Mitsubishi TDJ430D, TDJ300D Service Manual

'99 · TD-S · 001

MITSUBISHI
TRANSPORT REFRIGERATION UNIT

TDJ300D

TDJ430D

SERVICE MANUAL

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

Type 1 (Type 2)

In this manual, these are shown by abbreviating
as type 1 and 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 f ires 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.

1. Characteristics ··········································· 1

2. Specification················································ 2

3. General information ································· 4

3.1 Controller ··············································· 4

3.2 Drive system··········································· 4

3.3 Operation control···································· 4

3.4 Defroster ················································· 4

3.5 Protective device····································· 4

4. Name of each component······················ 5

5. Adjustment of test operation················ 6

5.1 Pre-operation inspection ·························· 6

5.2 Inspection during operation····················· 6

6. Daily operation ············································ 6

6.1 Description of operation for the
controller ·················································· 6

6.2 Other operations ······································· 7

6.3 Operation of special service switches ······ 7

6.4 Operation sequence ·································· 7

6.5 Operation of display switches ·················· 8

6.6 Defrosting operation and manual
defrosting ················································· 8

7. Loading ··························································· 9

7.1 Inspection before loading ························ 9

7.2 Loading procedure ··································· 9

7.3 Unloading ················································ 10

7.4 Caution to be taken for the usage ············ 10

8. Refrigerant piping system ····················· 11

8.1

Refrigerant piping system diagram

·········· 11

8.2 Freezing cycle ········································· 11

9. Control system ············································ 12

10. Description of main parts······················· 13

10.1 Compressor ·············································· 13

10.2 Magnet clutch ·········································· 13

10.3 Heat accumulator ····································· 14

10.4 Accumulator ············································ 14

10.5 Electromagnetic valve ····························· 15

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

10.16 Storage temperature sensor (TH) ············ 18

10.17 Td sensor (Td) ········································· 19

10.18 Controller ················································· 19

10.19 Drain hose heater (option) ······················· 20

11. Electric wiring diagram ··························· 21

11.1 Sequence diagram ···································· 21

11.2 Wiring layout drawing ····························· 24

11.3 Explanation of operation ························· 28

12. Periodic inspection ··································· 34

12.1 Inspection at the time of installation
and test run ·············································· 34

12.2 Daily inspection ······································· 34

12.3 Monthly inspection ·································· 35

12.4 Six-mouth inspection ······························· 35

12.5 Bolt tightening table for each section ······ 35

12.6 Caution to be taken at the time of
daily inspection ········································ 36

12.7 Caution to be taken at the time of
periodic inspection ·································· 38

12.8 Check sheet (Installation, test run and
periodic inspection) ································· 40

12.9 Pressure table for standard operation ······ 41

13. Defect and its cause ································· 42

13.1 Diagnosis of defects on refrigerant
system······················································ 42

13.2

Charging the refrigerant <R404A>

·········· 46

13.3 Diagnosis of defects on electric parts······ 47

14. Method to select a model with
jumper cable ················································· 64

15. Refrigerant saturated pressure
table (R404A) ················································ 65

16. Installation procedure ····························· 66

16.1 Cautionary points during installation ······ 66

16.2 Cautionary and requested points

during installation ···································· 67

16.3 Reference drawing of installation ············ 71

Contents

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.

– 1 –

Refrigeration unit

Controller

Compressor

Power source box

(Type 2 only)

Motor pack

(Type 2 only)

2. Specification

(1) TDJ300D

– 2 –

Ambient temperature

0°C

-18°C

Function

Inside air temperature
Outside air temperature

Drive method

Model
Discharge
Revolution
Refrigeration oil
Type
Fan
Revolution of fan
Fan motor
Type
Fan
Revolution of fan
Fan motor

Type

Power source
Revolution

Rated output
Enclosed refrigerant volume
Storage air temperature

adjustment
Defroster

Safety device

Refrigeration unit

Motor pack

Refrigeration unit

Compressor

Motor pack

Accessories

Type

Item

°C

W

(kcal/h)

°C
°C

cm

3

/rev

min

-1

cm

3

min

-1

W

min

-1

W

min

-1

kW

kg
°C

W×H×D

mm

kg

35

3490 (3000) 3490 (3000) * [2790 (2400)]

2150 (1850) 2150 (1850) * [1740 (1500)]

Cooling

-30 ~ 25

-5 ~ 40

CR2211L-A

110

600 ~ 3600 * (1420)

Diamond Freeze MA32, 350

Aluminum tube, Corrugate fin

Propeller fan, Directly connected to fan motor

2100

75 × 2

Copper pipe, Aluminum fin

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 controller)

Automatic defrosting (Timer system)

Dual-pressure switch

[High pressure side] CUT OUT 2.94MPa (30kgf/cm2), CUT IN 2.35MPa (24kgf/cm2)
[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

—

492 × 300 × 385

67

7.3 (Include magnet clutch)

—

54

11 45

Return air
temperature

Range of
usage

Performance

Compressor

Condenser

EvaporatorMotor

Unit size

Weight

Compressor: Belt-driven from a vehicle

engine

Condenser fan
Evaporator fan

}

Direct drive by direct current motor

Compressor: Belt-driven from a vehicle

engine and belt-driven by
motor

Note: (1) The capacity of refrigeration (performance) shown in the above parenthesis represents case of 60Hz motor drive.

TDJ300D - 1L2 TDJ300D - 2L2

(2) TDJ430D

– 3 –

Ambient temperature

0°C

-18°C

Function

Inside air temperature
Outside air temperature

Drive method

Model

Discharge

Revolution

Refrigeration oil

Type

Fan

Revolution of fan

Fan motor

Type

Fan

Revolution of fan

Fan motor

Type

Power source

Revolution

Rated output
Enclosed refrigerant volume
Storage air temperature

adjustment
Defroster

Safety device

Refrigeration unit

Motor pack

Refrigeration unit

Compressor

Motor pack

Accessories

Type

Item

°C

W

(kcal/h)

°C
°C

cm

3

/rev

min

-1

cm

3

min

-1

W

min

-1

W

min

-1

kW

kg
°C

W×H×D

mm

kg

35

5000 (4300) 5000 (4300) * [4070 (3500)]

2790 (2400) 2790 (2400) * [2210 (1900)]

Cooling

-30 ~ 25

-5 ~ 40

CR2318LWR

181.2

600 ~ 3600 * (1420)

Diamond Freeze MA32, 800

Aluminum tube, Corrugate fin

Propeller fan, Directly connected to fan motor

2100

75 × 2

Copper pipe, Aluminum fin

Centrifugal 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 controller)

Automatic defrosting (Timer system)

Dual-pressure switch

[High pressure side] CUT OUT 2.94MPa (30kgf/cm2), CUT IN 2.35MPa (24kgf/cm2)
[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

—

570 × 340 × 398

72

7.3 (Include magnet clutch)

—

85

11 47

Return air
temperature

Range of
usage

Performance

Compressor

Condenser

EvaporatorMotor

Unit size

Weight

Compressor: Belt-driven from a vehicle

engine

Condenser fan
Evaporator fan

}

Direct drive by direct current motor

Compressor: Belt-driven from a vehicle

engine and belt-driven by
motor

Note: (1) The capacity of refrigeration (performance) shown in the above parenthesis represents case of 60Hz motor drive.

TDJ430D - 1L2 TDJ430D - 2L2

3. General information

3.1 Controller

The refrigeration unit employs a new microcomputerized
controller which has a character display function, and
the desired inside temperature can be accurately and
digitally set with the soft touch type switch. Moreover,
a trouble can be easily diagnosed.

3.2 Drive system

(1) In case of engine drive from a running vehicle

The refrigeration unit is operated in which the
engine of a running vehicle drives the compressor
by belt and condenser fan and evaporator fan are
driven by a direct current motor respectively.

After having the ignition switch of its vehicle
turned on and the vehicle started, the refrigeration
unit can be operated with the controller operation
switch "ON".

(2) In case or motor drive (Type 2)

The refrigeration unit is equipped with a motor
drive besides engine drive from a running vehicle
and can be operated by the power supply (standard
specification, 3-phase AC 220V 60Hz, 380V
50/60Hz, 415V 50Hz) at a garage, truck terminal,
ferry boat, etc.

It can be operated with the controller operation
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.

3.4 Defroster

In order to prevent the evaporator from being covered
with frost and reducing its cooling effect, the defrost
timer (it will be established within three hours before
being shipped out from our factory) operates
defrosting.

When defrosting has been completed and temperature
of the evaporator has risen, changes to cooling
operation by the defrost thermostat. Also the evaporator
fan stops during the defrosting operation, keeping
warm air from going into the inside.

Further when the storage is loaded with watery goods
or cooling in the storage is slow, defrosting can be
made by manual operation.

3.5 Protective device

The refrigeration unit is protected both by a protective
device (dual pressure switch) which stops the unit when
discharging pressure of the compressor becomes
unusually high and the dissolving plug which
discharges refrigerant when the pressure becomes
higher due to fire, etc.

Also these devices will stop the refrigeration units
when discharging temperature of the compressor
becomes unusually high due to leakage of refrigerant,
etc. When the unit has been abnormally stopped by the
protective device (except fusible plug), an abnormal
indication lamp will display its abnormality.

– 4 –

4. Name of each component

(1) Refrigeration unit

(2) Controller

(3) Compressor

(a) TDJ300D

(b) TDJ430D

(4) Motor pack (only for type 2)

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

– 5 –

Discharge
service valve

Suction
service valve

Magnet clutch

Discharge
service valve

Magnet clutch

Suction
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)

Compresso

r

Alarm lamp

(red)

Defrost switch

Defrost indication lamp

(orange)

Operation indication lamp

(green)

Display indication lamp

(green)

Operation switch

Display switch

Alarm switch

Digital display

Hours switch

Hours indication lamp

(green)

Temperature setting
switches

5. Adjustment of test operation

5.1 Pre-operation inspection

(1) Check the seal going through the board of

refrigeration unit.
(2) Check if the clamp of the tubing is adequate.
(3) Check if the drain hose is connected properly and

the clamp is proper.
(4) Check the belt for looseness, degree of parallel

(Coming out of the interline) and flaw.
(5) Check if components such as compressor, pully,

belt, tubing and wiring are touching each other.
(6) More tightening of fixing bolts for the following

units.

•

Refrigeration unit

•

Compressor and bracket

•

Magnet clutch

•

Tension pulley and bracket

•

Fan motor and fan

(7) Check the electric wiring for mis-wiring and the

clamp for properness.
(8) Check the wiring terminal for looseness and the

covering of wiring for flaw.
(9) Check the refrigerant system for gas leakage (oil

leakage).
(10) Check electric wiring for grounding and defective

insulation. (Type 2 only)

5.2 Inspection during operation

(1) Check the compressor, magnet clutch, motor, fan

and tubing for abnormal sound and vibration.
(2) Check the refrigerant sight glass for color and

degree of flashing.
(3) Check the compressor and magnet clutch for start

and stop due to the thermostat.
(4) Check refrigeration (indication by temperature

display and high and low pressure).
(5) Check the defroster for operation.
(6) Check the dual pressure switch for operation.
(7) Check the motor for drive (Type 2 only) and

buzzer with ignition switch "ON".

6. Daily operation

6.1 Description of operation for the controller

Description of operation for the controller

Name Operation

The switch starts or stops the
refrigeration unit.

The lamp (green) is lit when the
operation switch is on.

The switch turns on the forcible
defrosting 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 unit.

When a fault occurs, the alarm lamp
(red) lights and blinks.

The in-container temperature,
incontainer preset temperature, fault
display code and integrated operation
time are displayed according to the
switches.

The switch changes the incontainer
preset temperature.

The switch makes the working time
(operation hours) of the evaporator
fan displayed.

Press the hours switch, and the lamp
(green) will come on.

When the refrigeration unit stops,
press this switch, and the incontainer
temperature will be displayed on the
digital display unit for 5 seconds.
Moreover, when the refrigeration unit
runs, press this switch, and the
incontainer temperature will be
displayed if the preset temperature,
fault code or integrated operation
time is displayed in the display unit.

Press the display switch, and the
lamp (green) will come on.

Buzzer prevents improper start.
Keeping the power code for motor
drive connected, turn the vehicle
ignition key to "ON", and the buzzer
integrated in the controller will sound
to stop the refrigeration unit.(Even if
the refrigeration unit stops, the buzzer
will sound.

– 6 –

3 Alarm lamp

(red)

2 Defrost switch

2 Defrost indication lamp

(orange)

1 Operation indication lamp

(green)

7 Display indication lamp

(green)

1 Operation switch

C Buzzer (built-in)

7 Display switch

3 Alarm switch

4 Digital display

6 Hours switch

6 Hours indication lamp

(green)

5 Temperature setting
switches

1 Operation switch

(ON/OFF)

2 Operation

indication lamp

3 Defrosting switch

4 Defrosting

indication lamp

5 Alarm switch

6 Alarm lamp

7 Digital display

8 Temperature

setting switches

9 Hours switch

0 Hours indication

lamp

A Display switch

B Display

indication lamp

C Buzzer

(Type 2 only)

6.2 Other operations

When the refrigeration unit stops (power is supplied),
the following operations are ready.

(1) Change of inside-container preset temperature

DISPLAY ··· To higher temperature

e

··· To lower temperature

After pressing "display switch", press the switch

or , and the inside-container preset
temperature will be displayed on the digital
display unit in the blinking mode to select the
inside-container temperature setting mode.

Continuously press the switch, and the preset
temperature will vary.

··· T o higher
temperature

··· T o lo wer
temperature

(Continuously press the switch or , and the
temperature will continue varying.)

5 seconds after the finger is released from the
switch, the inside-container temperature will be
displayed.

Then, the digital display unit will go out after
other 5 seconds. Thus, it will be completely set.

(2) Integrated operation time

DISPLAY e HOURS

After pressing "display switch", press "hours
switch", and the integrated operation time will be
displayed on the digital display unit.

5 seconds after the finger is released, the inside
container temperature will be displayed. Then, the
digital display unit will go out after other 5
seconds.
Thus, it will be completed.

6.3 Operation of special service switches

When the operation switch is "off", the following
operation is ready.

(1) How to clear the evaporator operation time

1 Press the display switch.
2 Press the hours switch and temperature setting

switch together for 4 seconds, and it will be
cleared.

(2) How to display the fault history

1 Press the display switch and alarm switch 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 temperature setting switch
together for other 4 seconds, and the fault history
will be cleared.

(3) How to change the defrost timer setting

1 Press the display switch and defrost switch

together for 4 seconds, and the preset temperature
will be displayed.

2 Press the defrosting switch together with the

temperature setting switch or , and the
defrosting time will be changed in the range of 1
to 6 hours.

6.4 Operation sequence

(1) In case of engine drive from a running vehicle

1 Start the engine which drives the car.
2 Turn the operation switch to "ON".

(When the operation switch comes "ON", the
operation lamp (green) will come on.)

3 Setting of inside-container temperature

Press either temperature setting switch or ,
and the inside-container setting temperature on the
digital display unit will blink to indicate the
inside-container temperature setting mode.

Keep the switch pressed as it is, and the setting
temperature will vary.

··· T o higher
temperature

··· T o lo wer
temperature

(Continuously press the switch or , and the
temperature will continue varying.)

Keep the temperature setting switch pressed, and
release the finger from the switch when the
temperature indicated on the digital display unit
reaches the inside container pressure temperature
(transportation temperature).

After 5 seconds, the digital display unit will return
to display the inside-container temperature. Thus,
the inside-container temperature setting mode will
be completed.

▼▲

Every push of the switch
changes the temperature
by 1°C.





▼

▲

▼▲

▼▲

▼

▼

▼▲

Every push of the switch
changes the temperature
by 1°C.





▼

▲

▼▲

▼

▲

– 7 –

Since the controller is provided with the function
(memory function) which memorizes the
temperatures preset in the refrigeration unit up to
now, check the preset temperature by pressing
either temperature setting switch or one
time for the assurance's sake.

4 Stopping

• To turn it "OFF", press the operation switch
again and the refrigeration operation will be
stopped.

• Turn the operation switch to "OFF", and the
operation indication lamp and digital display
unit will go out.

Note: Before turning the ignition switch of the car to

"OFF", be sure to turn the operation switch of the
refrigeration unit to "OFF".

(2) Motor driven type (Type 2 alone)

1 Turn the ignition switch of the vehicle to "OFF",

and connect the receptacle of the motor drive
power supply to supply electric power.

Note: Before connecting the power supply, make sure

that the operation switch is "OFF".

2 Press the operation switch to "ON".

When the operation switch becomes "ON", the
operation indication lamp will come on. (Green)

3 Inside temperature setting

Press either setting switch or , and the inside
set temperature on the digital display unit will be
displayed in the blinking mode with the inside
temperature setting mode selected.

Keep the switch pressed as it is, and the setting
temperature will vary.

··· T o higher
temperature

··· T o lo wer
temperature

(Continuously press the switch or , and the
temperature will continue varying.)

When the temperature indicated on the digital
display unit is brought to a desired inside
temperature (transportation temperature) by
pressing the temperature setting switch, release the
finger from the switch.

After 5 seconds, the 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 the refrigeration unit, press
either temperature setting switch or once
to check the memorized temperature for
caution's sake.

4 Stopping

• Press the operation switch again to turn it to
"OFF", and cooling operation will be stopped.

• Turn the operation switch to "OFF", and the
operation indication lamp and digital display
will go out.

Note: 1) Before disconnecting the receptacle of the

motor drive power supply, be sure to turn the
operation switch of the refrigeration switch to
"OFF".

2) Don't start or stop the unit by using the power

supply breaker or connecting/disconnecting
the power supply plug. Otherwise, it will
cause an electric circuit trouble or electric
shock.

3) Prevent rain and water from splashing over

the receptacle area of the power box, or it will
cause an electric shock when the motor is
driven.

6.5 Operation of display switches

(1) When the refrigeration unit is operating

When the preset temperature, fault code or
integrated operation time is displayed on the
digital display unit, it can be returned to the inside­container temperature.

(2) When the refrigeration unit is stopped

Press the display switch, and the inside-container
temperature will be displayed on the digital
display unit. At this time, press the following
switch, and the selected content will be displayed.

• Single push of or ····Preset temperature

• ALARM······························Fault code

• HOURS·······························Operation time

• DEFROST···························Defrost interval time

6.6 Defrosting operation and manual defrosting

Defrosting operation is applied to prevent the cooling
effect from dropping since the evaporator is frosted.

▼▲

▼▲

▼▲

Every push of the switch
changes the temperature
by 1°C.





▼

▲

▼▲

▼▲

– 8 –















The defrost timer (factory-set at every 3 hours at
shipment) will automatically work for automatic
defrosting.

When the delay timer of 1 minute runs out after
defrosting is completed, it will be automatically
switched into the cooling operation.

At this time, the evaporator fan is stopped to prevent
the warm wind from entering the room.

(1) Method to change the timer setting of defrosting.

Though the defrost timer was factory-set at every 3
hours at shipment, it is adjustable in the range of 1
to 6 hours.

1 Turn the operation switch to "OFF".
2 Press both display switch and defrost switch

together for 4 seconds, the preset time will be
displayed.

3 The preset time can be changed by pressing the

temperature setting switch or with the
defrost switch pressed.

(2) Manual defrosting method

If inside cooling becomes poor since frost sticks to
the evaporator, manual defrosting is possible.

Press the defrost switch during cooling operation.

• The defrost indication lamp (orange) is lit
during defrosting operation.

• The operation indication lamp is lit during
defrosting operation. (Green)

It will automatically return to the cooling
operation when defrosting is complete. (It can not
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. Loading

7.1 Inspection before loading

(1) Clean inside of the storage.
(2) Inspect the car side and the refrigeration unit.
(3) Establish a storage air temperature.
(4) Before loading, make sure to perform

cooling operation, and refrigerate the
storage up to an established temperature
in advance.

First of all, it is necessary to refrigerate a storage
in order to transport and deliver goods properly.

Under the blazing sun in midsummer, inside of a
storage may become as hot as 60°C. And so if
freight is put in it without cooling the storage in
advance, a defect due to improper transportation
temperature will happen.

• Operate the refrigeration unit under the shade.

• In case of engine drive, operate it with engine

running more than 800min

-1

.

• On Type 2, make pre-cooling operation done by
the motor drive.

(5) Check the sight glass during operation

and confirm that there is no bubbling and
that the checking color is green.

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 b y stopping the refrigeration

unit and in a short time, if possible.

▼▲

– 9 –












How to make an effective cooling
operation in advance.

(3) Load so as to allow cool air circulating every

corner of the storage.
To circulate cold wind, the clearance between the

cargo and room wall must be 30mm or more on
both sides and the following values on the rear
side, front side and floor except the blow-out area
from the ceiling evaporator.

The values in ( ) are applicable for TDJ430D.
(4) Make the upper side of the load as flat as can be.
(5) After loading, operate the refrigeration unit.

7.3 Unloading

(1) Perform unloading after stopping the

refrigeration unit.

(2) Opening the door of the storage once will make

the inside temperature going up momentarily, so

open and close the door quickly so as to not let the

cool air out.
(3) When loading and unloading, make sure to use a

curtain in order to keep outside air from coming in

and cool air going out.

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.

Remarks: Operation procedure operate the unit for about

15 minutes, After switching "ON" and "OFF"
repeat at intervals of several seconds.

In case of driving engine operation type operate by
idling condition.

(4) The display indication of the controller may flicker

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
Standard specification 3-phases AC 220V 60Hz,
380V 50/60Hz, 415V 50Hz

• In case of using commercial power source, a
measure to cope with electric leakage for power
supply circuit is required.

(6) Washing

• When washing a vehicle, be careful not to splash
water directly to the electric equipments inside
the refrigeration unit.

• When cleaning the condenser and evaporator
coil, never make a high pressure washing by a
high pressure washing machine as it crushes the
fin. Also never make a steam washing as it
increases pressure inside of the units unusually
and is dangerous.

– 10 –

8. Refrigerant piping system

8.1 Refrigerant piping system diagram

8.2 Freezing cycle

(1) Refrigeration cycle

– 11 –

Multi-function valve

Motor pack

(Type 2 only)

Accumlator

(Type 2 only)

Refrigeration unit

Discharge hose

Suction hose

To vehicle’s compressor

Condenser
fan motor

Condenser

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 motor

Accumlator

Compressor

AC motor

Conpressor (Engine side)

Dryer Liquid injection electromagnetic valve

(Discharge)

(Discharge)

(Suction)

(Suction)

Engine drive type

Motor drive type

Remarks:

The figure shows an example of Type 2.
Type 1 is not equipped with motor pack
and accumulator.

(2) Defrost cycle

9. Control system

– 12 –

Defrost
electromagnetic
valve (open)

Motor pack

Refrigeration unit

Engine drive type

Motor dirve type

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

Compressor

To ignition
switch

Td1 sensor

Remarks:

The figure shows an example of Type 2.
Type 1 is not equipped with motor pack
and accumulator.

10. Description of main parts

10.1 Compressor

(1) TDJ300D

(2) TDJ430D

(3) Service valve

The compressor are equipped with a suction
service valve and discharge service valve.

Note: When working the pipe for service, finally

connect the suction and discharge pipes of the
compressor since the refrigerator oil is highly
liable to absorb water.

(4) Lubrication system (TDJ430D)

Lubrication oil is supplied forcibly to respective
bearings, pistons, tank shaft pins and shaft seals by
the oil pump.

10.2 Magnet clutch

The magnet clutch is installed in 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 of
discharge

Revolution

Specification

CR2211L-A

110cm

3

/rev

600 ~ 3600min

-1

(motor 1420min-1)

Name

Weight

Lubricating
oil

Amount of
oil

Specification

7.3kg
(include magnet
clutch)

Diamond Freeze

MA32

350cm

3

CR2318LWR

Name

Model

Lubricating
method

Volume of
discharge

Revolution

Specification
CR2318LWR

Compulsory
lubrication

181.2cm

3

/rev

600 ~ 3600min

-1

(motor 1400min-1)

Name

Weight

Lubricating
oil

Amount of
oil

Specification

13.5kg
(include magnet
clutch)

Diamond Freeze

MA32

800cm

3

Service valve

Schematic diagram of lubrication system

– 14 –

Specification

How to determine defective or not defective.
When the battery voltage is applied between the lead
1 and the ground wire of the main body, the
compressor will turn if the pulley and the friction plate
stick together (it clinks).
If it will not turn even when voltage is applied, it is
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

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.

10.4 Accumulator (type 2 only)

Separate liquid refrigerant from gas refrigerant so as
not to let the compressor sucks the liquid refrigerant.
Here, the refrigerant is designed to flow from U type
tube only to the engine side or motor pack side where
the compressor is in operation.

Volume
Direction of revolving
Belt used

TDJ300D TDJ430D

53W 31W

Right

Type B × one each

Heat accumulator

Accumulator

Magnet clutch

10.5 Electromagnetic valve

(1) Defrost electromagnetic valve

It is installed in order to flow hot gas into the
evaporator side when defrosting.

How to determine defective or not defective:
When continuity of the lead between 1 and 2 is

measured, the coil is normal if there is continuity
and if not, it is defective.

Before the coil is electrified, the temperature at the
inlet and outlet of refrigerant differs. So if the
temperature becomes the same after the coil is
electrified, the plunger is operating normally.

If the temperature differs the plunger is stuck.
Easy way to find out the problem:
When you electrify the coil with your hand

touching the electromagnetic valve, it is normal if
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.

How to determine defective or not defective:
Same as defrost electromagnetic valve.
Refer to "defrost electromagnetic valve".

10.6 Check valve

It is installed to prevent the refrigerant from flowing
back ward.

How to determine defective or not defective:
Make a judgment by the difference of temperature at

the inlet and outlet of the check valve and replace it if it
is leaking.

10.7 Receiver

It reserves the refrigerant which has been liquefied by
the condenser.

The receiver has a dissolving stopper which will melt
and discharge the refrigerant in order to prevent a
danger due to unusual high temperature.

When the stopper has been melted, replace it with a
new one.

– 15 –

Defrost electromagnetic valve

Liquid injection electromagnetic valve

Arrow mark

Disk

Main valve

Spring

Check valve

Receiver

10.8 Sight glass

It can judge the circulating amount of refrigerant and
existence of water in the refrigerant.

If the refrigerant is short, repair the leaking place and
then charge gas.

How to determine existence of water:

Color of a color-check

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
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, replace it quickly. Here,
when installing the dryer, pay heed to its direction and
install it on the unit with the arrow mark aligned to the
flow of the refrigerant.

10.10 Condenser fan motor

Remarks: The brush can not be replaced

– 16 –

Dryer

Revolution

2100min

-1

Electric current

3.2A

Input

70W

Condenser fan motor

Sight glass

Green

Light green

Yellow

Judgment

Normal
Rather

abnormal
Abnormal

Moisture amount

Refrigerant
temperature 24°C

Refrigerant
temperature 38°C

15 ppm or less

15 ~90 ppm

90 ppm or more

30 ppm or less

30 ~140 ppm

140 ppm or more

10.11 Evaporator fan motor

Note: The fan motor is press-fit to the fan.

Replace it as the assembly of the fan.

10.12 Multi-function valve

The multi-function valve features the following.
(1) At the abnormally high pressure, the suction

pressure is controlled to allow the unit to operate
without any abnormal stop (high-pressure cutting).

(2) Since the main valve of the multi-function valve 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.

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
improper operation.

10.13 Expansion valve

The valve detects overheat at the outlet of the
evaporator so that proper amount of refrigerant can
flow into the evaporator, and make an automatic
adjustment.

When adjusting, turn the adjusting screw at a revolution
of 1/4 and then 1/2 little by little, and see how much
heated it is.

– 17 –

Revolution

2000min

-1

Electric current

2.92A or less

Input

70W

Multi-function valve

Evaporator fan motor (Fan assembly)

Expansion valve

10.14 Defrost thermostat (DTS)

It detects temperature of the evaporator coil and
indicates an end of defrosting.

CUT IN 0 ± 3°C

CUT OUT 8 ± 3°C
Not adjustable
How to determine defective or not defective
Put the defrost thermostat into a household electric

refrigerator and check as you look at a thermometer. It
is normal if there is continuity under 0°C and no
continuity above 8°C.

10.15 Dual pressure switch (DPS)

When the delivery pressure becomes excessively high
or low, it is dangerous. So, the dual pressure switch
(normally close type) is activated to stop the
compressor.

Setting valve MPa (kgf/cm

2

)

CUT OUT CUT IN

2.94 ± 0.2 2.35 ± 0.2

High pressure side

(30 ± 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 (30kgf/cm

2

) or lower during stop and

operation, and there is not when the pressure is

2.94MPa (30kgf/cm

2

) or higher, it is proper.

[Low pressure side]

If there is any continuity when the pressure is

0.20MPa (2.0kgf/cm

2

) or less during stop and

operation, and there is not when the pressure is

0.20MPa (2.0kgf/cm

2

), it is proper.

10.16 Storage temperature sensor (TH)

The sensor detects a storage temperature in order to
keep its temperature to an established temperature,
keeping the magnet clutch or the relay "ON" and
"OFF".

Setting of storage temperature is made by the
temperature setting switches of the controller.

– 18 –

Defrost thermostat

Dual pressure switch

Controller

How to determine defective or not defective
(a) Measure continuity by removing the connector at

the edge of temperature detection.

(b) Resistance value at the edge of temperature

detection in normal condition.

(Unit kΩ)

°C Rmin. Rnom. Rmax.

-30 25.293 26.316 27.376

-20 15.125 15.572 16.031

-10 9.342 9.524 9.709
0 5.940 6.000 6.060

10 3.810 3.882 3.995
20 2.505 2.573 2.644
25 2.049 2.113 2.179
30 1.687 1.746 1.808
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)

It detects delivery temperature of the compressor and
stops the refrigeration unit or opens the liquid injection
electromagnetic 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 than 135°C,
stops the refrigeration unit.

How to determine defective or not defective:
Measure the resistance value by removing the

connector.
Resistance value in normal condition

200°C 0.430kΩ 100°C 5.228kΩ
175°C 0.738kΩ 25°C 80.470kΩ
115°C 3.352kΩ

10.18 Controller

A new controller with a character display function has
been adopted, which enables to set digitally a desired
storage temperature accurately. In addition to it, pre­operation inspection for the refrigeration unit can be
made by a simple button operation and a diagnosis at
the time of the unit being defective can also be made
easily.

Display function

• Operation indication lamp

• Defrost indication lamp

• Alarm lamp

• Hours indication lamp

• Display indication lamp

– 19 –

Storage temperature sensor Td sensor

Controller

• Inside-container temperature

• Fault display

• Inside-container preset temperature

• 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

– 20 –









Displayed on
the digital
display unit.

Drain hose heater

11. Electric wiring diagram

11.1 Sequence diagram

(1) TDJ300D-1L2, TDJ430D-1L2

Remarks: Three FM

1

(evaporator fan motor) are provided on TDJ430D.

– 21 –

Explanation of mark

SYMBOL

SW

UP

SW

DOWN

SW

ALARM

SW

DEF

SW

HOURS

SW

ON/OFF

SW

DISP

PL

ALARM

PL

DEF

PL

HOURS

PL

DISP

TH
DPS
TD

1

DTS
FL
BA TT
IG

NAME
Temperature setting switch (up)
Temperature setting switch (down)
Alarm switch
Defrost switch
Hours switch
Operation switch
Display switch
Alarm lamp
Defrost indication lamp
Hours indication lamp
Display indication lamp
Storage temperature sensor
Dual pressure switch
Td sensor (engine side)

Defrost thermostat
Fusible link
Battery
Ignition terminal

SYMBOL

AR

1

AR

2

AR

3

AR

4

AR

5

AR

7

F

1

F

2

F

3

FM

1

FM

2

H
MCL

1

SV

1

SV

2

NAME
Thermostat relay
Liquid injection electromagnetic relay
Evaporator fan motor relay
Condenser fan motor relay
Defrost electromagnetic valve relay

Drain hose heater relay
Fuse (*1: 15A, *2: 25A)
Fuse (10A)
Fuse (15A)

Evaporator fan motor
Condenser fan motor
Drain hose heater (option)
Magnet clutch (engine side)

Defrost electromagnetic valve
Liquid injection electromagnetic valve

*1: TDJ300D
*2: TDJ430D

Code Wire color Code Wire color Code Wire color

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

Wire color codes

wire colors are identified by the following color codes.

(2) TDJ300D-2L2

– 22 –

Explanation of mark

SYMBOL

SW

UP

SW

DOWN

SW

ALARM

SW

DEF

SW

HOURS

SW

ON/OFF

SW

DISP

PL

ALARM

PL

DEF

PL

HOURS

PL

DISP

TH
DPS
TD

1

TD

2

FL
BA TT
IG

SYMBOL
GL

21

RL

21

F

21

F

22

AR

21

AR

22

AR

23

LS
MS
T

r

D

1, 2, 3

D

4, 5, 6

D

8, 9

C

M

NAME
Temperature setting switch (up)
Temperature setting switch (down)
Alarm switch
Defrost switch
Hours switch
Operation switch
Display switch
Alarm lamp
Defrost indication lamp
Hours indication lamp
Display indication lamp
Storage temperature sensor
Dual pressure switch
Td sensor (engine side)
Td sensor (motor 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)
Electromagnetic switch (with OCR)
Transformer
Diode
Diode
Diode
Condenser

Motor

SYMBOL

AR

1

AR

2

AR

3

AR

4

AR

5

AR

7

F

1

F

2

F

3

FM

1

FM

2

H
MCL

1

MCL

2

SV

1

SV

2

NAME
Thermostat relay
Liquid injection electromagnetic relay
Evaporator fan motor relay
Condenser fan motor relay
Defrost electromagnetic valve relay

Drain hose heater relay
Fuse (15A)
Fuse (10A)
Fuse (15A)

Evaporator fan motor
Condenser fan motor
Drain hose heater (option)
Magnet clutch (engine side)
Magnet clutch (motor side)

Defrost electromagnetic valve
Liquid injection electromagnetic valve

(3) TDJ430D-2L2

– 23 –

Explanation of mark

SYMBOL

SW

UP

SW

DOWN

SW

ALARM

SW

DEF

SW

HOURS

SW

ON/OFF

SW

DISP

PL

ALARM

PL

DEF

PL

HOURS

PL

DISP

TH
DPS
TD

1

TD

2

DTS
FL
BA TT
IG

SYMBOL

GL

21

RL

21

F

21

F

22

AR

21

AR

22

AR

23

LS
MS
T

r

D

1, 2, 3

D

4, 5, 6

D

8

C
APR

M

NAME
Temperature setting switch (up)
Temperature setting switch (down)
Alarm switch
Defrost switch
Hours switch
Operation switch
Display switch
Alarm lamp
Defrost indication lamp
Hours indication lamp
Display indication lamp
Storage temperature sensor
Dual pressure switch
Td sensor (engine side)
Td sensor (motor 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 (plug cap)
Electromagnetic switch (with OCR)
Transformer
Diode
Diode
Diode
Condenser
Antiphase detection relay

Motor

SYMBOL

AR

1

AR

2

AR

3

AR

4

AR

5

AR

7

F

1

F

2

F

3

FM

1

FM

2

H
MCL

1

SV

1

SV

2

NAME
Thermostat relay
Liquid injection electromagnetic relay
Evaporator fan motor relay
Condenser fan motor relay
Defrost electromagnetic valve relay

Drain hose heater relay

Fuse (25A)
Fuse (10A)
Fuse (15A)

Evaporator fan motor
Condenser fan motor
Drain hose heater (option)
Magnet clutch (engine side)

Defrost electromagnetic valve
Liquid injection electromagnetic valve

11.3 Explanation of operation (Explanation is made for TDJ300D-2L2)

(1) In case of engine drive

1. Start the engine of a vehicle to be run.

2. Turn the operation switch to "ON".

• Operation indication lamp will light. (green)

• AR

3

(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").

• AR

1

(thermostat relay) is energized, and MCL1(magnet clutch on engine side) is electrified and then the

condenser fan turns.

• AR

4

(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.

• AR

7

(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, AR

2

(Liquid injection relay) is energized and

SV

2

(Liquid injection electromagnetic valve) is electrified.

[Less than 120°C ······ non-energized]

– 28 –

A Cooling operation