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(c) Piping installation

1) Type 1 piping installation

2) Type 2 piping installation

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Содержание TDJ300D

Страница 1: ...99 TD S 001 MITSUBISHI TRANSPORT REFRIGERATION UNIT TDJ300D TDJ430D SERVICE MANUAL...

Страница 2: ...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...

Страница 3: ...nerated 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 insta...

Страница 4: ...10 12 Multi function valve 17 10 13 Expansion valve 17 10 14 Defrost thermostat DTS 18 10 15 Dual pressure switch DPS 18 10 16 Storage temperature sensor TH 18 10 17 Td sensor Td 19 10 18 Controller...

Страница 5: ...ion 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...

Страница 6: ...n Centrifugal fan Directly connected to fan motor 2000 70 2 Totally enclosed fan cooled 3 phase motor 3 phase AC220V 60Hz 380V 50 60Hz 415V 50Hz 1500 1800 50 60Hz 2 2 R404A 1 7 30 25 Microcomputer con...

Страница 7: ...rifugal fan Directly connected to fan motor 2000 70 3 Totally enclosed fan cooled 3 phase motor 3 phase AC220V 60Hz 380V 50 60Hz 415V 50Hz 1500 1800 50 60Hz 3 7 R404A 2 1 30 25 Microcomputer controlle...

Страница 8: ...ressor 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 compr...

Страница 9: ...on service valve Limit switch Power source outlet Power source indication lamp Alarm indication lamp Motor overcurrent relay active indicator Fuses Manual reset button For motor overcurrent relay Comp...

Страница 10: ...operation The lamp orange is lit when defrosting is in operation When the alarm lamp lights or blinks press the switch and all faults which occur will be indicated as the code on the digital display...

Страница 11: ...ch together for 4 seconds and max 5 faults which have occurred will be displayed with the codes in sequence from the newest one 2 When the fault history is displayed press the alarm switch and tempera...

Страница 12: ...digital display will return to the inside temperature with the temperature setting mode ended Since the controller has the function to memorize the temperature which was set during last operation of t...

Страница 13: ...cally returned to the cooling operation with the defrost forced ending timer integrated 7 Loading 7 1 Inspection before loading 1 Clean inside of the storage 2 Inspect the car side and the refrigerati...

Страница 14: ...f 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 Remarks Operation procedure...

Страница 15: ...r Dual pressure switch Defrost electromagnetic valve closed Strainer Motor pack Refrigeration unit Receiver Sight glass Multi function valve Heat accumlator Evaporator Expansion valve Evaporator fan m...

Страница 16: ...Refrigeration unit Power source box Td2 sensor Motor pack To battery terminal Fusible link On the 1 type connect it to the battery as it is In case of type2 Ground Ground Control box Controller Compr...

Страница 17: ...n the crank shaft of the compressor and turns on and off the compressor by indication of the thermostat When cooling is required it is ON and when not required it is OFF 13 CR2211L A Name Model Volume...

Страница 18: ...ch is defective replace its assembly Measuring of air gap TDJ300D 0 3 0 5mm TDJ430D 0 3 0 6mm 10 3 Heat accumulator While separating liquid refrigerant from gas refrigerant so as not to let the compre...

Страница 19: ...jection 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 How to determine defective...

Страница 20: ...ly Also if inside of the dryer is clogged during operation there will be a difference in temperature between the inlet and the outlet and the outlet side becomes cool When the dryer is replaced replac...

Страница 21: ...unit is stopped This will reduce the starting torque 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 bec...

Страница 22: ...2 24 2 0 20 0 02 0 23 0 02 Low pressure side 2 0 0 2 2 3 0 2 Adjustment is impossible Judgment whether is proper or not High pressure side If there is any continuity when the pressure is 2 94MPa 30kg...

Страница 23: ...ectromagnetic valve If the delivery temperature becomes more than 125 C opens the liquid injection electromagnetic valve in order to lower delivery temperature If the delivery temperature becomes more...

Страница 24: ...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 bein...

Страница 25: ...or engine side Defrost thermostat Fusible link Battery Ignition terminal SYMBOL AR1 AR2 AR3 AR4 AR5 AR7 F1 F2 F3 FM1 FM2 H MCL1 SV1 SV2 NAME Thermostat relay Liquid injection electromagnetic relay Eva...

Страница 26: ...tor side Fusible link Battery Ignition terminal NAME AC power indication lamp OCR operation indication lamp Fuse 3A Fuse 5A AC DC transfer relay Actuator relay OCR relay Limit switch plug cap Electrom...

Страница 27: ...side Defrost thermostat Fusible link Battery Ignition terminal NAME AC power indication lamp OCR operation indiction lamp Fuse 3A Fuse 5A AC DC transfer relay Actuator relay OCR relay Limit switch plu...

Страница 28: ...CL1 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...

Страница 29: ...rature 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 establi...

Страница 30: ...e 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...

Страница 31: ...operates The unit stops OFF at compressor delivery temperature 135 C and ON at 125 C The alarm lamp lights red AR1 thermostat relay is de energized MCL1 magnet clutch is disconnected and the compresso...

Страница 32: ...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 e...

Страница 33: ...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...

Страница 34: ...tubing for abnormal sound and vibration 11 Inspection of sight glass Color of the sight glass is to be green and the glass has to have no excessive bubbles 12 Check starting and stopping of compresso...

Страница 35: ...rs to be taken care of at the time of periodic inspection as shown on page 38 12 4 Six mouth inspection 1 Implement the checking items required at the time of installation test operation and monthly c...

Страница 36: ...are of it Rust in early stage can be well prevented from developing by touch up 1 When the unit is not used for long operate it about 15 minutes once in every three or four days In case of type 2 Run...

Страница 37: ...nit 1 Dimensions shown below are specially important The values in are applicable for TDJ430D 1 It may happen that temperature become uneven at lower and upper and front and rear sides of storage 2 Wh...

Страница 38: ...g operation for about an hour For type L specification perform defrost operation for about 15 minutes 2 After that recover refrigerant and replace receiver dryer or dryer Replace oil for compressor an...

Страница 39: ...if left alone Make an appropriate repair such as touch up after removing rust with wire brush sand paper etc and washing well 1 In case of tension pulley bearing using a bearing with different sealin...

Страница 40: ...ection 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...

Страница 41: ...0 5 5 0 4 4 0 3 3 0 2 2 0 1 1 0 0 Storage temperature 18 C Storage temperature 0 C Storage temperature 18 C Storage temperature 0 C High pressure Low pressure MPa kgf cm2 MPa kgf cm2 10 15 20 25 30 3...

Страница 42: ...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 c...

Страница 43: ...o low 1 Excessive refrigerant Accompanied by backing of liquid Take out refrigerant up to a fixed amount 2 Storage temperature is very high 1 Suction of compressor is defective due to cracking of valv...

Страница 44: ...de 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 thermost...

Страница 45: ...ened when outside temperature is 35 C or more 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 light...

Страница 46: ...Before running the engine slowly charge 30 to 50g amount for one charge hose through the suction operation valve D of the pump in the liquid state 3 When the temperature rises into the moderate state...

Страница 47: ...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 coils Use a brush and water to clean any dirt off For...

Страница 48: ...refer to page 21 23 48 Fuse F2 is broken Replace fuse F2 YES NO Is battery voltage measured at the terminal No B of controller Replace controller Contact of fuse holder is defective YES NO Is battery...

Страница 49: ...n terminal block of relay box and fuse holder is broken or contact of terminal is defective YES NO Is battery voltage measured at 1st side of fuse F3 YES NO Fuse F1 is broken Replace fuse F1 YES NO Is...

Страница 50: ...connector is defective BY and G lines between DPS and relay box and controller are broken or contact of connector is defective Controller is defective YES Clean coil YES NO YES Is battery voltage meas...

Страница 51: ...e power supply is com monly used by TD sensor and 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 Therefo...

Страница 52: ...relay box or contact of connector is defective WB line between ignition terminal and controller is broken or contact of connector is defective Connecting line between fuse F22 and controller is broken...

Страница 53: ...box F1 is broken or contact of connector is defective BR line between controller and relay box AR3 is broken or contact of connector is defective AR3 relay is defective GW and G lines between fan mot...

Страница 54: ...utch engine side connector Magnet clutch ground wire is off YES Is battery voltage measured at magnet clutch ground wire YES NO NO AR1 relay is defective GB and LR lines between magnet clutch and rela...

Страница 55: ...act of connector is defective Replace defrost thermostat Controller is defective Defrost thermostat Abnormal It is not ON under 0 C Normal It will not defrost Is battery voltage measured at LR line of...

Страница 56: ...It will not become OFF over 8 C Replace defrost thermostat 2 terminal RY line of controller is short circuited and grounded Normal Defrost operation is frequently made Check timeon defrost timer Abno...

Страница 57: ...defective BR line between controller and relay box AR7 is broken or contact of connector is defective AR7 relay is defective BrR and G lines between drain hose heater and relay box AR7 are broken or...

Страница 58: ...ource indication lamp GL21 light YES NO YES It will not operate even if the operation switch is turned on Is abnormal indication lamp ON OCR operation indication lamp YES Refer to page 60 OCR operatio...

Страница 59: ...and repair motor Is AR1 or relay excited NO YES YES BR line wire breakage or poor connector contact between controller and relay box AR1 Is 24V measured at AR1 coil BR line NO YES Defective controller...

Страница 60: ...tive Contract point of MS1 or MS2 electromagnetic switch is defective Check motor and repair Check operation electric current 15A Setting or OCR is defective if it operates under the above current NO...

Страница 61: ...inum foil conductive gloves etc b Input output connector pin numbers Input output connector pin assignment list 61 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DPS DTS APS LPS1 LPS2 TH TD1 TD2 S...

Страница 62: ...ay ON 0V Relay OFF Battery voltage Relay ON 0V Relay OFF Battery voltage High low pressure abnormal 0V High low pressure normal Battery voltage Defrost sensor on the low temp side 0V Defrost sensor on...

Страница 63: ...5 30 35 40 45 50 Resistance k 2 573 2 113 1 746 1 451 1 213 1 019 0 860 Voltage V 1 759 1 543 1 349 1 175 1 022 0 888 0 772 Temperature C 0 10 20 30 40 50 60 70 80 90 100 Resistance k 263 1 161 2 101...

Страница 64: ...hermo is off Jumper cable is not set FM1 OFF when thermo is off No 1 2 3 4 Item Model selection Refrigerant selection Heating selection FM1 switch evaporator fan Jumper cable No J11 12 J21 22 J3 J4 De...

Страница 65: ...5 274 6 2 8 304 0 3 1 333 4 3 4 362 9 3 7 392 3 4 0 431 5 4 4 460 9 4 7 500 1 5 1 539 4 5 5 578 6 5 9 Temperature C Saturated pressure kPa kgf cm2 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40...

Страница 66: ...he 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 thi...

Страница 67: ...and flared area perform air blow N2 blow after processing 3 Don t place piping materials copper pipe on the floor ground etc where it is dusty 4 When glazing pass N2 gas into the piping 5 Perform evac...

Страница 68: ...ntervals to avoid unnecessary sags 5 Don t clamp together with the high pressure gas pipe 6 Use the clamp according to the thickness of the harness And when pulled lightly it should not be slid or pul...

Страница 69: ...sufficiently seal it with sealer 1 The terminal area is clamped and sealer coated to prevent the ground cable from suffering of being internally broken owing to vibration during car running 2 Remove p...

Страница 70: ...ness may lead to troubles 1 If the direction 4 in the left is inevitably applied separately order the compression on which the discharge and suction are reversed since it is available for replacement...

Страница 71: ...ectric 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 fabri...

Страница 72: ...id 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...

Страница 73: ...e 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...

Страница 74: ...74 3 Outline drawing a Compressor 1 TDJ300D Unit mm Compressor 7 3kg 2 TDJ430D Compressor 13 5kg...

Страница 75: ...75 b Refrigeration unit Note Mark indicates the center of gravity Unit mm Refrigeration unit TDJ300D 67kg TDJ430D 72kg c Controller Controller 0 5kg...

Страница 76: ...d Motor pack 1 TDJ300D Motor pack 54kg e Power source box 1 TDJ300D Power source box 17kg 76 Note Mark indicates the center of gravity Unit mm 2 TDJ430D Motor pack 85kg 2 TDJ430D Power source box 19kg...

Страница 77: ...ely tightened 1 Position of mounting hole and bolt holes for the unit Mounting hole and bolt holes for the unit must restrict heat transfer 2 Unit mating surface 1 portion must be smooth in order to k...

Страница 78: ...ted 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 presen...

Страница 79: ...drawing Hole position must be gauged 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 us...

Страница 80: ...tity must be measured when engine runs at 1000min 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 compresso...

Страница 81: ...c Piping installation 1 Type 1 piping installation 2 Type 2 piping installation 81...

Страница 82: ...ng 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 U...

Страница 83: ...tallation 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 attac...

Страница 84: ...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...

Страница 85: ...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...

Страница 86: ...emperature 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 inst...

Страница 87: ...1C008CJ TJF001A001 TJF001A001AA TSJ502A060AM SSA324B027 SSA324C014A SSA324A032 TSJ321A003A TSJ321A005A TSJ321A004A TSJ032A002 CDB504A006 B002A10 16 N020A10 W200H10 W207H10 W200G10 1 1 4 4 4 4 1 1 1 1...

Страница 88: ...013F TSJ937A013L TSJ937A013N SSA937A100AF SSA937A405 SSA937C287N TSJ011H016 F107E12 SSA323M017 SSA323M018 F109E12 F109E20 F109E16 TJG006A006B TJF119A222 SSA911M219 SSA971G015F TJF200A005AF TJD200A008...

Страница 89: ...5MA SSA151B026LA TSJ321A001 TSJ321A003 TSJ321A004 TSJ321A005A TJD304A002 TJF321A231 TJF321A209A TJF321A209C TJF321A199 F107E06 F107E12 SSA323M018 SSA323M017 F109E16 F109E20 SSA323G003C TSJ385B001 SSA3...

Страница 90: ...ator assy Bracket No Required Item Name Part No TDJ300DTDJ430D Remarks L2 L2 SSA937A002R TSJ937A012B TSJ937A013F TSJ937A013L TSJ937A013N TJF351A007 TJF351A007A TSJ116A001B 5 5 5 15 15 2 2 15 15 1 1 2...

Страница 91: ...ONING 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...

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