50g (amount for one charge hose)
valve D (intermediate seat) and the service valve through the suction operation valve D of the
B with T joint, and do the evacuation at three pump in the liquid state.
places. If any gas leakage is checked with 3 When the temperature rises into the moderate
nitrogen, etc., purge the residual pressure from the state (the refrigerant liquid does not flow.), check
service valve B and do the evacuation. the charge amount.
(3) Gas charge Caution: Take care to prevent charging an
amount beyond the specified value.
1 As shown below, place the cylinder upside down
4 If the specified amount is not charged, slowly run
to charge the liquid through the service valve A.
the compressor (like idling) to additionally
charge the gas through the operation valve D.
If the specified amount is charged through the
service valve A, it is properly completed as it is.
Caution: Since the pressure of the service valve
A section becomes higher than that of
the cylinder when the compressor runs,
additional charging is impossible. For
additional charging, use the operation
Caution: In case of the orange belt painted valve D.
cylinder, charge the liquid, standing the For the standard working pressure at the
cylinder in the normal state. specified charge amount, refer to page 41.
– 46 –

13.3 Diagnosis of defects on electric parts
(1) Confirmation of trouble with controller

ALARM
• If the "alarm lamp" lights or flickers, press the "alarm switch" . All errors that are currently occurring will
be displayed as symbols on the "digital display". Confirm the state with the operation switch turned ON.
• Note that error displays or abnormalities in operation may occur due to strong radio waves, etc. In this case, turn
the refrigeration unit off and on once and confirm the operation.
• Always turn the operation switch OFF before inspecting the refrigeration unit.
Alarm
Digital display Remedies Unit state
lamp
∗11 • The fuse F2 for the magnet clutch has blown.
Unit stops
Inspect and replace the fuse F2 in the relay box.
2 • The fuse F3 for the condenser fan motor has blown.
Unit stops
Inspect and replace the fuse F3 in the relay box.
3 • The delivery temperature sensor is activated.
Through the sight glass, check for bubbling. If bubbling is Unit stops
found, check the refrigerant circuit.
4 • The fuse F1 for the evaporator fan motor has blown.
Inspect and replace the fuse F1 in the relay box. Unit stops
5
• The dual pressure switch has functioned.
For high pressure side
(1) Confirm that the condenser fan is rotating, and if it is
not, inspect the wiring for disconnections.
(2) Check whether dirt or mud is adhered on the condenser Unit stops
(lit) coils. Use a brush and water to clean any dirt off.
For low pressure side
The refrigerant runs out. Check for the refrigerant leak, and
refill the refrigerant.
6 • Broken wire in room temperature sensor or defective
Room temperature
connection contact.
Check the resistance value and wiring of the room temperature
sensor, and check the connector.
Unit stops
• Short circuit in room temperature sensor.
display
Check the resistance value and wiring of the room temperature

sensor, and check the connector.
∗2 7 • Delivery temperature sensor short circuit
Check the resistance, wiring and connector of the delivery Operation
(Blinki temperature sensor. continues.
ng)
Normal
(not lit)
Note: (1) ∗1 mark indicates that there are multiple abnormalities, and the indications are
done in preferential order of 1, 2 ··· as shown on the above table. Fuse installation position
(2) *2 indicates the delivery temperature sensor of the compressor on the
engine side.
indicates the delivery temperature sensor of the compressor on the
motor pack side.
(3) Make sure to replace the fuse with genuine fuse with the same capacity as the
original.
– 47 –

(2) How to diagnosis defect by controller indication
(The trouble diagnosis is explained for the main
example of Type 1.)
(a) Diagnosis of defect by the alarm lamp "ON"
Remarks: (1) Measure voltage by body ground wire.
For checking, press the alarm switch.
(2) LB, B and BG show the color of wiring.
(3) Refer to terminal number of controller in
1) In case indication on display is page 61.
: (4) As to wiring, refer to page 21 ~ 23.
YES
Fuse (F2) is broken. Replace fuse (F2)
NO
Is battery
voltage measured at the YES
terminal No.B of Replace controller
controller?
NO
Is battery LB line between controller and

YES relay box is disconnected or
voltage measured at 2nd
side of fuse (F2)? contact of connector is
defective.
NO
Is battery YES
voltage measured at 1st Contact of fuse holder is
side of fuse (F2)? defective.
NO
Is fusible ink YES

(FL) is broken? Replace fusible link.
NO
B line between battery and

relay box, between terminal
block and fuse holder is
disconnected or contact of
terminal is defective.
– 48 –

2) In case indication on display is :
YES
NO
Is battery
voltage measured at YES
Replace controller
controller C
terminal?
NO
Is battery YES L line between controller and

voltage measured at 2nd relay box is broken or contact
side of fuse (F3)? of connector is defective.
NO
Is battery YES
voltage measured at 1st Contact of fuse holder is
side of fuse (F3)? defective.
NO
B line between terminal block

of relay box and fuse holder is
broken or contact of terminal is
defective.
YES
NO
Is battery
voltage measured at YES
Replace controller
controller A
terminal?
NO
Is battery voltage YES LW line between controller and

measured at 2nd side of relay box is broken or contact
fuse (F1 )? of connector is defective.
NO
Is battery voltage YES

measured at 1st side of Contact of fuse holder is
fuse (F1 )? defective.
NO
Broken B wire between relay

box terminal block and fuse
holder.
– 49 –

Check dual Abnormal

pressure switch Replace dual pressure switch.
(DPS)
Normal
NO BY and G lines between DPS

Voltage (Battery voltage) and relay box and controller
between controller 1
terminal and ground are broken or contact of
wire is 0V connector is defective.
YES
Controller is defective.
Condenser
fan motor will Condenser coil
not turn. is stained.
YES YES
Clean coil.
Is L line between fan

battery voltage NO motor and relay box
measured at L line (F3 fuse) is broken or
of fan contact of connector is
defective.
YES
Is
battery voltage NO Check fan motor and
measured at GR line brush used for
of fan fanmotor.
YES
Is battery
voltage measured at NO
at terminal V of
controller?
YES
Controller Y NO
terminal is under
0.5V.
YES
• AR4 relay is defective.

• GR line and G line between AR4
and fan motor are broken or
contact of connector is defective.
– 50 –

5) or indicated on the digital display
( means the compressor on the engine side, and means the compressor on the motor pack.)
• For the voltage of the TD
sensor, refer to Page 63.
• Terminal Nos. of TD sensor Check
voltage of Abnormal
Replace Td sensor.
Engine drive TD1: 7G TD sensor.
Motor drive TD2 : 8H

Normal
Is 4V
(approx. 90°C) YES
measured at terminal Replace controller.
No. 7 or 8 of Td sensor?
NO
Is connector or YES Inspect and repair connector or

line short-circuited? wiring.
NO
Replace controller.
6) indicated on the digital display

Press display switch, and or will be displayed.
(1) If the following is displayed when
the display switch is pressed,
• indicates wire breakage Check Abnormal
resistance of inside Replace storage temperature
of storage temperature sensor. temperature sensor. sensor.
• indicates short circuit of

Normal
storage temperature sensor. (when
temperature of sensor area is 0°C)
Is Abnormal
NO *Check resistance
(2) For the resistance value of storage 2.8V measured at terminal of Td sensor. Replace Td sensor.
No.6 of controller?
temperature sensor, refer to Page 63.
YES Normal
∗: Since the power supply is com-
monly used by TD sensor and Replace controller. Inspect connector and wiring,
and repair as necessary.
storage temperature sensor, the
power supply of storage tempera-
ture sensor will be cut off if the
power supply of TD sensor is
short-circuited. Therefore, wire
breakage indication is
displayed for storage temperature
sensor.
– 51 –

(3) Diagnosis of defect other than abnormal indication
(a) In case the unit will not operate even turning the operation switch "ON".
Unit will not operate with

the operation switch ON.
Will operation NO
indication
lamp light?
YES
Is battery
voltage measured NO
at terminals and N Controller is defective.
and V of
controller?
YES
Refer to page 53, Refer to page 54, Refer to page 54,

evaporator fan motor compressor will not condensor fan motor
will not turn. turn. will not turn.
YES
Is fuse broken? Replace fuse.
NO
Is battery
voltage measured YES
at terminals and
A,B,C,L and M of
controller?
Note: No.M terminal is only
for motor drive. NO Are No.K andS NO G line is
terminals of controller broken or
grounded? contact of
• Line is broken between con troller connector is
and relay box, or contact of defective.
connector is defective. YES
• WB line between ignition
terminal and controller is broken
or contact of connector is Controller is defective.
defective.
• Connecting line between fuse (F22)
and controller is broken or contact
of connector is defective. (In
caseof motor drive only)
– 52 –

(b) In case evaporator fan motor will not operate.
Evaporator fan motor will not

operate.
Is battery LW line between FM1

voltage measured at LW NO connector and relay box F1 is
line of fan motor broken or contact of connector
conector? is defective.
YES
Is battery
voltage measured at YES Check and repair motor and
GW line of fan motor brush.
conector?
YES
Is battery BR line between controller and

voltage measured at NO relay box (AR3) is broken or
BR line of AR3 coil? contact of connector is
defective.
YES
Is under
0.5V measured at W NO
terminal of controller?
YES

• GW and G lines between fan
motor and relay box (AR3) is
broken or contact of connector
is defective.
– 53 –

(c) In case compressor will not operate.
Compressor will not operate.
Is battery
voltage measured at NO
GB line of magnet
clutch (engine side)
connector?
BR line between
Is battery controller and relay
YES voltage measured NO
box AR1 is broken or
at BR line of AR1 contact of connector is
coil? defective.
Is battery voltage YES Magnet clutch YES
measured at magnet clutch ground wire is
ground wire? off.
Is under
NO 0.5V measured NO
at O terminal of Controller is defective.
controller?
Magnet clutch is defective.
YES

• GB and LR lines between
magnet clutch and relay box
AR1 are broken or their
contact is defective.
(d) In case condenser fan motor will not operate:

In case indication on display is , refer to page 50.
(e) In case thermostat will not operate (will not become ON-OFF)
Refrigeration is defective ···· Refer to page 42, diagnosis of defects on refrigerant system.
– 54 –

(f) Defrost operation
1) In case the unit will not defrost.
It will not defrost.
Is storage NO Normal if it will

temperature under 0°C? not start defrosting.
YES
Is 2 terminal of NO (In case battery voltage)

controller 0V? Established value of defrost thermostat Abnormal
ON: 0°C (It is not “ON”
OFF: 8°C under 0°C)
YES Replace defrost
Defrost thermostat
thermostat.
Check time on Normal Change time on Normal

defrost timer. defrost timer (Refer
to page 7.)
2 terminal RY and G lines are
broken or contact of connector
Normal is defective.
Is battery
voltage measured at LR NO LR line between AR1 ~ SV1 is
line of defrost at LR line of defrost broken or contact of connector
electromagnetic valve (SV1)
connector? is defective.
YES
Is battery
voltage measured at NO Defective electromagnetic
LY line of defrost
electromagnetic valve valve (SV1) is defective.
connector?
YES

voltage measured at NO relay box AR5 is broken or
BR line of AR5 coil? contact of connector is
defective.
YES
Is P terminal of NO
controller under 0.5V? Controller is defective.
YES

• LY and G lines between SV1
and relay box (AR5) are
broken or contact of
connector is defective.
– 55 –

2) In case defrost operation will not recover.
Defrost operation will not

recover.
Abnormal
(It will not become
Check defrost “OFF” over 8°C)
thermostat Replace defrost thermostat.
Normal
2 terminal RY line of
controller is short-circuited
and grounded.
3) In case defrost operation is frequently made.
Defrost operation is frequently

made.
Remarks: If air pressure switch

(optional) is installed, check the air
pressure switch.
Check timeon Abnormal Change time of defrost timer.

defrost timer. Refer to page 7.
Normal
– 56 –

(g) In case drain hose will freeze.
Drain hose will freeze.
Is defrost operation NO Refer to page 55, defrost

normally made? operation.
YES
Is battery LW line between fuse (F1) and

voltage measured at LW NO drain hose heater is broken of
line of drain hose heater contact of connector is
connector? defective.
YES
Is battery
voltage measured at BrR NO
line of drain hose heater Drain hose heater is defective.
connector?
YES

voltage measured at BR NO relay box AR7 is broken or
line of AR7 coil? contact of connector is
defective.
YES
NO
Is (Battery voltage)
WR line of AR7 coil WR line of AR7 coil is broken
under 0.5V? or defective.
YES

• BrR and G lines between
drain hose heater and relay
box (AR7) are broken or
contact of connector is
defective.
– 57 –

(h) In case of motor drive
Only the items different from the previous ones are written here.
1) In case evaporator fan will not turn.································································· Refer to page 53.
2) In case condenser fan will not turn.·································································· Refer to page 54.
3) In case thermostat will not operate.·································································· Refer to page 54.
4) Defrost operation.·································································································· Refer to page 55.
5) In case drain hose will freeze.············································································ Refer to page 57.
6) In case the unit will not operate even if the operation switch is turned on.
It will not operate even if the

operation switch is turned on.
Is abnormal YES Refer to page 60

indication lamp "ON"? (OCR
operation indication "OCR operation".
Will AC
power source NO lamp)
indication lamp
(GL21) light? NO
YES
Is 3- • Check voltage on
phase 220V (60Hz), NO breaker side.
380V (50/60Hz), 415V (50Hz) • Power source cord is
measured at power box broken or contact is
Is fuse (F22) YES RST? defective.
broken? Replace fuse (F22)
YES
NO
Is fuse (F21) YES
broken? Replace fuse (F21).
NO
Is or 24V
measured between 2R NO Transformer is
of transformer secondary defective.
side and G line?
YES
• AR21 relay is
NO defective or coil 2R
Is AR21 relay of relay and G line
energized? are broken.
YES
As to the following items,

refer to page 52, (3)(a)
Will operation
lamp light?
– 58 –

7) In case compressor will not turn.
Compressor does not run.
NO
Is AR1 or relay excited?
Is 24V measured NO BR line, wire breakage or poor

at AR1 coil BR line? connector contact between
controller and relay box (AR1)
YES
Is 0.5V
or less measured at NO
terminal No.O of Defective controller
controller?
YES
• Defective AR1 relay

• LR line breakage or poor connector
contact on the way of AR22 coil (7E) to
power box terminal block 7CE, 7C to
relay box AR1
YES
• Defective AR22 relay

NO • Line breakage or poor contact on 7E
Is AR22 relay line or GND line of power box
excited? terminal block 7C to AR22 coil 7E line
YES
• MS1 or MS2 solenoid switch is

Is electromagnetic NO defective.
switch MS1 or MS2 • Line breakage or poor contact on MS1
excited? or MS2 solenoid switch coil R3 or R4,
or S line (including )
YES
Inspect and repair motor.
– 59 –

8) OCR (over-current relay) operation indication lamp lights.
OCR operation indication lamp

lights.
Abnormal
Check OCR operation
Note: For re-operation push
manual reset button.
Normal
Is 3-phase • Breaker is defective.

220V (60Hz), 380V NO • Power source cord is Are OCR terminals NO
(50/60Hz), 415V (50Hz) measured at
and electrified? OCR is defective.
power source box broken or contact is
RST ? defective.
YES YES
Is • Check operation electric Note: Operate and check.

3-phase 220V (60Hz),
NO RSTlines are current (15A).
380V (50/60Hz), 415V (50Hz) • Setting or OCR is defective if
measured at RST of MS1 or MS2
broken or contact is
electromagnetic switch defective. it operates under the above
primary current.
YES
Is
3-phase 220V Contract point of MS1
(60Hz), 380V (50/60Hz), 415V NO or MS2
(50Hz) measured at UVW of MS1 or MS2
electromagnetic switch electromagnetic
secondary side? switch is defective.
YES
Is 3-phase
220V (60Hz), 380V NO UVWlines are broken
(50/60Hz), 415V (50Hz) at terminals or contact is defective.
UVW of
motor side?
YES
Check motor and repair.
– 60 –

(4) Inspection of controller board
(a) Cautionary points for handling the printed-circuit board
1) When taking the board, prevent touching any pattern or part with hand.
To take the board, pinch it at both sides with hand.
2) Prevent touching the board with hand which oil or similar sticks to.
3) Prevent applying any load to the parts on the board with hand or similar.
4) Be sure to prevent any shock which is caused by drop or similar.
5) Prevent water from splashing on the board due to rain or similar.
6) Prevent handling any area where static electricity generates (dry area, room laid with carpet or similar and so on).
7) To temporarily put the board, store it, wrapping the aluminum foil, conductive gloves, etc.
(b) Input/output connector pin numbers
Input/output connector pin assignment list
1 DPS Sensor 21 Ground Power

2 DTS Sensor 22 Ignition Power
3 APS Sensor 23 Full-wave rectification Power
4 LPS1 Sensor 24 Relay common Voltage output
5 LPS2 Sensor 25 AR1 Load
6 TH Sensor 26 AR5 Load
7 TD1 Sensor 27 AR2 Load
8 TD2 Sensor 28 AR6 Load
9 Spare thermo sensor Sensor 29 Ground Power
10 Test mode For check 30 Ignition Power
11 FUSE1 Sensor 31 Full-wave rectification Power
12 FUSE2 Sensor 32 Relay common Voltage output
13 FUSE3 Sensor 33 AR3 Load
14 LS Sensor 34 AR7 Load
15 OCR Sensor 35 AR4 Load
16 Temperature sensor reference Voltage output 36 Controller (ON/OFF) output Load
17 Temperature sensor reference Voltage output
20 Ground Sensor
– 61 –

(c) Controller inspecting procedure
Power supply line breakage

Short circuit from pin M 0V } Fuse line breakage: 0V
Normal time: Battery voltage
Normal: 24V
Harness line breakage

Not connected. }
0V
Nomral: Battery voltage
Power supply line breakage
Short circuit from pin NO 0V }
Short circuit to GND: 0V Normal: Battery voltage
Normal, sensor line
breakage : 5V
∗1 Normal temperature (15°C):

Approx. 2V
Sensor short circuit : 5V Relay ON : 0V
Abnormal Sensor line breakage: 0V Relay OFF: Battery voltage
∗2 Normal time (90°C): Approx. 4V

Sensor short circuit : 5V
Abnormal Sensor line breakage: 0V
Relay ON : 0V
Relay OFF: Battery voltage
Normal: 0V
Harness wire breakage Battery
Abnormal SW }
voltage
Relay ON : 0V
Relay OFF: Battery voltage
Normal: 0V
High/low pressure abnormal: 0V

High/low pressure normal:
Battery voltage
Defrost sensor on the low temp. side: 0V ∗3

Defrost sensor on the high temp. side:
Battery voltage
∗1: For other voltage than 0.5V, refer to TH (storage • Measure voltage between ground (terminal 20) and
temperature sensor) conversion table (P.63). measured terminal.
∗2: For other voltage than 0.5V, refer to TD (Td sensor) • Though commercially available tester is applicable for
conversion table (P.63). check, use the tester whose tester rod is cut to sharp.
∗3: 8°C ± 3 (high pressure side)
(Approx. 1mm dia.)
0°C ± 3 (low pressure side) Output relay names

Inspection conditions Check terminal AR1 Thermostat relay
Unit operation 1345OPQRWXYZ AR2 Liquid injection electromagnetic relay
Car battery supply 267890FGHILN AR3 Evaporator fan motor relay
Unit stop TV
AR4 Condenser fan motor relay
AC power supply DMU
AR5 Defrost electromagnetic valve relay
Unit stop
AR7 Drain hose heater relay
Always ABC
Car battery Both are JKL
AC power supply not }
provided.
Note: 1) Car battery supply means that ignition switch is on.
2) AC power supply means that commercial power is
supplied from AC plug.
3) Unit operation means that car battery or AC power
supply unit are on.
– 62 –

(d) Storage temperature sensor resistance and voltage as reference
Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°C) Resistance (kΩ) Voltage (V)
-30 26.316 4.187 20 2.573 1.759
-25 20.155 4.004 25 2.113 1.543
-20 15.572 3.795 30 1.746 1.349
-15 12.131 3.564 35 1.451 1.175
-10 9.524 3.313 40 1.213 1.022
-5 7.533 3.050 45 1.019 0.888
0 6.000 2.779 50 0.860 0.772
5 4.811 2.509
10 3.882 2.246
15 3.154 1.995
(e) Td sensor resistance and voltage as reference
Temperature (°C) Resistance (kΩ) Voltage (V) Temperature (°C) Resistance (kΩ) Voltage (V)
0 263.1 4.952 110 3.881 3.295
10 161.2 4.929 120 2.916 2.962
20 101.4 4.894 130 2.220 2.628
30 65.34 4.842 140 1.707 2.300
40 43.09 4.769 150 1.327 1.993
50 29.01 4.669 160 1.041 1.710
60 19.91 4.535 170 0.824 1.458
70 13.92 4.364 180 0.658 1.237
80 9.892 4.152 190 0.530 1.047
90 7.139 3.900 200 0.430 0.884
100 5.228 3.611
– 63 –

14. Method to select a model with jumper cable
(1) The following functions are selectable with the jumper cables on the circuit-printed board.
No. Item Jumper cable No. Description

1 Model selection J11, 12 H, M, L
2 Refrigerant selection J21, 22 R22, HFC-134a, R401B, R404A
3 Heating selection J3 Refrigerant heating: Valid/invalid
FM1 switch When compressor is off, evaporator FM1 ON/OFF switch is at the
4 J4
(evaporator fan) evaporator FM1 ON as standard.
(2) Jumper cable installation position
1 Model selection jumper cables J11, 12 2 Refrigerant selection jumper cables J21, 22
Applicable temperature J11 J12 Remarks Refrigerant selection J21 J22 Remarks
L -30 ~ 25°C Set. Set. — R22 Set. Set. —
HFC-134a
M -20 ~ 25°C Set. Not set. — R401B Set. Not set. —
H -5 ~ 25°C Not set. Set. — R404A Not set. Set. —
HFC-134a
(M) -20 ~ 25°C Not set. Not set. Regarded as M selection
R401B Not set. Not set. Regarded as HFC-134a,
MP66 selection.
3 Heating selection jumper cables J3 4 FM1 (evaporator) switch jumper cable J4

Jumper cable is set.: Jumper cable is set.:
Refrigerant heating is invalid. FM1 ON when thermo is off.
Jumper cable is not set.: Jumper cable is not set.:
Refrigerant heating is valid. FM1 OFF when thermo is off.
– 64 –

15. REFRIGERANT SATURATED PRESSURE TABLE (R404A)
Temperature (°C) Saturated pressure kPa (kgf/cm2) Temperature (°C) Saturated pressure kPa (kgf/cm2)
-50 –19.2 (144.0mmHg) 6 627.6 (6.4)
-48 –10.6 (79.5mmHg) 8 666.9 (6.8)
-46 –1.3 (9.8mmHg) 10 715.9 (7.3)
-44 9.8 (0.1) 12 764.9 (7.8)
-42 19.6 (0.2) 14 814.0 (8.3)
-40 29.4 (0.3) 16 872.3 (8.9)
-38 39.2 (0.4) 18 921.8 (9.4)
-36 58.8 (0.6) 20 980.7 (10.0)
-34 68.7 (0.7) 22 1049.3 (10.7)
-32 88.3 (0.9) 24 1108.2 (11.3)
-30 98.1 (1.0) 26 1176.8 (12.0)
-28 117.7 (1.2) 28 1245.4 (12.7)
-26 137.3 (1.4) 30 1314.1 (13.4)
-24 156.9 (1.6) 32 1392.5 (14.2)
-22 176.5 (1.8) 34 1461.2 (14.9)
-20 196.1 (2.0) 36 1549.5 (15.8)
-18 225.6 (2.3) 38 1627.9 (16.6)
-16 245.2 (2.5) 40 1716.2 (17.5)
-14 274.6 (2.8) 42 1804.4 (18.4)
-12 304.0 (3.1) 44 1892.7 (19.3)
-10 333.4 (3.4) 46 1990.7 (20.3)
-8 362.9 (3.7) 48 2088.8 (21.3)
-6 392.3 (4.0) 50 2196.7 (22.4)
-4 431.5 (4.4) 52 2294.8 (23.4)
-2 460.9 (4.7) 54 2412.4 (24.6)
0 500.1 (5.1) 56 2520.3 (25.7)
2 539.4 (5.5) 58 2638.0 (26.9)
4 578.6 (5.9) 60 2765.5 (28.2)
– 65 –

16. INSTALLATION PROCEDURE
16.1 Cautionary points during installation
(1) Be absolutely sure to keep dust and moisture from (13) Route the high-/low-pressure hoses with care to
entering the piping of the refrigeration unit. consider the three-dimensional dislocation of the
Carry out the connecting of separate type of piping compressor as 15mm in each direction in order to
under a roof, and avoid a rainy or windy day and prevent them from interfering with each other.
outdoor work as much as possible.
(2) When glazing, pass N2 (nitrogen) gas through the
piping in order to keep it from oxidation.
(3) Pressurize with nitrogen gas before evacuating.
(4) It is desirable to evacuate the system under the
ambient temperature of 10°C or more for more
than 60 minutes. The degree of evacuation should
be –0.1 MPa (750mmHg) or more. In order to
check for leakage, leave it for 5 minutes, and there
is no leakage if it keeps –0.1 MPa (750mmHg).
(5) Put a cover or protector to the piping which sticks
out from the lowest tip of the body or the one
which is placed where it can be easily hit by stones
scattered by the wheel of the vehicle.
(6) Select a place of 80°C or less ambient temperature
for wiring routing.
(7) Clamp the cable at 500mm or less intervals to
avoid unnecessary sags. Use the clamp matching
to the thickness of the harness. And be sure that it
does not slide or pull out when slightly pulled.
Also be sure that the tip of the clamp does not cut
into or crush the harness.
(8) As for wiring under the floor or exposed to
splashing water, set up a trap to prevent the
connector of the unit terminal harness from drop
of water.
(9) Clamping of pipe and harness
(10) As for installation of the controller, select a place
strong enough to hold it. (Installation on plastic
section may cause damage to the unit.)
(11) Thermally insulate the low-pressure pipe.
(12) Adjust the installation position of the bracket, etc.
to align the engine and compressor (magnetic
clutch) at the deviation angle of 0.5 degrees or
less.
– 66 –

16.2 Cautionary and requested points during installation
No. Item Explanation Precaution for service Possible failure Corrective action (Remarks)
1 Direct coupled • When installing the 1. Adjust the misalignment to 0.5 degrees 1. Abnormal wear of V belt 1. Recondition, adjust or
type unit compressor with the or less. For visual check, tighten the 2. Trouble of idle pulley replace the bracket.
Pulley bracket on the vehicle's string. 3. Abnormal seal of 2. —
alignment engine, adjust the pulley 2. Adjust the tension of the belt with the compressor shaft 3. Replace the compressor.
alignment between tension gauge.
compressor and engine.
2 Route of • Since the engine vibrates, 1. Since the compressor may vibrate 1. The hose is holed. 1. Add the stay for fixture.
compressor install a hose which approx. 15mm upward/downward and 2. The flared area of the 2. Add the distance rubber.
hoses absorbs vibration of the leftward/rightward, prevent the ferrule is cracked.
installed compressor. surrounding parts from interfering with 3. Poor cooling results from
each other. gas leakage.
Install the distance rubber near each
part.
2. Bend the hose at the largest possible
curve.
3 Surrounding • Influence of engine heat 1. Route the hose at the surrounding area 1. The hose is holed. 1. Change the route of the
temperature of on the compressor hose of 80°C or less. 2. The hose is punctured. hose.
compressor If it is inevitably routed near the exhaust 3, The ferrule gets off from 2. Manufacture the heat
hose pipe, install the protector to suppress the the hose. protector of aluminum
surface temperature to 80°C or less. plate or similar.
4 Refrigerant • Penetration of moisture 1. Work on piping connection under a roof, 1. Clogging of water and 1. Investigation of
piping • Penetration of dust avoiding a rainy day. dust in the expansion abnormality on no
• Be most sure to keep 2. Because copper dust may enter the pipe valve and, clogging of freezing reveals that
moisture and dust from from its cut and flared area, perform air the dryer. many of the causes are
entering the piping in blow (N2 blow) after processing. due to sticking of copper
order to avoid the 3. Don't place piping materials (copper dust.
refrigerant cycle from pipe) on the floor, ground etc, where it is 2. Perform evacuation after
being damaged by them. dusty. applying pressure in
4. When glazing, pass N2 gas into the order to check for gas
piping. leakage from glazed area,
5. Perform evacuation for more than 60 etc. To check for leakage
minutes, and reaching of evacuation after glazing, leave the
should be over –0.1MPa (750mmHg). pipe alone for 5 minutes
6. Don't use the copper pipe which has to maintain –0.1MPa
been left alone for long and inside of (750mmHg).
which is rusted. 3. Plug the cut of the
refrigerant piping.
5 Low pressure • Insulate from heat the 1. Pass the low pressure pipe thru the heat 1. Rising of sucked gas 1. Apply insulation tube to
piping piping from the insulated tube. temperature the low pressure piping
(Excluding the evaporator outlet to 2. Apply vinyl tape on the connected area Rising of delivered gas in order to keep the
hose) sucking pipe of the of the tube. temperature sucked gas temperature
compressor. (excluding 3. Make the route of the piping as short as Early deterioration of from rising.
hose) possible. compressor oil
• Branch the pipe of Type 4. Use the branch pipe specified by our Breaking of compressor
2. company. 2. Oil is unevenly
distributed.
– 67 –

6 Clamp • The pipe, harness clamp 1. When the screw hole for the clamp is 1. Unless blocked by sealer, 1. No remedy for the body
mounting for or pipe cover is fastened drilled to the body, be sure to coat sealer. water infiltrates into the which has sucked water.
pipe and on the body with screws. t is recommended that seal will be insulated material of the
harness swelled out when the screw is tightened. body thru the clearance
And don't clamp it together with the to cause no-cooling.
high pressure pipe. 2. The seal plays the role of
preventing the screw
from loosening.
7 Setup of pipe • To protect the pipe and 1. Install pipe cover when the pipe is stuck 1. Refrigerant leakage from
cover harness from ice, snow out from the lowest tip of the chassis the cracked pipe and
and flying stone. and body or when the pipe is passed thru many abnormalities
• To install pipe cover in the place where the stones scattering generated from the
order to improve from the wheels of the vehicle can easily refrigerant leakage. In the
appearance. hit it. worst case, the
2. Use sealer when screws are driven. compressor will be
broken.
8 Wire harness • Wiring process 1. Before wiring works, disconnect the 1. If it is energized during 1. Verify that the battery
(electrical connecting relay box, battery terminal working, it will lead to terminal is disconnected.
wiring) controller, refrigeration short circuit troubles, etc.
unit and magnet clutch.
2. Take care of polarity of battery wiring. 2. If the polarities (+) and (-) 2. Replace the damaged
are reversely connected, part.
the electrical parts will be
damaged (burnt).
3. Select a place of 80°C or less 3. Cable sheath may be 3. Avoid placing it near the
atmospheric temperature for wire subjected to damage or engine exhaust pipe and
routing. fire. high pressure.
4. Clamp cable at 400 mm or less intervals 4. Interference with other 4.

to avoid unnecessary sags. equipments
5. Don't clamp together with the high 5. Temperature of high 5. Clamp the wire harness
pressure gas pipe. pressure gas pipe alone.
becomes high, causing
damage to the cover and
fire.
6. Use the clamp according to the thickness 6. Broken wire and 6.

of the harness. And when pulled lightly, effective contact
it should not be slid or pulled out. Also
be sure that the tip of the clamp does not
bites the wire harness or crush it. Clamp
the harness to the convenient direction.
Holding of body, etc. by
screw
– 68 –

7. When wiring is made under the floor or 7. Defective contact due to 7.

at a place where rain water splashes, set generation of rust and
up a trap on the straight line so as to broken wire.
prevent water drop from entering the
connectors of connecting equipments.
8. Be sure to use the specified cables 8. Unit may be subjected to 8. 9. Observe the electric
(thickness and sheath) for wiring. fire owing to heating or wiring standards.
9. Use the compression terminal or solder sheath thermal damage (Neglection is
type terminal to connect the cable. which is caused by prohibited. It has been
(Solder onto caulking section of crimp insufficient wire capacity. reported that fire
terminal. Hand-twisting and tape 9. Unit may be subjected to actually happened
retaining alone are prohibited.) fire owing to heating and owing to the
firing caused by increase neglection.)
of the contact resistance.
10. Fire may happen on the

10. Check the electrical wiring for damaged sheath of 10. Clamp cable securely.
interference with any vibratory object cable. Select the cable
on the way. 11. The connector may be connection area which
11. Insert the connector with lock until it removed by vibration. is free from oil or fuel
makes "click" sound. Here, do not sticking.
tighten the connector lock with a flat.
12. When installing the connection harness
in the box later, securely seal the
through hole of the box.
13. When using the closed end type
connector outside the box, sufficiently
seal it with sealer.
1. Many defects resulting in
9 Chassis • Treatment of grounding 1. The terminal area is clamped and sealer burning of alternator,
mounting and wire terminal for unit coated to prevent the ground cable from relay, etc.
supporting grounding wire and suffering of being internally broken
process of battery grounding wire owing to vibration during car running.
ground cable onto the vehicle chassis. 2. Remove paint from the chassis side.
1. Rain water enters the van

10 Countermeasu • Rain water is prevented 1. If any hole is produced on the van side through the thru-hole or 1. Verify that the hole
re for the from entering the van, or any clearance is produced on the clearance, and the clearance is wholly and
passing hole and the refrigerating passing-thru hole (unit mounting bolts, thermal insulator is securely sealed.
on the van capacity is prevented refrigerant pipe, electric wiring, drain moistened.
from dropping. hose, etc.) in the outfitting process, close 2. Thermal load enters
the hole or clearance by coating sealer. through the clearance of
the thermal insulator and
is moistened to cause
poor cooling.
– 69 –

11 Installation • The installation direction In case of CR2211L-A 1. Compressor may be 1. If the direction 4 in the
direction of of the compressor is damaged since liquid is left is inevitably applied,
compressor restricted. compressed at the start separately order the
because of liquid compression on which
accumulation. the discharge and suction
are reversed since it is
available for
replacement.
The installation directions 1, 2 and 3
above are possible.
The direction 4 is impossible.
12 Tightening • Rain water is prevented (observe the following tightening torques) 1. Gas leaks on the 1. Periodically retighten the
torques of flare from entering the van, 1. Standard tightening torques for flare refrigerant piping system bolt and nut, and check
nuts, general and the refrigerating nuts that they are tightened to
bolts and nuts capacity is prevented Applicable Tightening torque the specified torques.
from dropping. copper pipe N·m (kgf·cm) (Take sufficient care for
over tightening.)
ø6.35 9.8 ~ 19.6 (100 ~ 200)
ø9.52 19.6 ~ 29.4 (200 ~ 300)
ø12.7 29.4 ~ 39.2 (300 ~ 400)
ø15.88 39.2 ~ 49.0 (400 ~ 500)
ø19.05 49.0 ~ 58.8 (500 ~ 600)
2. Tightening torques of general bolts 2. General bolts and nuts

N·m (kgf·cm) • If overightened, the
Material bolt may break owing
He SS41C S45C SUS304
ad
ma to the excessive
rk
v
Thread No mark or 4 or 7 No mark elongation.

diameter
• If insufficiently
M3 0.6 ~ 1.0 1.0 ~ 1.5 0.8 ~ 1.0
(6 ~ 10) (10 ~ 15) (8 ~ 10) tightened, looseness
1.0 ~ 1.5 2.0 ~ 3.0 2.0 ~ 2.5 may lead to troubles.
M4
(10 ~ 15) (20 ~ 30) (20 ~ 25)
M5 2.0 ~ 3.0 4.0 ~ 5.0 3.4 ~ 4.4
(20 ~ 30) (40 ~ 50) (35 ~ 45)
M6 3.4 ~ 4.4 6.9 ~ 8.3 6.4 ~ 7.8
(35 ~ 45) (70 ~ 85) (65 ~ 80)
8.4 ~ 9.8 17.7 ~ 19.6 16.7 ~ 19.6
M8 (86 ~ 100) (180 ~ 200) (170 ~ 200)
17.0 ~ 19.6 35.3 ~ 40.2 33.3 ~ 38.2
M10 (173 ~ 200) (360 ~ 410) (340 ~ 390)
29.4 ~ 33.3 59.8 ~ 69.6 56.9 ~ 65.7
M12 (300 ~ 340) (610 ~ 710) (580 ~ 670)
47.1 ~ 53.0 96.1 ~ 107.9 91.2 ~ 104.9
M14 (480 ~ 540) (980 ~ 1100) (930 ~ 1070)
73.5 ~ 84.3 156.9 ~ 176.5 142.2 ~ 165.7
M16 (750 ~ 860) (1600 ~ 1800) (1450 ~ 1690)
– 70 –

16.3 Reference drawing of installation
(1) Overall installation drawing
Installation layout
Installation notice
WARNING
1. Installation must be done properly according to the installation drawing.
Improper installation may cause refrigerant leakage. Electric shock and/or fire.
2. Installation must be done properly to carry the weight of the unit. The unit may fall down
if not properly installed and causes accident and/or injury.
3. Never adjust the setting of safety devices.

Improper adjustments may cause explosion and/or fire.
4. Avoid contaminating the refrigerant circuit with air. It may cause abnormal high pressure
which may lead to explosion and/or injury.
5. Installation drawing must be followed. Any modification may cause electric shock, fire,
explosion and/or injury.
Notes:
1. This installation drawing is for models TDJ300D and TDJ430D.
2. Drawing on the upper shows illustration layout of models TDJ300D and TDJ430D.
3. The fabricated or renovated structure of the van must be designed for the installation of refrigeration units.
4. Either sides of the van must be strong enough to support the refrigeration equipment to be installed.
5. Balance of the vehicle must be considered when installing the refrigeration unit to maintain stable running
condition.
Before installing the refrigeration unit, check the location of refrigeration unit on the body of the van, confirm that
the location is high enough where the cabin can be tilted.
6. Check carefully the total condition of the installation using check sheet for trial running.
7. In this installation drawing, part no. of each part are shown in the table on pages 87.
– 71 –

(2) Cautions for safety installation
WARNING Caution for safety installation

Before installing the refrigeration unit, read first this installation manual and follow strictly the instructions to
prevent any trouble or accident.
1. Preparations for the vehicle
(1) Use stoppers for front and rear wheels to prevent the vehicle from forward and backward movement during
installation. Furthermore, the parking brake must be activated. If failed to do so. Accidents may occur causing
injuries to worker or operator due to mis-operation.
(2) Turn-off vehicle ignition switch and disconnect negative - terminal from the battery. Neglecting to do so would
damage or burn the electrical equipments and may cause accidents like electric shock, short circuit, etc. To
happen if battery terminal comes in contact with the vehicle body, tools or worker.
(3) Before installation, remove the ignition key and keep into a safer place. Then, display a warning sign like that of
"WARNING! work in progress. Don't start the engine". Otherwise, when another worker not knowing the works
starts the engine, and accident may happen.
2. Unit installation
(1) When carrying and installing the unit. Avoid finger or foot from getting squeezed. Furthermore, care must be
considered on the weight when handling each main component to avoid back injuries. To be safe, multiple
workers are required.
(2) Be careful of dangerous parts such as high temperature parts or sharp edges of the vehicle and of the
refrigeration unit to avoid from getting burn or other injuries. To be safe, use helmet, gloves and protecting
cover.
(3) When installing, use the right tools, apply the specified tightening torque indicated in this manual and observe
proper posture. To be safe, multiple workers are required.
(4) Mounting places of each component on the chassis must be properly checked for strength and rigidity.
Accidents such as breakage or shearing may occur in case of faulty welding, inappropriate thickness of plate,
etc.
(5) Clearance between moving or rotating parts such as engine, compressor, belt, fan, etc. Must be kept at 15 mm or
more without interference.
(6) Refrigerant circuit pipes and harness must be installed without contact with high temperature parts or edges. If
inevitable, provide protection or insulation.
(7) Earth must be secured properly to prevent short circuit.
Never work with the harness when the hands are wet with oil or water to avoid electric shock.
(8) When charging or discharging refrigerant gas. Extinguish lit cigar or any other fire to prevent production of
– 72 –

3. Test operations procedure
(1) Use stoppers for front and rear wheels to prevent the vehicle from forward and backward movement during test
operation. Furthermore, the parking brake must be activated. If failed to do so. Accident may occur causing
injuries to worker or operator due to mis-operation.
(2) Before starting the engine, confirm that no tools, gauges, or other parts are left in or on any movable, rotating, or
electrical part.
(3) Before starting the engine, initiate a warning sign such as alarm (sound) and make sure that there is nobody left
around or under the vehicle.
(4) Before starting the engine, press the brake pedal and make sure that the transmission is in neutral position.
(5) Do not operate the refrigeration unit control panel with wet hands.
(6) Take caution to prevent any part of the body. Hand or foot from being caught by the rotating components
(radiator fan, crank pulley, compressor, alternator, driving belts, etc.) inside the engine compartment or fans of
the evaporator or condenser.
(7) Avoid contact with high temperature parts of exhaust line cooling water line, and engine high pressure hose.
(8) Keep distance from rotating parts such as fan, belts, etc. To avoid severe injury from being hit by flying debris in
case those components break.
(9) When checking current of terminal, etc of electric circuit, care must be considered to prevent short circuit to
vehicle body or other parts.
– 73 –

(3) Outline drawing
(a) Compressor
1) TDJ300D Unit: mm
Compressor
7.3kg
2) TDJ430D
Compressor
13.5kg
– 74 –

(b) Refrigeration unit Note:
Mark indicates the center of gravity.
Unit: mm
Refrigeration unit
TDJ300D: 67kg, TDJ430D: 72kg
(c) Controller
Controller
0.5kg
– 75 –

Note:
Mark indicates the center of gravity.
(d) Motor pack Unit: mm
1) TDJ300D 2) TDJ430D
Motor pack Motor pack

54kg 85kg
(e) Power source box

1) TDJ300D 2) TDJ430D
Power source box Power source box

17kg 19kg
– 76 –

(4) Van body fabrication drawing Unit: mm
Must refer to this drawing when fabricating van body
(1) Van body size and interference with cabin must be considered using unit outline drawing.
(2) Balance of the vehicle must be considered when installing the refrigeration unit to maintain stability during
operation.
(3) The fabricated and renovated structure of the van must be designed for the installation of refrigeration unit,
weighing 72kg for TDJ430D & 67kg for TDJ300D. (Must withstand vibration shock of 7G).
(4) The bolt must be securely tightened.
1. Position of mounting hole and bolt holes for the unit
Mounting hole and bolt holes for the unit must restrict heat transfer.
Front view of van A-A

(Unit installation)
2. Unit mating surface
1. portion must be smooth in order to keep tightness.
Furthermore, unit mounting bolt face and unit mating surface must be aligned and smooth.
2. After the installation, seal the gap between the unit and the van to maintain airtightness.
Front view of van
3. Inside of van body

(1)Install the protection guard to prevent the unit from
hitting the bulk.
(2)Install the bulkhead and keep the air inlet space.
Refer to dimension below.
4. Cover
(1)Provide a clearance of 2mm from unit mating surface
to the cover end face. (Right figure)
– 77 –

(5) Motor pack, power source box and accumulator installation drawing Unit: mm
Notes:
1. The fabricated or renovated structure of the van must be designed for the installation of motor pack, accumulator
unit and power source box. (Type 2 only)
2. Dimensions and limitations indicated in the layout must be followed in case of parts installed are in different
position from this drawing.
3. The bolts must be securely tightened.
4. If the exhaust pipe port of the car muffler is present in front of the
motor pack and accumulator, the unit can not show its performance.
Therefore, dislocate the exhaust pipe to be positioned behind the motor
pack and accumulator.
Motor pack Power source box

Model
M1 M2 N1 N2
TDJ300D 300 450 401 90
TDJ430D 330 530 330 90
– 78 –

(6) Piping installation
(a) In case of type 1
Notes:
1. For charging mass of refrigerant refer to note 2 of next page.
2. Connection of pipings must be gauged.
3. It must be free from any foreign matters to prevent clogging of valves, malfunction of solenoid valves and damage
of compressor. It must be free from moisture that can cause clogging due to ice formation and must not be
scratched to prevent leakage of refrigerant.
4. Apply refrigerant oil between fittings and use Pipe ø Torque N·m (kgf·m)
double spanner when tightening. ø9.52 1.96 ~ 29.4 (2 ~3)
For torque requirements refer to table right ø12.7 29.4 ~ 39.2 (3 ~4)
5. Item 7, 8 refrigerant hose installation. ø15.88 39.2 ~ 49.0 (4 ~5)
(1) Bending radius of the hose must be equal or ø19.05 49.0 ~ 58.8 (5 ~ 6)
more than the minimum R to prevent
deformation and restriction of flow. Hose type Hose outside ø Min. bent radius
(2) Be careful not to twist the hose when fastening High press ø18.1 90mm
the fittings. ø25.2 120mm
Low press
ø21.5 130mm
6. For clamp prepared hole, refer to the table below.
Clamp installation drawing
(Hole position must be gauged) Material Installation dwg. Hole size
Aluminum or FRP ø3.0

7. Compressor selection
In case of CR2211L-A
1 ········ Left downward position
( 23 ··· Upward position
4 ········ Right downward position)
1 2 3 are ordinary type, 4 is not applicable to use.
Another type of compressor is prepared wherein ports are on the
In case of CR2318LWR reversed position. Inquire us for details.
1 and 2 compressor must be installed at standing position.
8. Compressor outlet and inlet pipe should be fixed because water absorption power of oil is high.
9. Pipe must be fixed lastly the same as compressor pipe, because dryer is already installed.
Connect quickly when its raining.
10.After vacuum process, it must be charged with small volume of liquid refrigerant (30 ~ 50g) from the suction
operation valve.
11.Avoid excessive leakage of refrigerant during charging.
– 79 –

(b) In case of type 2 (Install to motor pack)
Notes:
1. This drawing shows type 2 of piping installation. As part of condenser and evaporator unit, refer to page 79.
2. Charging mass of refrigerant.
Charging quantity must be measured when engine runs at 1000min-1.
Changing mass of
Model Refrigerant refrigerant (kg)
Type 1 Type 2
TDJ300D R404A 1.7 1.7
TDJ430D R404A 2.1 2.1
3. Compressor outlet and inlet pipe should be fixed because water absorption power of oil is high.
4. Pipe should be fixed lastly the same as compressor pipe. Because dryer and sight glass are already installed.
Connect quickly when its raining.
– 80 –

(c) Piping installation
1) Type 1 piping installation
2) Type 2 piping installation
– 81 –

(7) Wiring connection
Notes:
1. Remove the negative (-) terminal of the battery.
2. Never interchange battery connections otherwise it will burn or damage the electrical parts.
3. Remove the painting on the frame before connecting the ground terminal.
4. Each wiring should be routed along with the existing harness or piping.
5. Wiring harness should be tied-up with band.
Item 31 & 32 of parts list.
6. Use ø35 hole on the toe board for wiring to pass through.
7. Fix the wire harness firmly in their relative positions with band & clamp to protect from wire damage & sparks
caused by vibration.
– 82 –

(8) Installation of controller at inside panel (option)
(a) Applicable for Mitsubishi FK, FM vehicles of Model '92 and following
Notes:
1. This installation drawing of controller is for Mitsubishi FK, FM which is available after '92 model.
2. Installation procedure
(1) Remove the center panel.
(2) Remove the accessory box with center panel.
(Remove and discard the lower accessory box)
(3) Bracket (RH: TJF116A053), (LH: TJF116A053A) and accessory must be attach securely to the controller with
screw.
(4) Insert the connector to the controller.
(5) Fix the controller assy in the inside panel with screw (H071D05X014).
(6) Install center panel.
(7) Install control panel (TJF133A001) (Center panel insertion)
– 83 –

(b) Applicable for Mitsubishi FE, FG vehicles sold since November, '93
Notes:
1. This installation drawing of controller is for Mitsubishi FE, FG which is available after november of '93.
2. Installation procedure
(1) Remove the instrument vessel.
(2) Remove the radio & accessory box with inside panel bracket.
(3) Remove & discard the lower accessory box.
(4) Fix bracket B (TJD116A043) to the inside panel bracket with tapping screw (W010D05X010).
(5) Fix bracket (LH: TJD116A042) & bracket (RH: TJD116A042A) to the controller with tapping screw.
(6) Insert the connector to the controller.
(7) After completing (5) & (6), fix the controller to the inside panel bracket & bracket (B) (TJD116A043) with
tapping screw (W010D05X010).
(8) Fix the radio & controller to the inside panel bracket assembly.
(9) Re-assemble the instrument vessel.
(10) Install the control panel (TJF133A001A) using clip (SSA937C321).
3. For maintenance, just remove the controller & bracket (LH) & (RH) assemblies.
(First, remove clip SSA937C321).
– 84 –

(9) Cautions for electric wiring
The following are procedures on repair and addition of wiring for fire prevention
(a) General guidelines on addition and repair of wiring:
See JIS C3406 (for low voltage wiring for automobile), JASO 0608 (heat resistance low voltage wiring for
automobile), JIS C2336 (insulation tape for wiring) vinyl tape or equivalent.
1 General procedures for wiring installation:
1) Clamp the wires on the frame, chassis and other parts of the van to prevent hanging of wires. Use clamps to avoid
contact with chassis. Sharp edges, vibrating and rotating parts or use grommet for holes with sharp edges to
prevent wire damage and short circuit.
For details refer to the figure on the right.
2) In case of inevitable contact with sharp edges, fix the wire with clamp to be stable and cover with protector to
prevent wire damage caused by vibration.
Refer to the left figure below.
If the preceding method is not applicable, cover the wire with sleeve or tube.
Refer to the right figure below.
3) Band the wires along with the existing harness using vinyl tape. Never attach along with brake system and fuel
pipe (metal, vinyl chloride, vinyl hose, etc.) and provide a minimum distance as shown in the table below.
Path Distance
Parallel 10mm or above
Crossing 20mm or above
4) For wires within the engine compartment, clamp the harness along with the existing wiring and must be far from
heat source. Use heat resistance vinyl tape or metal clamp (rubber or vinyl coated). Do not use ordinary tape which
can loose its function due to high temperature.
5) Clamp the wires along with the existing wiring and provide an allowance for sagging for wires that are attached to
vibrating parts to absorbed its relative movements.
6) Female type giboshi connector must be for live line to avoid short circuit when disconnecting.
7) Never cut the battery cable if addition or shortening of length is required.
Rather replace with the required length. Retain wire clamping method.
Position and wire sagging condition especially between starter and the parts attached to the frame.
8) When connecting an extension wire, use the dame nominal size and color.
Use solder or connector to connect the wires securely. Never connect the wires by splicing. Do not use MCI as a
medium of reactance for soldering method.
Insulate the connection along the chassis properly to prevent water penetration.
9) For long wires, loop the wires and band together along with the existing wiring using vinyl tape without cutting.
2 Clamp
1) The clamp must be insulated with coating or rubber.
For different types of clamp see the figure below.
2) For distance between clamps, refer to the table below.
Harness DIA. Clamp distance
ø5 or less 300mm or less
ø5 ~ ø10 400mm
ø5 ~ ø10 500mm
– 85 –

3 Caution on welding works
Battery terminals must be detached before welding. Do not position the ground terminal near the electronic parts or
the electronic parts lie between it and the area to be weld to prevent damage.
Even the parts have switches. But still must follow the guidelines below.
1) Detached the battery terminal
2) Position the ground terminal near the object to be weld.
(b) Wire selection
For heat resistance wire, refer to the table below.
(JASO D 609: Applicable current for low voltage wire for automobile).
Type of wire Ambient temp. Remarks

AV wire
60°C of below Applicable at ordinary condition
(Low voltage wire for automobile)
AXV wire Applicable near the engine or at
(Heat resistance low voltage 70°C of below any heat source
wire for automobile)
AEX wire Applicable near the engine or at
(High temp. heat resistance low 90°C of below any heat source
voltage wire for automobile)
A void installing the wire at temperature above 70°C. If necessary use AEX type of wire.
(10) Installation of marker lamp (user’s option)
Notes:
1. When installing marker lamp (user’s option) at the side of refrigeration unit. It must be installed according to the
dimension shown in this drawing. (Both sides of cover)
2. Marker lamp is not included in the refrigeration unit, it must be prepared separately.
3. Unit: mm
– 86 –

(11) Part list
No. Required
Item Name Part No. TDJ300D TDJ430D Remarks
L2 L2
ACA201A304 1 CR2318LWR (TCP18H2)
1 Compressor assembly ACA200A009A 1 CR2211L-A (TCP11F2)
CSA272C004 Either 1 TCP18C2-KT1

2 Clutch, EM 
TSJ272C042 1 piece TCP18C2-KT2
B070B10 × 035 4 M10 × 35
B070B10 × 025 4 M10 × 25
3 Bolt & washer
SSA911C008CG 4 M8 × 25
SSA911C008CJ 4 M8 × 35
TJF001A001 1 TDJ430DL2
5 Refrigeration unit assy
TJF001A001AA 1 TDJ300DL2
TSJ502A060AM 1 1
6 Controller
SSA324B027 1 1
7 Hose (HP)
SSA324C014A 1
8 Hose (LP)
SSA324A032 1
TSJ321A003A 1 1 ø12.7 × 3m
9
Pipe
TSJ321A005A 1 ø19.05 × 3m
10
TSJ321A004A 1 ø15.88 × 3m
11 Cover TSJ032A002 1 1
12
13
14
15 Harness assembly CDB504A006 1 1 With diode
16
17
18
19
20
21 Bolt B002A10 × 16 4 4 M10 × 16
22
23
24
25 Nut N020A10 6 6 M10 (Use those used in the packaging)
26 W200H10 6 M10
27 Washer W207H10 6 6 M10 (Use those used in the packaging)
28 W200G10 4 4 For M10 (SUS)
Note: When procuring the part, be sure to refer to Parts List separately issued.
– 87 –

No. Required
L2 L2
29 W220R10 6 6 M10 (Use those used in the packaging)
Washer, spring
30 W220G10 4 4 For M10 (SUS)
31 SSA937D045A 20 20
Band
32 SSA937D045B 10 10
33
34
35 Hose, drain TSJ423A015 1 2
36 Port, drain TSJ423J008 2 2
37 Insulation SSA151B459CA 1 1 L = 2m
38
39
40 TSJ937A013F 10 10 ø12
41 TSJ937A013L 2 2 ø20
42 TSJ937A013N 10 10 ø25
43 Clamp SSA937A100AF 1 1
44 SSA937A405 1 1
45
46
47 Clip SSA937C287N 1 2 For drain hose
48 Label TSJ011H016 1 1 Belt size
49
50 F107E12 2 2
51
Nut, flare
SSA323M017 1 2 ø19.05 with hole
52
SSA323M018 1 ø15.88 with hole
53 F109E12 1 1
Union F109E20 1
54
F109E16 1
55 Kit, oil (tank) TJG006A006B 1 Diamond Freeze MA32, 200cc
56 Plate TJF119A222 1
57 Bolt SSA911M219 1
58 Sealer SSA971G015F 1 TOSHIBA SILICON CO., in 100g tube
59
TJF200A005AF 1 TPK18F2
60 Pack, motor
TJD200A008 1 TPK11F2
61
62
TJF501A019A 1
63 Box, power
TJD501A009B 1
64
65
– 88 –

No. Required
L2 L2
66 Plug SSA566B011 1 1
67 E011 × 02F003 3 3
Terminal
68 SSA562D003C 1 1
69 TJD504A014C None Power box ~ relay box (5.5m)
70 Harness assembly TJD504A020A None None Td sensor (5m)
71 TJF504A079 1 1 Power box ~ relay box (9.3m)
72 Bolt, upset B010A10 × 025 16 8 M10 × 25
73 Bolt & washer B070A06 × 020 5 M6 × 20
74 N020A10 12 4 M10
75 Nut N020A06 5 M6
76 SSA914B007AC 5 M6 with serration
77 Washer W200H10 16 8 For M10
78 Washer, spring W220R10 16 8 For M10
79
80
SSA151B035NA 2 ø22 × 1.1m
81
Insulation, rubber SSA151B035MA 3 ø16 × 1m
82 SSA151B026LA 2 ø13 × 0.9m
83 TSJ321A001 1 1 ø6.35 × 2m
TSJ321A003 1 1 ø12.7 × 2m
84
Pipe
TSJ321A004 1 ø15.88 × 2m
85
TSJ321A005A 1 ø19.05 × 3m
86 TJD304A002 None None
87 TJF321A231 1 1
Pipe assy TJF321A209A 1
88
TJF321A209C 1
89 TJF321A199 None None For ø12.7
90 F107E06 2 2
91 F107E12 5 7
Nut, flare
92 SSA323M018 6 1 ø15.88 with hole
93 SSA323M017 4 ø19.05 with hole
F109E16 2
94
Union F109E20 3 ø19.05 × ø15.88 diff. dia.
95 SSA323G003C 1
96 Valve, check TSJ385B001 None None
97 Valve, shuttle SSA385D004 1 1
98 Strainer assembly TJB357A002B 1 1
99 Tapping screw W010G05 × 016 30 30
100 SSA937A002G 5 5 ø6
Clamp
101 SSA937A002K 5 ø12
– 89 –

No. Required
L2 L2
102 SSA937A002R 5 ø20
103 TSJ937A012B 5 5 ø6
104 Clamp TSJ937A013F 15 15 ø12
105 TSJ937A013L 2 2 ø20
106 TSJ937A013N 15 15 ø25
107
TJF351A007 1
108 Accumulator assy
TJF351A007A 1
109
110 Bracket TSJ116A001B 2 2
111
112
113
114
115
116
117
118
119
120
– 90 –

AIR-CONDITIONING & REFRIGERATION MACHINERY WORKS
AUTOMOTIVE & COLD CHAIN MACHINERY BUSINESS SECTION
3-1, Asahimachi, Nishibiwajima-cho, Nishikasugai-gun, Aichi-pref., 452-8561, Japan
Phone : (052) 503-9209
Fax : (052) 503-2638
No.079 (1.3A) R

Mitsubishi Reefer Tdj430d

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MITSUBISHI

TRANSPORT REFRIGERATION UNIT

'99 · TD-S · 001

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• How to read the type

Indication of power voltage

TDJ300D - 1 L 2 In this manual, these are shown by abbreviating

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(7) Do not make modifications.

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1. Characteristics ··········································· 1 10.16 Storage temperature sensor (TH) ············ 18

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Power source box

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3-phase AC220V 60Hz,

Defroster Automatic defrosting (Timer system)

Refrigeration unit W×H×D

Compressor 7.3 (Include magnet clutch)

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3-phase AC220V 60Hz,

Defroster Automatic defrosting (Timer system)

Refrigeration unit W×H×D

Compressor 7.3 (Include magnet clutch)

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In order to prevent the evaporator from being covered

After having the ignition switch of its vehicle

3.3 Operation control

When a storage air temperature is higher than the

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(3) Compressor (4) Motor pack (only for type 2)

(b) TDJ430D (5) Power source box (only for type 2)

Alarm indication lamp

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5.1 Pre-operation inspection 6.1 Description of operation for the controller

4 Digital display 2 Defrost indication lamp

(4) Check the belt for looseness, degree of parallel

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(Continuously press the switch ▲ or ▼ , and the

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7.2 Loading procedure

(1) Load a refrigerator freight truck with the

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7.4 Caution to be taken for the usage

(1) In case of using a refrigerator freight truck as a

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(1) Refrigeration cycle

Conpressor (Engine side)

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Engine drive type

Controller Power source

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Schematic diagram of lubrication system

10.2 Magnet clutch

Volume of 181.2cm3/rev Amount of

Revolution 600 ~ 3600min-1

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While separating liquid refrigerant from gas refrigerant

Belt used Type B × one each

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It is installed to prevent the refrigerant from flowing

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It can judge the circulating amount of refrigerant and

When the dryer is replaced, replace it quickly. Here,