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.

i
 Safety Precautions
● Read the “Safety Precautions” thoroughly before starting 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 serious results
depending on the situation. In any case, important information related to safety is described, and must be
observed.
● The meanings of the symbols used in this manual are as follows.

Never carry out. Always follow the instructions and carry out.

Repairs and disassembly must be done by

Never touch. qualified personnel.

WARNINGS
(1) Never touch the high temperature sections such as the movable sections, exhaust
pipe, and high-pressure side of piping while the refrigeration unit is operating.
Failure to observe this could lead to burns.
(2) Do not place flammable materials near the exhaust pipes.
Failure to observe this could lead to fires.

(3) When starting the inspection or servicing of the refrigeration unit, turn “OFF” the
operation switch on the control panel and the main switch at the right-hand side of
the unit and disconnect the battery terminals. Then wait for more than 1 minute
before starting the work.
• Even if the operation switch is turned to “START/RUN”, the refrigeration unit may be stopped by
the function of the remote control unit or thermostat. Remember that the refrigeration unit may
start automatically during inspection if these devices start to function. Oversight of this precaution
could lead to physical injuries.
• Control power supply circuit has some sections charged with high voltage. Touching these
sections could lead to electric shocks.
(4) Always turn off the motor power supply before starting service of the sub-engine
such as inspection of the oil level.
Failure to do so could lead to injuries, electric shocks or fires.

(5) If the refrigerant gas leaks during work, always ventilate the area.
Toxic gas could be generated if the refrigerant gas contacts fire.

(6) If the refrigerant gas leaks, do not only additionally charge the gas. Instead find the
leak and accurately repair it. Then, charge the refrigerant gas, and check that there
are not leaks.
If the leak cannot be found and repairs are to be stopped, pump down and tighten the service valve.
The refrigerant gas itself is harmless, but toxic gas could be generated if it contacts fire such as in a
fan heater, stove or range.
(7) Install the unit securely in accordance with this manual.
Any improper practice in the installation could lead to the leakage of refrigerant, electric shocks or
fires.

ii
 WARNINGS
(8) When installing the refrigeration unit, use sturdy gears that could support its weight
safely.
If the capacity of strength is insufficient or installation is imperfect, it could lead to accidents or
injuries when, for example, the product unit has dropped off.
(9) Do not change the setting values for the protective and safety devices.
Otherwise, it could lead to the fracture or fires on the product unit.

(10) Be sure to prevent any refrigerant other than the specified, air, etc. from mixing in
the refrigeration cycle.
Otherwise, the refrigeration cycle could become over pressure, resulting in fracture or injury.
(11) Do not make modifications.
Making modifications could lead to injuries, electric shocks or fires due to abnormal operation.

(12) Temperatures of engine oil and engine cooling water could become extremely
higher. Wait till the temperatures drop sufficiently before starting inspection,
refilling or exchange.
(13) Put on protective eyeglasses and groves when handling the refrigerant.
Direct contact with the refrigerant could freeze the skin. If it enters in the eyes, it could lead to loss
of eyesight.
(14) Do not load volatile or inflammable substances in the container.

(15) Refrain from attempting any dangerous acts such as riding on the unit, hanging on
to, grasping, stepping on the unit, or others.

(16) Always use a dedicated circuit and leakage breaker for the electric work.
Insufficient electric circuit capacity or incorrect work could lead to electric shocks or fires.

(17) Do not insert fingers or rods in air intake and outlet ports.
A fan is rotating at a high speed inside, and inserting fingers or rods could lead to injuries.

(18) Do not directly apply water on the electric parts, or wash the electric parts with
water.
Application of water could lead to short circuits or electric shocks.
(19) Do not wash the unit with a high-pressure washer or steam washer.
Washing with high-pressure fluids could cause the condenser fins to damage. Washing with steam
could cause the internal pressure to rise abnormally and lead to ruptures.
(20) Never touch the electric parts such as the power supply plug with wet hands. Never
operate the switches with wet hands.
Failure to observe this could lead to electric shocks.
(21) Be cautious for burn when exchanging of high temperature engine oil and engine
cooling water.

iii
 WARNINGS
(22) Always hold the power supply plug when disconnecting the power supply cord.
Pulling on the cord could cause some wires to break and lead to heating or fires.

(23) Confirm that there is no dust on the power supply plug, and that the plug is not
loose before connecting it securely.
Adherence of dust or incomplete connection could lead to electric shocks or fires.

(24) Do not leave combustible objects around the exhaust pipe.

These could catch fire.

(25) Do not use the refrigeration unit in explosive atmosphere.

It could cause explosion, fire, or other accident.

(26) Persons other than repair technicians or qualified personnel must never
disassemble or repair the unit.
Incorrect disassembly or repairs could lead to injuries from abnormal operations or to electric
shocks or fires, etc.

CAUTIONS
(1) 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.
(2) Use a battery dedicated for the refrigeration unit.
Never use the same battery used for the truck. Failure to observe this could lead to electric shocks
or trouble.
(3) Use a battery having a voltage of DC 12 V and capacity of 72 AH or more.
Failure to do so could lead to electric shocks or trouble.

(4) Do not run the motor at an incorrect voltage.

It could lead to faults in the refrigeration unit or fires.

(5) Take care of the polarity of the battery wiring.

Connecting the + and – poles in reverse could lead to electric shocks or trouble.

(6) If using a commercial power supply to drive the motor, take current leakage
measures for the power supply circuit.

(7) Periodically confirm the operation of the leakage breaker.

Use of the leakage breaker in a fault state could impair operation in the event of a current leakage or
could lead to electric shocks.
(8) Do not discharge a refrigerant in the atmosphere.
It could cause environmental disruption.

iv
 CONTENTS

1. FEATURES................................................. 1 11.19 Dryer................................................................... 25

2. SPECIFICATIONS...................................... 2 11.20 Heat exchanger................................................... 26
3. GENERAL DESCRIPTION ........................ 3 11.21 Electronic expansion valve................................. 26
3.1 Operation control...................................................... 3 11.22 Return air temperature sensor (TH1),
3.2 Defrosting.................................................................. 3 supply air temperature sensor (THD)................. 26
3.3 Protective functions................................................... 3 11.23 Discharge gas temperature sensor (TDS)........... 26
3.4 Other functions......................................................... 4 12. WIRING DIAGRAM ................................ 27
4. COMPONENTS .......................................... 6 12.1 Ladder diagram..................................................... 27
4.1 Detail of the refrigeration unit................................... 6 12.2 Wiring layout drawing.......................................... 28
4.2 Detail of the control panel......................................... 7 13. DESCRIPTION OF OPERATION ........... 29
4.3 Detail of digital display area...................................... 7 13.1 Sub-engine drive................................................... 29
5. TEST OPERATION AND ADJUSTMENT ... 8 13.2 Motor drive........................................................... 34
5.1 Inspection before operation....................................... 8 13.3 Unit control method.............................................. 39
5.2 Inspection during operation....................................... 8 14. DETAIL SETTING .................................. 44
5.3 Driving with commercial power supply.................... 8 14.1 Setting change mode............................................. 44
6. DAILY OPERATION ................................... 8 14.2 User setting mode.................................................. 56
6.1 Inspection before operation....................................... 8 14.3 Service and maintenance mode ............................ 94
6.2 Operation mode selection.......................................... 9 15. INSPECTION ........................................ 114
6.3 Operation sequence.................................................... 9 15.1 Daily inspection.................................................. 114
7. CAUTIONS DURING OPERATION .......... 16 15.2 Periodic inspection.............................................. 114
7.1 Inspection during operation..................................... 16 15.3 Inspection, service and repair methods ............... 115
7.2 Cautions during operation........................................ 16 15.4 List of flare nut and bolt tightening torque.......... 118
8. CARGO LOADING ................................... 17 15.5 Greases and oils................................................... 119
8.1 Check before cargo loading..................................... 17 15.6 Methods of refrigerant recovery, evacuation
8.2 Cargo loading procedure ......................................... 17 and refrigerant charging .................................... 120
8.3 Unloading ............................................................... 17 15.7 Cautionary points for daily inspection................. 121
9. REFRIGERANT PIPING SYSTEM ........... 18 15.8 Cautionary points for periodical inspection ........ 126
9.1 Cooling cycle........................................................... 18 15.9 Installation and test run check sheet.................... 131
9.2 Heating cycle........................................................... 18 15.10 Periodic inspection check sheet......................... 132
9.3 Defrosting cycle....................................................... 19 15.11 Standard operating pressure list ........................ 133
10. DRIVE SYSTEM ..................................... 19 16. TROUBLESHOOTING .......................... 134
11. DESCRIPTION OF MAJOR 16.1 Troubleshooting of refrigerant system................ 134
COMPONENTS ..................................... 20 16.2 Troubleshooting of sub-engine and related
11.1 Compressor........................................................... 20 components ........................................................ 138
11.2 Sub-engine............................................................. 20 16.3 Troubleshooting of electrical components........... 143
11.3 Motor .................................................................... 20 17. INSTALLATION PROCEDURE............. 149
11.4 Centrifugal clutch.................................................. 20 17.1 Reference illustration for installation ................. 149
11.5 Sub-engine throttle solenoid................................. 20 17.2 Safety precautions at installation........................ 150
11.6 Airflow indicator .................................................. 21 17.3 Cautionary and requested points during
11.7 Alternator.............................................................. 21 installation ......................................................... 152
11.8 Magnet clutch ....................................................... 21 17.4 Unit hanging procedure ...................................... 154
11.9 Bearing unit .......................................................... 22 17.5 Appearance and dimensions of the unit ............. 155
11.10 Low-pressure sensor .......................................... 22 17.6 Specifications required for the van...................... 156
11.11 High-pressure sensor........................................... 22 17.7 Installation view of the unit ................................ 158
11.12 Evaporator outlet temperature sensor (EVT)...... 22 17.8 Fuel system･electrical system connection,
11.13 Over current relay (OCR).................................... 22 refrigerant system handling drawing.................. 159
11.14 Flywheel sensor (FWS)....................................... 23 17.9 Parts list for installation....................................... 160
11.15 High-pressure switch........................................... 23 17.10 Optional parts installation outline drawing........ 161
11.16 Solenoid valve .................................................... 24 18. SATURATED TEMPERATURE
11.17 Receiver............................................................... 25 PRESSURE TABLE (R404A).............. 162
11.18 Sight glass............................................................ 25 19. ABBREVIATIONS AND CODES........... 163

v
1. FEATURES
(1) This refrigeration unit features a large capacity and the minimum dimension of depth in the class for a trailer truck.
Protrusion into the cargo space is restrained by the optimized layout of devices so that a longer cargo space is
secured for loading.
(2) By introducing a new type controller, the visibility and operability have been enhanced significantly. Its data
logging function allows outputting the temperature control records, or other, quite easily.
(3) The refrigeration unit can conduct the refrigeration operation at the ambient temperature range of –20～+40°C, and
the inside container temperature* can be maintained within the range of –30～+25°C.
(4) The compressor is driven selectively with the sub-engine or the standby motor. Sub-engine is equipped with an
enlarged oil pan, and the interval of oil exchange has been extended substantially. The standby motor is operable
with the commercial power supply as well.
(5) New type turbo fans have been introduced for the evaporator fan and the condenser fan. The evaporator boasts the
maximum-scale supply air capacity. By introducing ribbed belts, the life of belts has been extended significantly.
(6) The function to defrost with the timer or manual control enables to remove frost speedily and maintains a powerful
cooling effect always.
(7) Employment of electronic expansion valves and the compressor with unloader enables to control the inside
container temperatures more accurately.
Speedy pull-down is assured with the multiplier effect of the maximum-scale cooling capacity and the evaporator
supply air capacity, and the irregular distribution of temperature is restrained to the minimum level.

*Note: The inside container temperature is usually defined as the temperature detected by the return air temperature sensor of
the evaporator. However, the user can select the temperature detected by the supply air temperature of the evaporator
as the inside container temperature if desired. (See page 56 or 73)

Refrigeration unit

Control panel Fuel tank

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2. SPECIFICATIONS
Model
Item TFV2000D-E
Conditions (Ambient temp. 30°C) °C Return air temperature ‐20 Return air temperature 0
Freezing
capacity

Sub-engine drive 9770 19060

W
Standby motor drive (50Hz) 6970 12490
Functions Cooling/heating
dimensions environment
Working

Inside container temperature ‐30～+25

°C
Ambient temperature ‐20～+40
Outside 2000 × 2138 × 430
Unit

WxHxD mm
Inside 1659 × 1150 × 100
Unit weight kg 860 (Excluding battery)
Drive system Exclusive sub-engine and standby motor
Operating system Automatic start/stop and continuous operation selecting
Model 4TNV88-SMRE
3
Displacement cm 2189
Sub-engine

Bore x Stroke x Cylinders mm ø88 × 90 × 4

Continuous operation fuel consumption L/h 5.2 (Ambient temperature 30°C, inside container temperature 0°C)
Oil capacity L 13.5 (Diesel oil 10W30, CE (API))
Fuel Diesel fuel (Intense cold season: cold weather fuel)
Rated output/speed kW/min-1 <High speed> 25.7/2100, <Low speed> 17.7/1450
Model CR2453LVR-A
Compressor

-1
Working speed min <High speed> 2100, <Low speed> 1450
Bore x Stroke x Cylinders mm ø55 × 55.6 × 4
Refrigeration machine oil charge volume L 2.4 (Diamond Freeze MA32R)
Type Aluminum fin & copper tubes
Evaporator

Fan Double suction turbo fan with casing

Sub-engine drive: <High speed> 2550, <Low speed> 1760,
Fan speed min-1
Standby motor drive (50Hz): 1333
Type Aluminum fin & copper tubes
Standby motor Condenser

Fan Turbo fan x 2

Sub-engine drive: <High speed> 2550, <Low speed> 1760,
Fan speed min-1
Standby motor drive (50Hz): 1333
Type Totally-enclosed fan-cooled outdoor type
Power supply 3-phase AC 400V 50Hz
Rated output kW(50Hz) 10.8
Number of poles 4
Refrigerant charge volume kg R404A, 8.0
High pressure side 3.24
Design pressure MPa
Low pressure side 2.26
Sound power level dB 104
Inside container temperature control Electronic thermostat
Operation control Microcomputer controller
Defrosting device Automatic (with defrost timer) and manual
High-pressure switch, engine oil pressure switch, engine water
Safety device
temperature switch, fusible plug, motor over current relay, limit switch

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 3. GENERAL DESCRIPTION
3.2 Defrosting
3.1 Operation control To prevent the refrigerating performance from dropping
when frost builds up on the evaporator, the defrosting
(1) Sub-engine drive
timer (set to 6 hours at the factory) functions to accurately
● The refrigeration unit drives the compressor,
defrost the unit. The setting time on the defrost timer can
condenser fan and evaporator fan by means of the
be changed between 1 and 12, depending on the
automatic start/stop or continuous operation
condition of load and the frosting speed.
(selectable) of sub-engine. Evaporator fan is driven
It is changed to the cooling operation depending on the
by a belt, which is activated by the solenoid clutch.
temperature at the evaporator outlet sensor. Moreover,
If the WHISPER switch is pressed, the sub-engine is
during defrosting, hot air will not be released to the
operable with the fixed slow speed operation.
inside container because the power supply to the
● When the automatic start/stop is selected
electromagnetic clutch of evaporator fan is shut down
The sub-engine runs at 2 speeds. It starts by operating
and the fan is stopped.
the operation switch, let the refrigeration unit conduct
As the defrosting operation is stopped, the sub-engine or
the cooling operation if the inside container
motor is stopped temporarily before resuming the
temperature is higher than the setting temperature of
cooling operation.
thermostat, or stop automatically when the
When much watery cargo is loaded or when cooling in
temperature reaches the setting temperature. If the
the inside container is slow, defrosting can be carried out
inside container temperature is lower than the setting
in the manual mode.
temperature, the unit conducts the heating operation
and stops as the temperature reaches the setting
3.3 Protective functions
temperature.
This refrigeration unit is provided with following
There is a function to stop the operation automatically
protective functions.
to protect cargoes from freezing when the cooling
(1) If the discharge pressure of compressor becomes
operation is performed with the setting temperature
excessively high, the high-pressure switch [3.18MPa
within the range of –5～+5°C. A function is provided
(32.5kgf/cm2)] will trip to stop the sub-engine or
to invalidate the freeze prevention from the control
motor.
panel.
(2) If the temperature or pressure becomes higher because
● When the continuous operation is selected
of fire, etc., the fusible plug will melt to release the
When the refrigeration unit has been started with the
refrigerant. (Fusible temperature: 90～95°C)
operation switch on the control panel and the inside
(3) If the hydraulic pressure of sub-engine becomes lower
container temperature is higher than the setting
[0.05MPa (0.5kgf/cm2)], the oil pressure switch will
temperature of thermostat, the unit conducts the
stop the sub-engine to protect it from being seized up.
cooling operation while the unit conducts the heating
(4) If the sub-engine cooling water temperature becomes
operation if the inside container temperature is lower
higher (110°C or higher), the water temperature switch
than the setting temperature of thermostat.
will protect the engine from being over-heated.
In order to maintain the inside container temperature
(5) If any abnormal current flows through the motor, the
at the setting temperature, the unit repeats the cooling
over current relay (20A) will operate to prevent
or heating and controls the supply air temperature.
failure or accident.
(6) When the service door is opened or only partially closed,
(2) Driving with commercial power supply
the unit will not operate inhibited by the door limit
● The refrigeration unit is equipped also with a circuit
switch.
to drive with the commercial power supply, in
(7) When any abnormal current flows through the output
addition to the sub-engine drive, so that the unit can
relay, fuses and blown fuse are displayed on the
be operated at any place if a power supply (3-phase,
control panel with an error code.
400V, 50Hz) is available.
(8) When any abnormal current flows through the fan
● If the drive selector switch is set at the “STANDBY
electromagnetic clutch, fuses and blown fuse are
MOTOR” on the control panel after connecting to the
displayed on the control panel with an error code.
commercial power supply, the unit can be operated
(9) If the engine revolutions are less than 700min-1 at 15
with motor drive in the same way as the sub-engine
seconds after supplying the power to the starter
drive. Motor operates only in 1 speed.
motor, it is judged as a failure of engine start, so the
operation stops.
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(10) If the engine revolutions have continued at 300～ during the inspection of short-circuit, the operation
1000min-1 for more than 10 seconds when operating stops.
the sub-engine (after the speed rose higher than (25) If short-circuit is detected on the throttle solenoid
700min-1), the operation stops. The unit tries to restart during the inspection of short-circuit, the operation
operation automatically (restart) up to 9 times and, if stops.
it fails to return to the normal speed, the operation is (26) If short-circuit is detected on the standby motor drive
stopped. circuit during the inspection of short-circuit, the
(11) If the refrigerant has decreased extremely, the operation stops.
operation stops. (27) If short-circuit is detected on the pre-heater drive
(12) When the low pressure has become 0 MPa circuit during the inspection of short-circuit, the
(0kgf/cm2) or it has been detected a broken coil or operation stops.
short-circuit on the low-pressure sensor, the automatic
resetting operation (restart) is tried up to 4 times, and When the above devices are activated, the error lamp on
if it fails, the operation is stopped. the control panel is lit or flickers and the unit operation
(13) When a broken wire or short-circuit on the stops automatically. While the operation is stopped by an
high-pressure sensor have been detected, the error, the error content is shown on the control panel
operation stops. display.
(14) When the hydraulic pressure has dropped due to oil
shortage during driving with the sub-engine (after the 3.4 Other functions
speed has picked up higher than 700min-1), the Moreover, the unit is provided with other functions as
operation stops. follows:
(15) When the engine speed has risen to higher than (1) Function to protect the battery from being fully
3000min-1 during driving with the sub-engine, the discharged.
operation stops. This function operates the sub-engine or motor for
(16) When the state that the battery voltage is less than the specified period of time to prevent the battery
11V and the voltage generated by the alternator is less voltage is discharged completely.
than 3V has continued for more than 5 seconds, (2) Backup operation against the temperature sensor error
during operation with the sub-engine or motor, the When any error occurs on the temperature sensor,
operation stops. operation of the refrigeration unit is continued with
(17) When broken coil or short-circuit has occurred on all the following methods.
inside container temperature sensors (return air (a) Return air temperature sensor error
temperature sensor, supply air temperature sensors 1 If broken wire or short-circuit occurs on the return air
and 2), the operation stops. temperature sensor, the operation is controlled with
(18) When it has failed to reset for more than 30 minutes the supply air temperature sensor.
after the trip of high-pressure switch or the (b) Supply air temperature sensor error
high-pressure switch has operated at the high pressure If broken wire or short-circuit occurs on either one of
of 0.5MPa～2.5MPa, the operation stops. a pair of supply air temperature sensors, the operation
(19) If any communication error occurs between the main is controlled with the normal sensor.
printed board and the display printed board, the When the fault has occurred on both supply air
operation stops. temperature sensors, the control is carried out by the
(20) If any error occurs on a contactor during the motor return air temperature sensor.
operation, the operation stops. (c) Evaporator outlet temperature sensor error
(21) When the speed becomes less than 100min-1 during If broken wire or short-circuit occurs on the
the sub-engine operation (after the speed has picked evaporator outlet temperature sensor, the operation is
up to 700min-1 or higher), the operation stops. controlled with the low-pressure sensor.
(22) When any short-circuit on relay is detected during the (3) Function to finish defrosting forcibly
sub-engine or motor operation, the operation stops. Defrosting operation is stopped forcibly 30 minutes
(23) If short-circuit is detected on the electronic later lest the defrosting continue for a long time.
expansion valve during the inspection of short-circuit, (4) Pump-down stop function
the operation stops. This function purges the liquid refrigerant to the
(24) If short-circuit is detected on the stop solenoid condenser side to prevent the liquid refrigerant from
-4-
 accumulating in the compressor when the refrigeration
unit is stopped or the thermostat is turned off.
(5) Sleep operation
(Protective operation for long-term stop)
When the refrigeration unit is left over without
operation for a long period of time the battery voltage
drops by the spontaneous discharge so much that it
becomes unable to start the sub-engine. If the
compressor is left over without operation for a long
period of time, a lot of liquid refrigerant tends to
accumulate in the compressor. If operation is resumed
in this condition, it could damage the compressor as a
result of the liquid compression. In order to prevent
such trouble, if the unit is stopped for more than 2
weeks, the unit is operated automatically for about 5
minutes.
While the protective operation is going on, a message
“ ” is displayed on the LCD.
Upon completion of the protective operation, the unit
operation stops automatically.
(a) Contents of the sleep operation
• Air is not supplied to the inside container.
(Evaporator fan is stopped.)
• Protective operation takes place during 10:00 ～
16:00 hours. It is necessary to complete the time
setting before starting to use the refrigeration unit.
• When the refrigeration unit is connected to the
commercial power supply, the unit operates with the
motor. If it is not, the sub-engine drives the unit.
(Setting with the drive selector switch is neglected.)
• Sub-engine runs at the slow speed during the engine
drive operation.
• Operating time is approximately 5 minutes,
including the time for start and stop.

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4. COMPONENTS
4.1 Detail of the refrigeration unit

Refrigeration unit

Reservoir tank Ribbed belt (6 ribs) Right condenser fan

Door opening lever

Left condenser fan

Alternator

V belt

Standby motor

Ribbed belt (10 ribs)

Air cleaner

Front door lock Compressor

Commercial power supply
connecting receptacle Oil filter V belt
Control panel
(Bottom face)
Engine Fuel filter

Main switch

Remote control
unit switch

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4.2 Detail of the control panel

UP switch DOWN switch

Digital display area CONT./AUTO
(LCD) changeover switch

WHISPER switch Motor select

indicator lamp
(Orange)

DEFROST switch

Drive selector switch

PRETRIP switch

Defrost indicator lamp Run indicator lamp

(Orange) (Green)

Cooling operation lamp

Operation switch
(Green)

External device
connector

SET switch

Heating operation lamp MODE switch Printer connector Alarm indicator lamp
(Orange) (Red)

4.3 Detail of digital display area (LCD)

Function icons

Inside container temperature icon

Setting temperature icon

Temperature symbol

Left 7-segment display Right 7-segment display

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5. TEST OF OPERATION AND 6. DAILY OPERATION
ADJUSTMENT 6.1 Inspection before operation
Check the following items during test operation and 6.1.1 In case of sub-engine drive
adjustment, and record necessary data on the check sheet (1) Engine oil amount check
(page 131). Be careful that if the engine oil decreases below the
allowable level, it will result in thermal seizure of the
5.1 Inspection before operation sub-engine.
(1) Check whether the refrigeration unit is placed at the Confirm that it is pointing at the upper limit of the
proper position or not. standard value on the level gauge while the gauge is
(2) Check whether the end of mounting bolts is fully inserted.
completely sealed or not.
Oil inlet
(3) Check whether the mounting bolts are tightened
securely or not.
(4) Check whether the drain hose is guided properly or
Oil level gauge
not, and whether clamps are used properly or not.
(5) Check whether the sealant is applied completely at
the opening on the van or not.
(6) Check whether the fuel hose is fixed properly or not.
(7) Check whether the amounts of engine oil, cooling
water and fuel are proper or not.
(8) Check the drive belt and the tension pulley center
bolt for looseness.
Standard value
(9) Check the refrigeration system for gas leakage, and
oil, fuel and cooling water for leakage.
(10) Check the moving parts for interference (fans,
pulleys, belt, etc. with the piping and the wiring).
(11) Check whether the operation valves of the
refrigeration system are opened or not.
(12) Check whether the protectors and the guards are
mounted properly or not. (2) Fuel amount check
(13) Cleaning of the container. Fuel must be filled to the proper level in order to
prevent fuel shortage on the way.
5.2 Inspection during operation (3) Cooling water check
(1) Check for abnormal noise and vibration. Check whether cooling water is filled in the reservoir
(2) Check the sub-engine and the fan for proper tank or not.
revolution. (4) Check engine oil, fuel and cooling water for leakage.
(3) Check the color in the sight glass and the volume of (5) Check the moving parts for interference.
refrigerant.
(4) Check whether the high and low pressures are proper 6.1.2 In case of the drive with commercial
or not. power supply
(5) Check whether the sub-engine start or stop is (1) After connecting to the power supply, select
controlled properly by the thermostat or not. “STANDBY MOTOR” with the drive selector switch
(6) Check whether a correct temperature is shown on the and set the operation switch at “START/RUN” side.
display or not. Confirm the fans, solenoid valves, etc. start to
(7) Check the operation of the defroster. operate.
(8) Check the operation of high-pressure switch. (2) Check for any abnormal noise or vibration

5.3 Driving with commercial power supply

Inspect the power supply wires (grounding cable, poor
insulation).

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6.2 Operation mode selection
The refrigeration unit can select the automatic start/stop and the continuous operation (selection system).
(1) In case of loading frozen cargoes, it is recommended that the automatic start/stop mode is selected to save fuel.
(2) In case of loading refrigerated cargoes, it is recommended that the automatic start/stop mode is selected when fuel
saving is important, and that the continuous operation mode be selected when distribution of the inside container
temperature is important.

6.3 Operation sequence

6.3.1 Details of the control panel
UP switch DOWN switch
Digital display area CONT./AUTO
(LCD) changeover switch

WHISPER switch Motor select

indicator lamp

DEFROST switch
Drive selector switch
PRETRIP switch

Defrost indicator lamp Run indicator lamp

Cooling operation lamp

Operation switch

External device
connector

SET switch

Heating operation lamp MODE switch Printer connector Alarm indicator lamp

(1) Operation switch (2) Drive selector switch

This switch starts or stops the refrigeration unit. If this This switch selects the engine drive or the motor drive
switch is turned to “START/RUN” side till a click is operation. Set the switch at “ENGINE” for the engine
heard, the unit conducts the initial automatic diagnosis drive or at “STANDBY MOTOR” for the motor drive.
for 10 seconds, and if the condition is normal, starts the When the unit is connected to the commercial power
operation. If any error is detected, it displays the error supply, the sub-engine cannot drive the unit. The motor
code and takes necessary measures automatically. can be driven with the power supply (3-phase, AC 400V,
If the operation switch is turned to “OFF” till a click is 50Hz) provided at the garage, truck terminal, ferryboat,
heard, the unit stops about 20 seconds later. If the switch etc.
is held at the “OFF” position for more than 2 seconds, The sub-engine or motor drives the compressor,
the unit stops instantly. The unit should be stopped by condenser fan and evaporator fan. Evaporator fan is
the normal stop other than any emergency occasions. activated by an electromagnetic clutch.

-9-
(3) CONT./AUTO selector switch (4) External device connector

This switch selects the “AUTO START-STOP” or the This connector is for connection with a terminal device
“CONTINUOUS”. to read out the log data or a remote device.

(5) Printer connector

Automatic start/stop operation
This switch starts or stops the sub-engine during the
engine drive operation, or the motor during the motor
drive operation, in order to maintain the inside container
temperature at around the setting temperature. Fuel
consumption is smaller than the continuous operation but
the extent of fluctuation on the inside container
This connector is for connection with a printer to print
temperature becomes larger. This operation is adequate
the inside container temperature history data.
for cargoes of which the temperature control has a larger
allowance.
(6) Control switch
Operation is conducted with 2 speeds for the sub-engine
drive while it is 1 speed for the motor drive.
After starting operation with the operation switch, if the
inside container temperature becomes higher than the
setting temperature of thermostat, the unit performs the
cooling operation and stops automatically as the
temperature drops to the setting temperature.
There is a function to stop the cooling operation
automatically before the temperature reaches the setting
temperature in order to protect the cargoes from freezing
when conducting the cooling operation with the setting
temperature range of –5～+5°C. This function can be
invalidated with user setting mode.
① UP switch .............Changes the setting temperature
and various setting screens.
Continuous operation
② DOWN switch .......Changes the setting temperature
The unit operates continuously without stopping, but
and various setting screens.
maintains the inside container temperature at around the
③ SET switch ............Registers a setting.
setting temperature by automatically adjusting the heating
④ MODE switch ........Selects the normal display screen
and cooling capacities. This operation can maintain the
or the setting change screen.
inside container temperature very close to the setting
⑤ PRETRIP switch ....Starts/stops the self diagnosis
temperature and thus is adequate for the chilled
operation (PTI).
transportation, which requires a strict temperature control.
⑥ WHISPER switch ...Selects the normal operation or
Operation is conducted with 2 speeds for the sub-engine
the whisper operation.
drive while it is 1 speed for the motor drive.
⑦ DEFROST switch ...Performs the manual defrost
After starting operation with the operation switch, if the
operation
inside container temperature becomes higher than the
setting temperature of thermostat, the unit performs the
cooling operation. If it becomes lower than the setting
temperature, instead, the unit conducts the heating
operation automatically. In order to maintain the
temperature at the setting temperature, the unit controls
the supply air temperature by repeating heating and
cooling.

- 10 -
(7) Indicator lamps .......... Display for the self diagnosis operation
(PTI). Lit when executing PTI.

.......... Display for the external communication

condition. Lit when communicating with an
external device such as remote device, etc.

.......... Display for the printer. Lit when sending

data to the printer.
① Defrost indicator lamp......Lit during the defrosting
operation. .......... Display for the whisper operation. Lit when
② Cooling operation lamp.....Lit during the cooling the whisper operation is selected.
operation.
③ Heating operation lamp.....Lit during the heating .......... Display for the timer. Lit when it is set to
operation. the timer operation.
④ Alarm indicator lamp........Lit or flickers when any
error occurs on the unit. .......... Display for the commercial power supply.
Lit when the unit is connected to the
(8) Digital display area (LCD) commercial power supply.

.......... Display for registration. Lit when urging to

finalize a setting.

(9) Main switch/remote control unit switch

The LCD displays the setting temperature, inside container

temperature during operation, operation mode, various
setting modes, and error code upon occurrence of error.

①Left 7-segment........ Displays the inside container tem-

display perature during operation. When
changing the setting, it displays The main switch shuts down the power supply during
the name of setting mode (code). inspection or servicing, and the remote control unit
②Right 7-segment…... Displays the setting temperature switch allows turning ON or OFF the remote control unit
display during operation. or remote monitoring equipment.
Displays the content of setting
when changing the setting.
③Inside container....... Lit when the 7-segment display
temperature icon shows the inside container
temperature.
④Setting temperature...Lit when the 7-segment display
icon shows the setting temperature.
⑤Temperature............. °C is lit when Celsius is selected
symbol or °F when Fahrenheit is selected.
(Celsius is selected at the
shipment.)
⑥ Function icons..........Either one of these is lit when
corresponding function is operating.

- 11 -
6.3.2 Operation sequence
(1) Setting temperatures
Temperatures can be set in the unit of 0.5 over the range of –30°C to +25°C. Change the temperature as follows
according to the cargoes to carry.

1 When the unit is stopped, press the [MODE] switch to start the controller.
When the unit is operating, this step is not necessary.

2 Pressing the [UP] or [DOWN] switch changes the display to

the setting temperature changing screen, and the current
setting temperature being displayed on the right 7-segment
display starts to flicker.

Pressing the [SET] switch while the setting temperature

flickers finalizes the temperature at the value shown on
the display at that time. Do not press the [SET] switch till
the step 3 is completed.

3 Press the [UP] or [DOWN] switch to display the temperature

you desire to set.

Each push on the [UP] switch increases the value by 0.5

while each push on the [DOWN] switch decreases the
value by 0.5. Holding down either switch changes the
value continuously.

4 Press the [SET] switch to finalize the change of setting.

This is all for the change of setting temperature. The display returns automatically to the normal display screen.

- 12 -
(2) Switching between the sub-engine drive and the motor drive
Use the drive selector switch on the control panel to select the sub-engine drive or the motor drive.

Operating with the sub-engine

Turn the drive selector switch to the “Engine”.

Operating with the motor

Turn the drive selector switch to the “STANDBY MOTOR”.
Motor select indicator lamp (orange) is lit.

When the unit is connected to the commercial power supply,

the unit cannot operate with the sub-engine drive.
When it is necessary to connect or disconnect the power
plug to and from the commercial power outlet, “ ”
flickers on the 7-segment of LCD.

(3) Switching between the automatic start/stop operation and the continuous operation
This refrigeration unit operates selectively with the automatic start/stop operation or the continuous operation.
Use the operation selector switch to select either operation.

Selecting the auto start/stop operation

Set the CONT./AUTO changeover switch at the
“AUTO START/STOP”.

Selecting the continuous operation

Set the CONT./AUTO changeover switch at the
“CONTINUOUS”.

What is the automatic start/stop operation?

Inside container temperature is maintained at around the setting
temperature by operating or stopping the sub-engine during the engine
drive or by operating or stopping the motor during the motor drive.
Automatic start/stop operation consumes less fuel (electricity) than the
continuous operation but has a large deviation on the inside container
temperature. This pattern of operation is fit to cargoes with a larger
allowance in the control temperature.

What is the continuous operation?

With continuous operation, the unit operates continuously without stop,
in which the inside container temperature is maintained at around the
setting temperature by adjusting the freezing and heating capacities
automatically.
Since this operation can maintain the inside container temperature
very close to the setting temperature, it fits to cases such as the chilled
transport, which require a strict quality control.

- 13 -
(4) Starting the operation
Turn the operation switch on the control panel to the
“START/RUN” till a click is heard.
(The switch returns to its center position if the finger is released.)

Confirm that the operation lamp (green) is lit and the LCD shows
the temperature.

Alarm buzzer sounds for 5 seconds before the start of sub-engine

or motor operation to announce the start of operation.
The unit operates with the drive (sub-engine/motor) and the
pattern of CONT./AUTO (auto start-stop/continuous operation)
selected with the switches.

· While the unit panel is opened, the unit will not start to operate because the safety device is turned
on. (Error code E030 is displayed. Close the panel. Then the unit starts automatically.)
· Engine drive operation is inhibited while the power plug is connected to the AC power outlet. At this
time, “ ” is flickering on the LCD. If the plug is disconnected, the unit starts automatically.
· If the unit is operated with the motor drive without connecting the power plug to the commercial
power supply outlet, “ ” flickers on the LCD. If the plug is connected to the outlet, the unit
starts automatically.
· When the auto start/stop is selected and the inside container temperature is near to the setting
temperature, the unit may not start.

(5) Stopping the operation

Turn the operation switch on the control panel to the OFF till a click is heard.
(The switch returns to its center position if the finger is released.)
The unit can be stopped either by the normal stop or the emergency stop.

Normal stop
If the switch is turned down shortly (less than 2 seconds), the unit conducts the device protecting operation for 10 to
20 seconds before stopping. During the protective operation, “ Pu_d ” flickers on the left 7-segment display and
“ StoP ” flickers on the right 7-segment display. When the unit has been operating normally, stop it with the
normal stop.

Emergency stop
If the switch is turned down a little longer (more than 2 seconds), the unit stops immediately.
Use the emergency stop when it is necessary to stop the operation urgently after a unit error, etc.

If all sequence for the operation stop is completed, the controller is turned OFF automatically.

When stopping the motor drive operation, the buzzer sounds (3 times), and the LCD displays
“ AC PLUG ” in order to prevent forgetting disconnection of the power plug from the AC outlet.

- 14 -
(6) WHISPER operation
Pressing the “WHISPER” switch on the control panel enables
the whisper operation, and one more push on the switch
cancels the operation.
(The whisper operation can be set only when the controller is
operating and the drive selector switch is turned to the
Engine.) When the whisper operation is enabled, the turtles
whisper operation icon lights on the icon bar.

Even when the whisper operation is enabled, the setting is

reset as the unit operation is stopped.
Renew the whisper operation setting by pressing the “WHISPER”
switch at every time when the whisper operation is necessary.

What is the whisper operation?

During the whisper operation, the sub-engine runs at the slow speed revolution only. This function is
convenient in such occasions when it is desirable to suppress temporarily the sound of unit
operation for a temporary stop of vehicle, etc.

Setting to enable the whisper operation can be changed so that it continues even after stopping the
unit operation. For details, refer to page 87.

(7) Manual defrost operation

The defrost operation can be conducted any time during the
cooling operation by pressing the “DEFROST” switch.
(Manual defrost operation is inhibited during the stop or
heating operation.) Content of the defrost operation is same as
the automatically initiated defrost operation.
Defrost indicator lamp is lit during the defrost operation.

Starting
Press the “DEFROST” switch once during the cooling
operation (the cooling operation lamp ON).

Stopping
As the defrost operation completes, the unit returns
automatically to the normal operation.
To interrupt the defrost operation and return to the cooling
operation, press the “DEFROST” switch once more.
If the operation switch is turned to the “OFF”, the defrost operation is interrupted and the unit operation stops.

Manual defrost operation may be started even during the stop with the thermostat OFF (such
situation that the operation is stopped because the inside container temperature is close to the
setting temperature).

- 15 -
7. CAUTIONS DURING OPERATION

7.1 Inspection during operation

(1) Observe the LCD on the control panel to confirm that the inside container temperature is maintained at the setting
temperature.

Inside container Setting temperature

temperature display display

(2) Check the remaining quantity of fuel.

[CAUTION] When the drive by commercial power supply is selected, confirm that the power supply cable is
connected.
(3) Check if any abnormal noise is heard from the refrigeration unit.
If it is, stop the refrigeration unit, check from where it is generating and take necessary measures (repair, security of
cargo temperature, etc).

7.2 Cautions during operation

(1) When operating the refrigeration unit at a fixed position, select a place where the unit is not exposed to direct
sunlight and where it is well ventilated.
(2) Indication at the temperature/mode setting display on the control panel may flicker due to noises emitted from
illegal wireless devices, etc.

- 16 -
8. CARGO LOADING

8.1 Check before cargo loading

(1) Practice the inspection before operation as described on page 8.
(2) Clean the inside of container.
(3) Before loading cargoes, be sure to do the pre-cooling until the inside container temperature reaches the setting
temperature. (Carry it out according to the operation sequence on page 9.)
Temperature inside the container may rise as hot as 60°C under the blazing sun in midsummer. If any cargo is
directly loaded in such a hot container, it will surely result in abnormal temperature for transportation.

8.2 Cargo loading procedure

(1) Before loading to the container, cargoes must be pre-cooled to the specified temperature by other refrigeration
unit. (It is strictly prohibited to load cargoes bearing high temperatures because it could melt other cargoes,
resulting in material losses, and cause the refrigeration unit stopping by the abnormal stop.)
(2) When loading cargoes, stop the operation of refrigeration unit and finish up the loading as quick as possible.
(3) Load cargoes so as to allow cool air circulating to every corner of the storage.
(4) Try to make the top of cargoes as flat as possible.

Refrigeration unit

300~400mm Lower than supply air outlet Evaporator supply air outlet

Minimum 30mm Minimum 30mm

Minimum 100mm

Evaporator supply air outlet

Minimum 100mm Minimum 50mm

(5) When loading any cargo, which must be protected from wetting with water, the cargo loaded close to the evaporator
supply air outlet must be covered with a waterproof sheet, etc.

WARNING
Depending on the extent of frost accumulated on the evaporator coil, some water may be splashed
after defrosting. To avoid physical loss or damage, take adequate waterproofing measures for any
cargo, which must be protected from wetting with water.

(6) After the loading, operate the refrigeration unit.

8.3 Unloading
(1) Perform unloading after stopping the refrigeration unit.
(2) Inside container temperature will rise momentarily whenever the door is opened. The door should be opened and
closed as quickly as possible not to release the cool air to the outside.

- 17 -
9. REFRIGERANT PIPING SYSTEM
9.1 Cooling cycle
Condenser (R)

Receiver tank
Discharge pressure
regulator Check valve Fusible plug
Check valve

Dryer Sight glass

(Applicable to the units with serial number
_of up to 869400101BL.)
Ambient
temperature Check Service valve
sensor joint
Sight glass
Condenser Condenser (L) (Applicable to the units with serial number
inlet solenoid _of 869400102BL and after.)
valve Orifice Drain pan heater
High-pressure sensor High-pressure Defrost solenoid valve
switch Electronic
Discharge
temperature expansion
sensor Unloader valve
solenoid
valve
Evaporator
Evaporator outlet Return air
temperature sensor temperature sensor
Discharge
valve

Suction valve
Liquid bypass
Compressor solenoid valve Heat exchanger Low-pressure sensor Supply air temperature sensor
Check joint

9.2 Heating cycle

Condenser (R)

*1 Opened/closed when adjusting

Receiver tank (increase/decrease) the heating
Discharge pressure capacity.
regulator Check valve Fusible plug *2 Opened when the discharge side
Check valve pressure is higher than 1.8MPa
(18kgf/cm2).
*3 Opened/closed when adjusting
(decrease) the heating capacity.

Sight glass
Dryer
(Applicable to the units with serial number
_of up to 869400101BL.)
*2 Ambient
Check
temperature Service valve
sensor joint
Sight glass
Condenser Condenser (L) (Applicable to the units with serial number
inlet solenoid _of 869400102BL and after.)
valve Orifice Drain pan heater
High-pressure sensor High-pressure Defrost solenoid valve
switch *1
Discharge Electronic
temperature expansion
sensor Unloader valve
solenoid
valve
Evaporator
Evaporator outlet Return air
temperature sensor temperature sensor
Discharge
valve

Suction valve *3
Liquid bypass
Compressor solenoid valve Heat exchanger Low-pressure sensor Supply air temperature sensor
Check joint

- 18 -
9.3 Defrosting cycle
Condenser (R)

Discharge pressure
Receiver tank
regulator Check valve
Fusible plug
Check valve
*2 Opened when the discharge side
pressure is higher than 1.8MPa
(18kgf/cm2).

Sight glass
Dryer
(Applicable to the units with serial number
_of up to 869400101BL.)
*2 Ambient
temperature Check Service valve
sensor joint
Sight glass
Condenser Condenser (L) (Applicable to the units with serial number
inlet solenoid _of 869400102BL and after.)
valve Orifice Drain pan heater
High-pressure sensor High-pressure Defrost solenoid valve
switch Electronic
Discharge
temperature expansion
sensor Unloader valve
solenoid
valve
Evaporator
Evaporator outlet Return air
temperature sensor temperature sensor
Discharge
valve

Suction valve
Liquid bypass
Compressor solenoid valve Heat exchanger Low-pressure sensor Supply air temperature sensor
Check joint

10. DRIVE SYSTEM

Left Right
condenser condenser
fan fan

Alternator
belt Alternator Fan belt

Compressor
belt Standby motor

B
Sub-engine
Water pump belt
Compressor

A-A A

- 19 -
11. DESCRIPTIONS OF MAJOR 11.3 Standby motor
_COMPONENTS
Specifications
11.1 Compressor Type Totally-closed fan-cooled outdoor type
Outline of structure and function Power supply 3ø400V(50Hz)
Driven by the motor or sub-engine, the compressor sucks Rated output 10.8kW
and compresses the refrigerant with the reciprocal motion Number of poles 4
of piston. Oil pump circulates lubrication oil forcibly to the
rotating section. 11.4 Centrifugal clutch
The clutch is mounted on the crankshaft of the sub-engine.
When the sub-engine exceeds the specified speed, the
centrifugal force of the engine overcomes the centripetal
force of the spring to bring the frictional shoe into contact
with the power transmission surface of pulley. Thus, the
pulley starts rotating. As the revolution speed increases
further, the contact pressure on the power transmission
face will increase to generate the frictional force, which
resists the load torque. Thus, the power will be transmitted
from the sub-engine shaft. Moreover, when the motor runs,
the centrifugal clutch does not operate, so the power of
sub-engine is not transmitted.

Compressor
① Cylinder head cover ② Valve plate ③ Piston
④ Crankshaft ⑤ Oil pump ⑥ Pump cover ⑦ Crank case
⑧ Oil strainer ⑨ Bottom cover ⑩ Sight glass
⑪ Relief valve ⑫ Shaft seal ⑬ Connecting rod
Centrifugal clutch
Specifications Engage speed: 700±100min-1
Item Unit Specification Lining abrasion limit: 2 mm (4 mm for new lining)
Model CR2453LVR-A
Revolution speed min-1 <High speed> 2100, <Low speed> 1450
11.5 Sub-engine throttle solenoid
Displacement cc 528
The sub-engine speed is changed to the high or low rated
speed or stopped by this solenoid.
Bore x Stroke x Cylinders mm ø55 x 55.6 x 4
Refrigeration Type Diamond Freeze MA32R
machine oil Charge quantity L 2.4

11.2 Sub-engine
Specifications
Model 4TNV88-SMRE Sub-engine throttle solenoid
Rated output 27.1kW (36.8PS) 2200min-1 (1) To check the sub-engine speed, change the controller
Displacement 2189 cc display to the analog sensor display mode while the
Continuous operation 5.2L (Ambient temp. 30°C,
fuel consumption inside container temp. 0°C) refrigeration unit is operating. (See page 110.)
Bore x Stroke x Cylinders ø88 x 90 x 4
Oil capacity 13.5L
Fuel Diesel fuel
(Intense cold season: cold weather fuel)
Cooling method Water-cooled
Revolution speed <High speed> 2100min-1, <Low speed> 1450min-1

- 20 -
 B
Display the sub-engine speed.
0.5µF
When the sub-engine speed display largely fluctuates, T L 10Ω～30Ω

make sure to check it on the speed meter and carry out S

the following adjustment. VB

(2) Sub-engine speed adjustment procedure

(a) While running the sub-engine at a high speed, adjust
IC regulator
the adjusting rod ① to set the speed at 2100min-1.
(b) After the high speed adjustment, run the sub-engine Circuit diagram
at a low speed, and adjust the slow speed set bolt ② (3) Specifications
to set the speed at 1450min-1.
Model A007TA1971
(c) After the installation and adjustment, be sure to make
Rating Continuous
a test run and check to see that it operates and stops.
Voltage DC12V
Output capacity 45A

11.8 Magnet clutch

The clutch is mounted on the fan shaft, and turns ON or
OFF of the fan drive as demanded by the controller.

11.6 Airflow indicator (Option)

The indicator is mounted on the sub-engine air intake. It
pops off when the pressure reaches the specified pressure,
Specifications
and urges the cleaning or replacement of air cleaner.
Voltage DC12V
Power consumption 43.1W
Reset button Static friction torque 74N·m (7.5kgf·m)
Allowable speed 7000min-1
Revolving direction Right
Belt Ribbed belt (6 ribs)

Airflow indicator Judgment of condition

Fan will run if the pulley and the friction plate are
contacted (a click is heard) when a voltage is applied
11.7 Alternator
between the lead wires and the main unit ground.
(1) Alternator is driven by the sub-engine or motor via a
If it fails to run after applying the voltage, check the
belt, and generates power to charge the battery.
continuity between the lead wires and the main unit
(2) Alternator has a built-in IC regulator.
ground with a tester. If there is no continuity, the coil is
broken. If any abnormal noise is heard, the bearing could
be worn.
When replacing the magnet clutch, replace it as an
assembly. When the air gap is not in the range of 0.3～
0.5mm, replace.
Magnet clutch center bolt tightening torque: 31.8 N･m
(3.25 kgf･m)

Alternator
- 21 -
11.9 Bearing unit 11.12 Evaporator outlet temperature
This bearing is used between the fan shaft and the frame. sensor (EVT)
This sensor monitors the gas temperature at the evaporator
Shaft locking screw exit to control super-heat with the electronic expansion
Tightening torque: 4.9N·m (0.5 kgf·m) valve, and the start or stop of defrosting.
Defrosting start, stop temperatures
OFF: 25.0 ± 1.5°C
ON: 1.0 ± 1.5°C
Judgment of sensor condition
(1) Disconnecting the thermistor sensor lead wires at
the connector, measure the continuity.
(2) Check by referring to the temperature/resistance
characteristic value of thermistor.
Bearing unit (3) If the resistance value deviates largely, remove the
sensor from the connector and replace.
11.10 Low-pressure sensor
Thermistor Case
This sensor detects the low pressure. If it drops to the
protective pressure, the sensor trips to stop the unit.

Filling resin Tube

Evaporator outlet temperature sensor

Unit: k∧
°C Min. Standard Max.
Low-pressure sensor
-30 25.293 26.316 27.376
Specifications
-20 15.125 15.572 16.031
Low pressure Output voltage
-10 9.342 9.524 9.709
-0.1MPa (750mmHg) 0.2V 0 5.940 6.000 6.060
0MPa (0kgf/cm2) 0.5V 10 3.810 3.882 3.955
0.5MPa (5kgf/cm2) 2.0V 20 2.505 2.573 2.644
1.0MPa (10kgf/cm2) 3.5V 25 2.049 2.113 2.179
30 1.687 1.746 1.808
11.11 High-pressure sensor 40 1.163 1.213 1.265
This sensor detects the high pressure. If it rises to the 50 0.819 0.860 0.903
protective pressure, the sensor trips to stop the unit.

11.13 Over current relay (OCR)

When an over current flows into the motor during motor
operation, the relay stops the motor to protect it. If it lapses
more than 3 minutes after the current returned to the
normal value, it is reset automatically.

High-pressure sensor
Specifications
High pressure Output voltage
2
0MPa (0kgf/cm ) 0.5V
2
2.08MPa (21.2kgf/cm ) 2.0V
4.15MPa (42.3kgf/cm2) 3.5V

Over current relay

Setting value: 20A
- 22 -
11.14 Flywheel sensor (FWS) (2) Inspection
The sensor monitors the sub-engine speed and input the (a) Check if the clearance to the ring gear is maintained
result to the controller. If it detects a speed lower than the
at the setting value shown in the above figure.
setting speed, it stops the sub-engine.
Setting value: 1 ± 0.2mm
(b) Inspection of flywheel sensor
Flywheel sensor

Black

Yellow

Ring gear

Flywheel sensor

(1) Flywheel sensor mounting procedure Removing the connector, measure the resistance
(a) Assemble the sensor in the bracket, and turn it till it between ① and ②.
contacts the ring gear lightly. (See the figure.) Normal resistance: 2.3±0.2k∧.

Hexagon nut
11.15 High-pressure switch
When the compressor discharge pressure goes up
Flywheel sensor
abnormally higher, the high-pressure switch trips and stops
the operation to prevent the dangerous situation.

Setting value: MPa (kgf/cm2)

Bracket CUT OUT 3.18 (32.5)
CUT IN 2.21 (22.5) (Auto reset)
Ring gear

The switch cannot be adjusted. If it is defective, replace as

(b) Return the sensor by 1mm ± 0.2 (2/3 turn) from the an assembly.
position it contacted. (See the figure.)
Movable
Pin contact point Lead cable
1mm+0.2
Hexagon nut

Flywheel sensor

Pressure disk Fixed contact point

Bracket High-pressure switch

Ring gear

(c) Fix the flywheel sensor on the bracket with the

hexagon nut.
Tightening torque: 29.4 ± 4.9N·m (3 ± 0.5 kgf·m)

- 23 -
11.16 Solenoid valve Judgment of condition
(1) Condenser inlet solenoid valve When testing the continuity between connector
• It opens during cooling operation and let refrigerant terminals, if there is the continuity, the coil is normal.
flow into the condenser side. Otherwise, the coil is defective.
• During defrosting, the solenoid valve is closed. If there is a difference in the refrigerant inlet and outlet
• This solenoid valve is normally closed. When the temperatures before supplying the power to the coil,
power is supplied, the plunger is at the top and the and the temperatures become same after supplying the
disk is open. power, the plunger is operating normally.
If there is a difference in the temperatures, the plunger
Main valve Valve assy
is stuck.
Plunger Simple diagnosis
When the power is supplied to the coil, if a shock from
Spring
the plunger, which hops up with a click, is felt by the
finger placed on the solenoid valve, it is normal.

Spring (3) Liquid bypass solenoid valve

This valve is mounted on the liquid line and controls
the volume of refrigerant injected into the compressor
with the controller in order to protect the compressor
Coil Disk
compression chamber from overheat.
Condenser inlet solenoid valve
Coil

Judgment of condition
When testing the lead cables, if there is the continuity,
the coil is normal. Otherwise, the coil is defective. If
Spring
there is a difference in the refrigerant inlet and outlet
Connector
temperatures before supplying the power to the coil and Plunger

the temperatures become same after supplying the

power, the plunger is operating normally.
If there is a difference in the temperatures, the plunger Liquid bypass solenoid valve
is stuck.
Judgment of condition
Simple diagnosis When testing the continuity between connector
When the power is supplied to the coil, if a shock from terminals, if there is the continuity, the coil is normal.
the plunger, which hops up with a click, is felt by the Otherwise, the coil is defective.
finger placed on the solenoid valve, it is normal. If there is a difference in the refrigerant inlet and outlet
temperatures before supplying the power to the coil,
(2) Defrost solenoid valve and the temperatures become same after supplying the
It is installed in order to flow hot gas of refrigerant into power, the plunger is operating normally.
the evaporator side when defrosting. If there is a difference in the temperatures, the plunger
is stuck.

Connector Coil Simple diagnosis

When the power is supplied to the coil, if a shock from
the plunger, which hops up with a click, is felt by the
Spring finger placed on the solenoid valve, it is normal.

Plunger (4) Unloader solenoid valve

This valve switches the capacity of compressor. When
the power is supplied to the valve, the compressor is
operated with the partial operation (2-cylinder
operation) while the compressor is operated with the
Defrost solenoid valve full load operation (4-cylinder operation) if the power
is not supplied.
- 24 -
 Coil
Connector
If the refrigerant is short, repair the leaking place,
recover the refrigerant, evacuate the system and then
Spring measure and charge the specified amount of refrigerant.

(2) Judging the amount of contained moisture

Plunger
Water content in R404A
Check color Judgment Refrigerant Refrigerant
temperature 25°C temperature 43°C
Less than Less than
Green Normal
20ppm 25ppm
Slightly 20~70 25~100
Yellow/green
abnormal ppm ppm
Flare nut Flare nut
70ppm 100ppm
Yellow Abnormal
or more or more
Unloader solenoid valve
When the color is yellow, water is contained. Replace
11.17 Receiver the dryer and conduct the evacuation.
It reserves the refrigerant, which has been liquefied by the
condenser. <For the sight glass on the refrigerant piping> (Applicable
It has a fusible plug that melts under abnormally higher to the units with serial number of 869400102BL and after)
temperatures and discharges the refrigerant to the (1) Judging the volume of refrigerant
atmosphere to prevent the dangerous condition. When the Amount of refrigerant is Amount of refrigerant is
plug has melted, replace with a new plug. proper short
Bubble Bubble
Sight glass

Inlet Check color Check color

(A few bubbles are (A lot of bubbles are seen

Outlet moving or no bubbles) and it looks like flushing
when the refrigerant is
Sight glass Upper extremely in shortage. Note
Applicable to the that flushing could be seen
units with serial
number of up to
when the inside container
869400101BL. temperature is high even if
Lower
Fusible plug the amount of refrigerant is
proper.)
If the refrigerant shortage is suspected, measure and
compare the high and low pressure of the refrigerant with
Receiver
the standard pressure shown in page 133. If the result is
11.18 Sight glass too low, repair the leaking place, recover the refrigerant,
Sight glass allows judging the circulation volume of evacuate the system and then measure and charge the
refrigerant and moisture contained in the refrigerant. specified amount of refrigerant.

<For the sight glasses on the receiver> (Applicable to the (2) Judging the amount of contained moisture
units with serial number of up to 869400101BL) Moisture amount (Refrigerant
(1) Judging the volume of refrigerant Check color Judgment temperature 38 degC)
Judge the volume with the position of red float in the R404A
sight glass. Green Normal 30 ppm or less
Adequate Insufficient Excessive Light green Rather abnormal 30 ~ 140 ppm
volume volume volume
Yellow Abnormal 140 ppm or more
When the color is yellow, water is contained. Replace the
Sight glass
(upper) dryer and conduct the evacuation.

11.19 Dryer
Dryer removes moisture and foreign matters from the
Sight glass refrigerant. When the desiccant in the dryer has become
(upper)
unable to remove moisture any more (check color in the
sight glass is yellow), replace the dryer.
- 25 -
 Arrow The electronic expansion valve has a built-in stepping
motor and adjusts the valve aperture steplessly by the
electric pulse signals.

11.22 Return air temperature sensor

(TH1) and supply air temperature
Inlet Outlet sensor (THD)
The return air temperature sensor and the supply air
temperature sensor monitor the evaporator return and
Dryer supply air temperatures in order to maintain them at the
When mounting the dryer on the refrigeration unit, align the setting temperatures on the controller.
arrow on the dryer with the flow direction of refrigerant. Specifications of these sensors are same as those of the
evaporator outlet temperature sensor.
11.20 Heat exchanger
The heat exchanger increases the refrigerating capacity by 11.23 Discharge gas temperature sensor
exchanging the heat between the high-temperature liquid (TDS)
refrigerant and the low-temperature gas refrigerant. This sensor monitors the compressor discharge
temperature so as to stop the refrigeration unit or open the
High temperature High temperature
liquid refrigerant liquid refrigerant liquid bypass solenoid valve as the discharge temperature
(From condenser) (To evaporator) becomes higher.
• If the temperature becomes higher than 140°C, it opens
the liquid bypass valve to bring down the discharge
Low temperature Low temperature
temperature by the refrigerant.
gas refrigerant gas refrigerant • If the temperature becomes higher than 145°C, it stops
(To compressor) (From evaporator)
the refrigeration unit.
Heat exchanger
Sensor Connector
11.21 Electronic expansion valve
This valve controls not only super-heat at the evaporator
outlet but also refrigeration capacity according to the heat Tie band Lead wire
load as well as the protection from high pressure cut-off of
the compressor and so on. Discharge gas temperature sensor
The valve controls the super-heat by the temperature and
pressure of the refrigerant at the evaporator outlet. When Solenoid valve open: 140°C
the return air temperature* becomes close to the setting Solenoid valve close: 130°C (or 120°C at supply air
temperature, the capacity control will be started by control)
monitoring the supply and return air temperatures of the Unit abnormal stop: 145°C
evaporator. The refrigerant flow will also be controlled to Unit operation after
prevent high pressure cut-off due to excessively high abnormal stop: 100°C
pressure at the discharge port of the compressor.
(*: The supply air temperature will be checked in case of Judgment of condition
the supply air temperature control mode.) Removing the connector, measure the resistance value.

Resistance values under normal state

200°C 0.430kΩ 100°C 5.228kΩ
Needle
175°C 0.738kΩ 25°C 80.470kΩ
Inlet
115°C 3.352kΩ
Terminal housing

Outlet

Electronic expansion valve

- 26 -
12. WIRING DIAGRAM
12.1 Ladder diagram
Power supply

CON

Unit section Control box section

Code Name Code Name Code Name Code Name Code Name Code Name Code Name Code Name Code Name
BATT Battery SV2-1 Defrost solenoid valve HPT High-pressure sensor HPS High-pressure switch FL1 No.1 current fuse SW ON-OFF On-Off switch AR SOL Engine stop solenoid relay PL M Run lamp SW PTI Switch (pti)
GU Alternator SV2-2 Defrost solenoid valve LPT Low-pressure sensor OPS Oil pressure switch FL2 No.2 current fuse SW D-E Diesel-elec switch AR HS Engine high solenoid relay PL C Cooling lamp SW WISP Switch (whisper)
SM Starter motor SV3 Unloader solenoid valve TDS Discharge gas temperature sensor WTS Water temperature switch F1 Control line fuse SW CONT Run mode change switch AR MO Motor relay PL H Heating lamp SW DEF Switch (defrost)
PH Pre-heater SV4 Condenser solenoid valve EVT Evaporator outlet temperature sensor LM Limit switch F2 Relay circuit fuse SW M Main switch AR M Run switch relay PL MOT Motor lamp SW UP Switch (up)
SOL RS Engine stop solenoid SV5 Liquid bypass solenoid valve TH1 Return air temperature sensor OLS Oil level switch F3 SOLHS fuse SW REM Remote control unit switch AR AC AC power supply detection relay PL D Defrost lamp SW DOWN Switch (down)
SOL HS Engine high solenoid EEV1 Electronic expansion valve THD1-1 Supply air temperature sensor FWS Flywheel sensor F4 Fan magnetic clutch fuse MC1 Motor contactor AR SR Starter relay PL EM Alarm lamp SW MODE Switch (mode)
MCL Fan magnetic clutch THD1-2 Supply air temperature sensor F8 External load fuse MC2 Motor contactor AR PH Pre-heater relay BZ Buzzer (unit) SW ENT Switch (enter)
M Motor ATS Ambient air temperature sensor APR Opposite phase relay (RCU) Remote control unit
OCR Over current relay

- 27 -
12.2 Wiring layout drawing

- 28 -
13. DESCRIPTION OF OPERATION
13.1 Sub-engine drive
(1) Startup control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Operation
sequence

Code SOL EEV1

AR AR AR AR AR AR AR AR
RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5 Expansion
Operating SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture

① Operation switch ON ○ ○ ○ × × × × × × × × × × × 0 pulse ○ ○

② 2 seconds after ① × ○ ○ × × × × × × × × × × × 0 pulse ○ ○
③ 10 seconds after ① × ○ ○ × × ○ × × ○ × × ○ ○ × 0 pulse ○ ○
④ 15 seconds after ① × ○ ○ ○ × × ○ × ○ × × ○ ○ × 0 pulse ○ ○
⑤ Engine speed≧700/min- 1 × ○ × × × × ○ × ○ × × ○ ○ × 0 pulse ○ ○
⑥ 3 seconds after ⑤ × ○ × × × × ○ × ○ × × ○ ○ × 0 pulse ○ ○
Specified
⑦ 8 seconds after ⑤ × ○ × × × × ○ × ○ × × ○ ○ × aperture ○ ○
At cooling
× Specified
⑧ 11 seconds after ⑤ × ○ × × × × ○ × ○ × ○ ○ × aperture ○ ○
At heating
〇
At cooling At cooling
Initial
× 〇 aperture at
⑨ 13 seconds after ⑤ × ○ × × × × ○ × ○ × ○ × cooling ○ ○
At heating At heating 0 pulse at
〇 × heating

- 29 -
(2) Cooling operation control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Operation
sequence

Code SOL EEV1

AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5
SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture

Just after startup control × ○ × × × × ○ × ○ × × ○ ○ × ※4 ○ ○

※1 Capacity control ① × ○ × × × × ○ × ○ × × ○ ○ ×※5 ※4 ○ ○
Capacity control ② × ○ × × × × ○ × ○ × × × ○ × ※4 ○ ○
※2 Capacity control ③ ※3 × ○ × × × × ○ ○ ○ × × × ○ × ※4 ○ ○
※ 3: No capacity control ③ at whisper operation
※ 4: EEV1 controls super-heat.

1. Capacity control 2. Protective control

(1) Capacity control switching conditions (Under the When it falls in one of the following conditions, the
following conditions, the capacity control proceeds in capacity control proceeds in the order of ③→②→①.
the order of ①→②→③. ※ 1) (1) High pressure protection
(a) Supply air temperature > Supply air temperature When High pressure ≧ High pressure protection
judgment value value, and in case of capacity control ①, EEV1 is
(b) Operation time is longer than the specified. squeezed.
(c) High pressure ≦ High pressure standard value (2) Low pressure protection
When Low pressure ≦ Low pressure protection value,
(2) Capacity control switching conditions (Under the
and in case of capacity control ①, EEV1 is opened.
following conditions, the capacity control proceeds in
(3) High temperature protection
the order of ③→②→①. ※ 2)
When Discharge gas temperature ≧ High temperature
(a) Supply air temperature < Supply air temperature
protection value, and in case of capacity control ①,
judgment value
SV5 is energized. ※5
(b) Operation time is longer than the specified.
(c) EEV1 aperture is at the specified value.

- 30 -
(3) Heating operation control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Operation
sequence

Code SOL EEV1

AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5
SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture

Just after startup control × ○ × × × × ○ × ○ × ○ ○ × × 0 pulse ○ ○

※1 Capacity control ① × ○ × × × × ○ × ○ × ○ ○ × ×※5 0 pulse ※4 ○ ○
Capacity control ② × ○ × × × × ○ × ○ ○ × × × ×※5 0 pulse ※4 ○ ○
※ 2 Capacity control ③ ※ 3 × ○ × × × × ○ ○ ○ ○ × × × ×※5 0 pulse ※4 ○ ○
※ 5 When continued
beyond standard time ○ ○
Specified
(Starts operation with × ○ × × × × ○ × ○ ×5 sec. ×5 sec. × ○ ○ aperture
○ ○
capacity control ② later later
20 seconds later.)
※ 3: No capacity control ③ at whisper operation

1. Capacity control 2. Protective control

(1) Capacity control switching conditions (Under the (1) High pressure protection
following conditions, the capacity control proceeds When High pressure ≧ High pressure protection value,
in the order of ①→②→③. ※ 1) and in case of that EEV1 is opened at capacity control
(a) Supply air temperature < Supply air temperature ① and ②, EEV1 is squeezed and SV4 is energized.
judgment value (2) Low pressure protection
(b) Operation time is longer than the specified. When Low pressure ≦ Low pressure protection value,
(c) EEV1 = 0 pulse SV2-1, SV2-2 and SV5 are energized.
(3) High temperature protection
(2) Capacity control switching conditions (Under the
When Discharge gas temperature ≧ High temperature
following conditions, the capacity control proceeds
protection value, SV5 is energized.
in the order of ③→②→①. ※ 2)
(a) Supply air temperature > Supply air temperature ※ 5 When High pressure ≦ High pressure standard value,
judgment value SV5 is energized.
(b) Operation time is longer than the specified.
(c) EEV1 aperture is at the specified value.

※4 In case of capacity control ① or ② and Supply air

temperature > Supply air temperature judgment value,
EEV1 is opened.

- 31 -
(4) Defrost operation control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Code SOL EEV1
AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5 DCS1 DCS2
SOL (HOLD) PH SR MO HS MCL valve
conditions aperture
At normal × ○ × × × × ○ ○ × ○ ○ × × ×※1 0 pulse ○ ○
At defrosting
At Whisper × ○ × × × × ○ × × ○ ○ × × ×※1 0 pulse ○ ○

1. Defrost starting conditions 4. Protective control

(1) Defrost timer is switched on. When one of the following conditions is satisfied:
(2) Defrost switch is depressed. (1) High pressure protection
When High pressure ≧ High pressure protection value,
2. Defrost ending conditions
SV4 is energized.
(1) Evaporator outlet temperature sensor ≧ Specified
temperature (2) Low pressure protection
(2) Defrost operation continued for more than 30 minutes. When Low pressure ≦ Low pressure protection value,
(3) When defrosting with the defrost switch depressed, the SV2-1, SV2-2 and SV5 are energized.
defrost switch is depressed once more. (3) High temperature protection
When Discharge gas temperature ≧ High temperature
3. Return operation from defrosting
protection value, SV5 is energized.
(1) If defrost ending conditions are satisfied, the processing
stops temporarily. ※ 1 When High pressure ≦ High pressure standard value,
(2) After the temporary stop, the unit operates for several SV5 is energized.
seconds and stops again.
(3) After stopping for 5 seconds, it returns to normal
operation.

- 32 -
(5) Stop process control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Operation
sequence

Code SOL EEV1

AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5
SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture
Operation switch OFF or
①
Thermostat OFF condition × ○ × × × × ○ × ○ ○ ○ ○ ○ × 0 pulse ○ ○
is established.
EEV1 full closure
②
completes. × ○ × × × × ○ × ○ × × ○ ○ × 0 pulse ○ ○
(Retightening completes.)

③ Low pressure≦0.1MPa
continued for more than
10 sec. or 20 sec.
× × × × × × × × × × × × ○ × 0 pulse × ×
elapsed from ② .
④ 2 sec. elapsed from ③ . × × × × × × × × × × × × × × 0 pulse × ×

- 33 -
13.2 Motor drive
(1) Startup control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Operation
sequence

Code SOL EEV1

AR
RS
AR AR AR
BZ GU
AR AR
SV2-1 SV 2-2 SV3 SV4 SV5 Expansion AR AR
Operating SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture

① Operation switch ON × × × × × ○ × × ○ × × × × × 0 pulse ○ ○

② 5 sec. after ① × × × × ○ × ○ × ○ × × ○ ○ × 0 pulse ○ ○
③ 3 sec. after ② × × × × ○ × ○ × ○ × × ○ ○ × 0 pulse ○ ○
Specified
④ 8 sec. after ② × × × × ○ × ○ × ○ × × ○ ○ × aperture ○ ○
At cooling
× Specified
⑤ 11 sec. after ② × × × × ○ × ○ × ○ × ○ ○ × aperture ○ ○
At heating
〇
At cooling At cooling
Initial
× 〇 aperture at
⑥ 13 sec. after ② × × × × ○ × ○ × ○ × ○ × cooling ○ ○
At heating At heating 0 pulse at
〇 × heating

- 34 -
(2) Cooling operation control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
EEV1
Operation
sequence

Code SOL
AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5
SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture

Just after startup control × × × × ○ × ○ × ○ × × ○ ○ × ※3 ○ ○

※1 Capacity control ① × × × × ○ × ○ × ○ × × ○ ○ ×※4 ※3 ○ ○
※2 Capacity control ② × × × × ○ × ○ × ○ × × × ○ × ※3 ○ ○
※ 3: EEV1 controls super-heat.

1. Capacity control 2. Protective control

(1) Capacity control switching conditions (Under the When it falls in one of the following conditions, the
following conditions, the capacity control proceeds in capacity control proceeds in the order of ②→①.
the order of ①→②. ※ 1) (1) High pressure protection
(a) Supply air temperature > Supply air temperature When High pressure ≧ High pressure protection
judgment value value, and in case of capacity control ①, EEV1 is
(b) Operation time is longer than the specified. squeezed.
(c) High pressure ≦ High pressure standard value (2) Low pressure protection
When Low pressure ≦ Low pressure protection value,
(2) Capacity control switching conditions (Under the
and in case of capacity control ①, EEV1 is opened.
following conditions, the capacity control proceeds in
(3) High temperature protection
the order of ②→①. ※ 2)
When Discharge gas temperature ≧ High temperature
(a) Supply air temperature < Supply air temperature
protection value, and in case of capacity control ①,
judgment value
SV5 is energized. ※4
(b) Operation time is longer than the specified.
(c) EEV1 aperture is at the specified value.

- 35 -
(3) Heating operation control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
EEV1
Operation
sequence

Code SOL
AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5
SOL PH SR MO HS MCL valve DCS1 DCS2
conditions (HOLD) aperture

Just after startup control × × × × ○ × ○ × ○ × ○ ○ × × 0 pulse ○ ○

※1 Capacity control ① × × × × ○ × ○ × ○ × ○ ○ × ×※4 0 pulse ※3 ○ ○
※2 Capacity control ② × × × × ○ × ○ × ○ ○ × × × ×※4 0 pulse ※3 ○ ○
※ 4 When continued
beyond standard time ○ ○
Specified
(Starts operation with × × × × ○ × ○ × ○ ×5 sec. ×5 sec. × ○ ○ aperture ○ ○
capacity control ② later later
20 seconds later.)

1. Capacity control 2. Protective control

(1) Capacity control switching conditions (Under the (1) High pressure protection
following conditions, the capacity control proceeds When High pressure ≧ High pressure protection value,
in the order of ①→②. ※ 1) and in case of that EEV1 is opened at capacity control
(a) Supply air temperature < Supply air temperature ① and ②, EEV1 is squeezed and SV4 is energized.
judgment value (2) Low pressure protection
(b) Operation time is longer than the specified. When Low pressure ≦ Low pressure protection value,
(c) EEV1 = 0 pulse SV2-1, SV2-2 and SV5 are energized.
(3) High temperature protection
(2) Capacity control switching conditions (Under the
When Discharge gas temperature ≧ High temperature
following conditions, the capacity control proceeds
protection value, SV5 is energized.
in the order of ②→①. ※ 2)
(a) Supply air temperature > Supply air temperature ※ 4 When High pressure ≦ High pressure standard value,
judgment value SV5 is energized.
(b) Operation time is longer than the specified.
(c) EEV1 aperture is at the specified value.

※ 3 In case of capacity control ① or ② and Supply air

temperature > Supply air temperature judgment value,
EEV1 is opened.

- 36 -
(4) Defrost operation control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Code SOL EEV1
AR AR AR AR AR AR Expansion AR AR
Operating RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5 DCS1 DCS2
SOL (HOLD) PH SR MO HS MCL valve
conditions aperture
At defrosting × × × × ○ × ○ × × ○ × × × ×※1 0 pulse ○ ○

1. Defrost starting conditions 4. Protective control

(1) Defrost timer is switched on. When one of the following conditions is satisfied:
(2) Defrost switch is depressed. (1) High pressure protection
When High pressure ≧ High pressure protection value,
2. Defrost ending conditions
SV4 is energized.
(1) When the defrosting operation has continued for more
than 2 minutes with Evaporator outlet temperature sensor (2) Low pressure protection
≧25°C. When Low pressure ≦ Low pressure protection value,
(2) Defrost operation continued for more than 30 minutes. SV2-1, SV2-2 and SV5 are energized.
(3) When defrosting with the defrost switch depressed, the (3) High temperature protection
defrost switch is depressed once more. When Discharge gas temperature ≧ High temperature
protection value, SV5 is energized.
3. Return operation from defrosting
(1) If defrost ending conditions are satisfied, the processing ※ 1 When High pressure ≦ High pressure standard value,
stops temporarily. SV5 is energized.
(2) After the temporary stop, the unit operates for several
seconds and stops again.
(3) After stopping for 5 seconds, it returns to normal
operation.

- 37 -
(5) Stop process control

Status of operation of relays or solenoid valves is as shown below. (○: Power on, ×: Power off)
Code SOL EEV1
Operation
sequence

AR AR AR AR AR AR Expansion AR AR
RS BZ GU SV2-1 SV 2-2 SV3 SV4 SV5
Operating SOL PH SR MO HS MCL valve DCS1 DCS2
(HOLD) aperture
conditions
Operation switch OFF or
① Thermostat OFF condition × × × × ○ × ○ × ○ ○ ○ ○ ○ × 0 pulse ○ ○
is established.
EEV1 full closure
② completes. × × × × ○ × ○ × ○ × × ○ ○ × 0 pulse ○ ○
(Retightening completes.)
Low pressure≦0.1MPa
③ continued for more than
10 seconds or 20 seconds
× × × × × ○※1 × × × × × × ○ × 0 pulse × ×
elapsed from ②.

④ 2 sec. elapsed from ③. × × × × × ○※1 × × × × × × × × 0 pulse × ×

※1: Buzzer sounds 3 times.

- 38 -
13.3 Unit control method
(1) Automatic start/stop operation
In this operation pattern, the sub-engine or motor is started or stopped depending on the judgment of thermostat in order
to maintain the inside container temperature at around the setting temperature.
As it reaches the setting temperature (for the heating operation in the chilled range only, the setting temperature + 1°C),
the thermostat turns OFF and the cooling or heating operation stops. (However, if it is shorter than the minimum power
operation time, the sub-engine or motor continues to run even after reaching the setting temperature.)
If the difference between the setting temperature and the inside container temperature exceeds the specified value (see
table below), the thermostat turns ON and the operation restores. (However, until the minimum power stop time is
satisfied, the operation is suspended.) There is no heating operation in the frozen range.

(a) Setting temperature range

Temperature Range Setting Temperature Range
Frozen range Setting temperature ≦ -12°C
Soft frozen range -12°C < Setting temperature < -5°C
Chilled range -5°C ≦ Setting temperature ≦ +5°C
Cooling, normal temperature range +5°C < Setting temperature

(b) Thermostat judgment

Temperature range
Frozen range Soft frozen range Cooling･normal temperature range Chilled range
Thermostat condition
Inside container temperature sensor has detected higher than the setting temperature + 2°C
Stop →Thermostat ON
(Changeable between +1 and +6°C *).
Cooling

Inside container temperature sensor has detected higher than the setting temperature + 2°C
Thermostat OFF→ON
(Changeable between +1 and +6°C *) for more than 5 seconds.
Inside container temperature sensor has detected lower than the setting temperature for more
Thermostat ON→OFF
than 5 seconds.
Inside container temperature sensor has detected Inside container temperature sensor
Stop →Thermostat ON lower than the setting temperature –2°C has detected lower than the setting
(Changeable between –1 and – 6°C *). temperature –1°C.
Inside container temperature sensor has detected Inside container temperature sensor
lower than the setting temperature –2°C has detected lower than the setting
Heating

Thermostat OFF→ON (Changeable between –1 and – 6°C *) for more temperature –1°C for more than 5
than 5 seconds. seconds.
Inside container temperature sensor
Inside container temperature sensor has detected
has detected higher than the setting
Thermostat ON→OFF higher than the setting temperature for more
temperature +1°C for more than 5
than 5 seconds.
seconds.
* If this value (thermostat resetting temperature difference) of the inside container temperature sensor is changed, both
the cooling and heating sides are changed to the same value with different signs at soft frozen range and cooling･
normal temperature range. (See page 64 for changing procedure.)

(c) Thermostat switching map

Thermostat switching in frozen range

Cooling thermostat ON

Thermostat OFF stop

Heating thermostat ON

.-3.0 -2.0 -1.0 0 +1.0 +2.0 +3.0 (°C)

Difference between setting temperature and inside container temperature

- 39 -
 Thermostat switching in soft frozen range and cooling-normal temperature range

Cooling thermostat ON

Thermostat OFF stop

Heating thermostat ON

.-3.0 -2.0 -1.0 0 +1.0 +2.0 +3.0 (°C)

Difference between setting temperature and inside container temperature

Thermostat switching in chilled range

See Item (d).

Cooling thermostat ON

Thermostat OFF stop

Heating thermostat ON

.-3.0 -2.0 -1.0 0 +1.0 +2.0 +3.0 (°C)

Difference between setting temperature and inside container temperature

(d) Chilled cooling forced thermostat OFF

When all of certain conditions are satisfied during the cooling operation in the chilled range, even if the difference
between the setting temperature and the inside container temperature meets the thermostat ON condition, the
thermostat is turned OFF forcibly in order to prevent freezing hazard.

(2) Auto start/stop capacity control

(a) Cooling operation
As the startup of sub-engine or motor completes, the super-heat control is conducted by means of the electronic
expansion valve in order to use the maximum capacity. Capacity control with the sub-engine or motor is as follows.

Capacity control at engine drive

Operation No. Throttle Solenoid (ARHS) Unloader Solenoid Valve (SV3)

1 Power off Low: 1450 + 100min-1 Power on Compressor partial (50%: 2-cylinder)

2 Power off Low: 1450 + 100min-1 Power off Compressor full load (100%: 4-cylinder)
-1
3 Power on Hi: 2100 + 100min Power off Compressor full load (100%: 4-cylinder)

Capacity control at motor drive

Operation No. AC Motor Relay (ARMO) Unloader Solenoid Valve (SV3)

1 Power on Motor running Power on Compressor partial (50%: 2-cylinder)

2 Power on Motor running Power off Compressor full load (100%: 4-cylinder)

- 40 -
 After completing the startup, the unit operates with the cooling operation No. 1. If the supply air temperature becomes
higher than the specified value, the high pressure becomes lower than the specified value and further the operation of
same No. has continued for more than 130 seconds, the unit raises its capacity in the order of the cooling operation No.
1→No. 2→No. 3 (for the motor drive operation, the cooling operation No. 1→No. 2).
If the supply air temperature is lower than the specified value and the operation of same operation No. has continued
for 130 seconds, the capacity is brought down in the order of No. 3→No. 2→No. 1 (for the motor drive operation, the
cooling operation No. 2→No. 1).
When the supply air temperature during the cooling operation No. 1 is lower than the specified value, the capacity
control is carried out with the electronic expansion valve.
During the WHISPER operation with the sub-engine, the capacity control does not use the cooling operation No. 3.

(b) Heating operation

Capacity control during engine drive
Defrost Solenoid Valve Defrost Solenoid Valve
Operation No. Throttle Solenoid (ARHS) Unloader Solenoid Valve (SV3) (SV2-1) (SV2-2)
-1
1 Power off Low: 1450 + 100min Power on Compressor partial (50%: 2-cylinder) Power off Power on
2 Power off Low: 1450 + 100min-1 Power off Compressor full load (100%: 4-cylinder) Power on Power off
3 Power on Hi: 2100 + 100min-1 Power off Compressor full load (100%: 4-cylinder) Power on Power on

Capacity control at motor drive

Defrost Solenoid Valve Defrost Solenoid Valve
Operation No. AC Motor Relay (ARMO) Unloader Solenoid Valve (SV3) (SV2-1) (SV2-2)

1 Power on Motor running Power on Compressor partial (50%: 2-cylinder) Power off Power on
2 Power on Motor running Power off Compressor full load (100%: 4-cylinder) Power on Power off

After completing the startup, the unit operates with the heating operation No. 1. If the supply air temperature is lower
than the specified value and an operation continues for certain period (60 seconds for the heating operation No. 1 or
130 seconds for the heating operation No. 2), the unit increases its capacity in the order of the heating operation No. 1
→No. 2→No. 3 (for the motor drive operation, the heating operation No. 1→No. 2).
If the supply air temperature is higher than the specified value and the operation of same operation No. has continued
for 130 seconds, the capacity is brought down in the order of No. 3→No. 2→No. 1 (for the motor drive operation, the
heating operation No. 2→No. 1).
When the supply air temperature during heating operation No. 1 and No. 2 is higher than the specified value, the
capacity control is carried out with the electronic expansion valve. (Simultaneous operations of the cooling circuit and
the heating circuit)

(3) Continuous operation

With this operation pattern, the sub-engine or motor operates continuously and the capacity is controlled by the control
of circulated amount of refrigerant, etc. in order to maintain the inside container temperature at the setting temperature.

Cooling operation

Capacity control

Heating operation

.-3.0 -2.0 -1.0 0 +1.0 +2.0 +3.0 (°C)

Difference between setting temperature and inside container temperature
If the temperature is brought to the setting temperature by means of the pull-up or pull-down, the capacity control is
taken care with the electronic expansion valve. The capacity control maintains the inside container temperature at the
setting temperature by keeping the supply air temperature to the specified value with the control of electronic expansion
valve. If the inside container temperature becomes more than +1.5°C higher than the setting temperature, as shown by
the figure above, the cooling operation is controlled in the same way as the automatic start/stop operation. If the
temperature becomes more than –1.5°C lower than the setting temperature, the heating operation is controlled in the
same way as the automatic start/stop operation.
- 41 -
(4) Defrost operation
To prevent the loss of cooling effect by the frost accumulated on the evaporator, the defrost timer (which is set at 6
hours at the shipping from factory) initiates a more sure removal of frost.
Setting time of the defrost timer can be changed at the unit of one hour up to 12 hours in consideration of the frosting
speed, etc.
Evaporator outlet temperature sensor switches the operation to cooling. When being driven with the sub-engine, the
defrost operation is conducted at the high speed operation. Heating operation No. 3 is used with the sub-engine drive
operation, while it is the heating operation No. 2 with the motor drive operation. (When the WHISPER operation is
selected, the heating operation No. 2 is used also with the sub-engine drive operation.) If the defrost operation continues
still 30 minutes after the start of defrost operation, the defrost operation is terminated forcibly. During the defrost
operation, the magnet clutch is de-energized to stop the evaporator fan so that hot air will not be released into the
container.
As the defrosting completes, the sub-engine or motor stops temporarily, restarts and then starts the cooling operation.
When very watery cargoes have been loaded or the cooling in the container is slow, the defrost operation can be carried
out manually. Manual defrost can be started with the thermostat being turned off. Manual defrost operation can be
stopped any time by pressing the defrost switch once more.

(5) Return air temperature control

If the return air temperature control is selected under the inside container temperature control setting or any error occurs
on the supply air temperature sensor, the return air temperature control is carried out. In this case, it controls to maintain
the return air temperature at the setting temperature.
With the return air temperature control, the automatic start/stop operation is conducted forcibly regardless of the setting
with the operation pattern selector switch.

(6) Supply air temperature control

If the supply air temperature control is selected under the inside container temperature control setting or any error
occurs on the return air temperature sensor, the supply air temperature control is carried out.
With the supply air temperature control, the capacity control under the continuous operation is conducted forcibly
regardless of the setting with the operation pattern selector switch.
During the supply air temperature control, the supply air temperature is displayed as the inside container temperature
and the “ ” icon is turned off.

(7) PTI operation (Self diagnosis function)

PTI (Pre-trip inspection) is a function to automatically self-diagnose the unit’s component parts.
To start the PTI, start up the control panel and press the PTI switch. When the unit is operated with the sub-engine or
motor, pressing the PTI switch stops the drive temporarily before starting the PTI operation. Control panel shows
“ ” on the LCD.
As the PTI completes the LCD on the control panel displays “ ”. If the PTI switch is pressed once again or
the START/RUN-OFF switch is set to OFF, the control panel stops.
If the PTI switch is depressed or the operation switch is set to “OFF” during PTI operation, the PTI stops on the way
(the control panel also stops).
PTI operation is conducted assuming the engine drive operation even if the motor drive operation is selected. If the unit
is connected to the commercial power supply, inspection of motor is conducted at the last step.

- 42 -
Contents of inspection by PTI
Step No. Inspection Time Inspection Item Description
F2 (Operation circuit)
5 sec. F3 (Throttle solenoid)
Checks each fuse for blowing.
1 (Max. 30 sec.) F4 (Fan solenoid clutch)
F8 (External load)
2 5 sec. Battery voltage Checks whether the battery voltage is higher than 12V or not.

3 Approx. 15 sec. MOS FET drive relay Turns each switch ON/OFF to find broken wire or short-circuit.

4 5 sec. Door limit switch Checks the door limit switch.

Return air temperature sensor
Supply air temperature sensor 1
5 sec. Supply air temperature sensor 2
Checks each temperature sensor for broken wire or short-circuit.
5 (Max. 30 sec.) Evaporator outlet temperature sensor
Ambient temperature sensor
Discharge gas temperature sensor
5 sec. High-pressure sensor Energizes the defrost solenoid valves 1 and 2 to see whether the pressures
6 (Max. 30 sec.) Low-pressure sensor balance or not.
High-pressure switch
5 sec. Water temperature switch
Checks contactor on each switch.
7 (Max. 30 sec.) Oil pressure switch
Oil level switch
5 sec. Energizes the condenser inlet solenoid valve to check the high pressure.
8 (Max. 30 sec.) Gas leakage (This is not performed if the ambient temperature is lower than –10°C.)
9 5 sec. Pre-heater Energizes the pre-heater to check the voltage drop.

10 5 sec. Starter motor Energizes the starter motor to check the voltage drop.
Checks whether the engine can be started up or not. Checks also the engine
11 Approx. 30 sec. Engine startup speed sensor.
5 sec. Checks the discharge gas temperature sensor. (This is not performed if the
12 (Max. 90 sec.) Discharge gas temperature sensor ambient temperature is lower than –20°C.)
13 5 sec. Alternator Checks the alternator generating voltage.
5 sec.
14 Engine low speed Checks the engine low speed.
(Max. 90 sec.)
Turns power ON/OFF to the throttle solenoid to check the difference of
15 10 sec. Throttle solenoid engine speeds.
16 5 sec. (Max. 90 sec.) Engine high speed Checks the engine high speed.
Approx. 20 sec. Initiates the pump-down stop to see if the low pressure becomes negative or
17 (Max. 60 sec.) Pump-down not.
Opens the electronic expansion valve to see if the low pressure restores from
18 5 sec. (Max. 15 sec.) EEV negative pressure or not.
Approx. 60 sec. Restarts the engine. Energizes and de-energizes the unloader solenoid valve
19 (Max. 90 sec.) SV3 to check the low pressure difference.
Approx. 30 sec. Energizes and de-energizes the condenser inlet solenoid valve to check the
20 (Max. 60 sec.) SV4 high pressure difference.
Energizes the defrost solenoid valve 1 under the negative pressure state after
21 15 sec. SV2-1 the pump-down stop, to see if it restores from negative pressure or not.
Restarts the engine. Energizes the defrost solenoid valve 2 under the negative
22 Approx. 50 sec. SV2-2
pressure state, to see if it restores from negative pressure or not.
Restarts the engine. Energizes the liquid bypass solenoid valve under the
23 Approx. 50 sec. SV5 negative pressure after the pump-down stop, to see if it restore from negative
pressure or not.
Checks the motor operation.
24 Approx. 90 sec. Motor operation This check is skipped unless the unit is connected to commercial power
supply.

- 43 -
14. DETAIL SETTING
14.1Setting change mode
Press the [MODE] switch once on the normal display screen to select the setting change mode. Each push on the [UP] or
[DOWN] switch changes the display.
In the following figure, the [DOWN] switch progresses the changes while the [UP] switch reverses the sequence.

Current error display mode

Displays the code of error
being detected.

Normal display screen

Printer output setting mode Clock setting mode

Mode to print the log data. Mode to display and set
Optional printer is the current time.
necessary to print.

See page 45 See page 54

Defrost interval timer setting mode Cumulative time 3 display mode (Motor)
Mode to display and set Displays the cumulative
the defrost interval timer. motor operation time
Unit is hour. This is set at recorded on the controller.
6 hours at shipping from
factory.

See page 47 See page 53

ON timer setting mode Cumulative time 2 display mode

Mode to set the time when Displays the cumulative
starting automatically the sub-engine operation time
operation of refrigeration 2 recorded on the
unit. controller.

See page 48 See page 53

OFF timer setting mode Cumulative time 1 display mode

Mode to set the time when Displays the cumulative
stopping automatically the sub-engine operation time
operation of refrigeration 1 recorded on the
unit. controller.
The time can be reset.

See page 50 See page 53

Sleep operation setting mode User setting mode

Mode to shift automatically Mode to display and set
to the protective operation the functions related to the
setting when the unit oper- controller operability, etc.
ation has been stopped for
more than 2 weeks.

See page 52 See page 56

- 44 -
(1) Setting the printer

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to select the printer

output setting mode.

Press the [SET] switch to change to the print out

start/stop setting screen.

Press the [UP] or [DOWN] switch to select ON.

- 45 -
Press the [SET] switch to confirm the setting and to
change to the printout range setting change screen.

Press the [UP] or [DOWN] switch to select how many

hours earlier from the present the data to output was
recorded.

Time can be selected from 9 steps ranging from

the minimum of 12H (12 hours earlier) to the
maximum of 7d (7 days earlier).

Press the [SET] switch to start the printing.

- 46 -
(2) Setting the defrost interval timer

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to select the defrost

interval timer setting mode.

Press the [SET] switch to change to the setting time

change screen.

Change the setting time using the [UP] or [DOWN]

switch.

Time can be selected from 12 steps ranging from

the minimum of 1H (per hour) to the maximum of
12H (at every 12 hours).

Press the [SET] switch to complete the setting.

- 47 -
(3) Setting the ON timer

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to select the ON timer

setting mode.

Press the [SET] switch to change to the ON timer

enable/disable setting screen.

Press the [UP] or [DOWN] switch to select ON.

- 48 -
Press the [SET] switch to change to the ON time change
screen.

Press the [UP] or [DOWN] switch to adjust to the setting

time (hour).

Clock shows the time up to 24 hours.

Set 19 (hours) if it is 7 o’clock PM.

Press the [SET] switch to change to the time setting

(minute).

Press the [UP] or [DOWN] switch to adjust to the setting

time (minute).

Press the [SET] switch to complete the setting.

- 49 -
(4) Setting the OFF timer

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to select the OFF timer

setting mode.

Press the [SET] switch to change to the OFF timer

enable/disable screen.

Press the [UP] or [DOWN] switch to select ON.

- 50 -
Press the [SET] switch to change to the OFF time change
screen.

Press the [UP] or [DOWN] switch to adjust to the setting

time (hour).

Clock shows the time up to 24 hours.

Set 19 (hours) if it is 7 o’clock PM.

Press the [SET] switch to change to the time setting

(minute).

Press the [UP] or [DOWN] switch to adjust to the setting

time (minute).

Press the [SET] switch to complete the setting.

- 51 -
(5) Setting the sleep operation

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to select the sleep

operation setting mode.

Press the [SET] switch to change to the sleep operation

enable/disable screen.

Press the [UP] or [DOWN] switch to select ON.

Press the [SET] switch to complete the setting. For further details, refer to page 4.

- 52 -
(6) Displaying the cumulative times 1, 2 and 3 (Motor)

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the

cumulative time 1.

Cumulative time 1 can be reset. See page 92.

Pressing the [DOWN] switch once while the cumulative

time 1 is displayed changes the display to the
cumulative time 2.

Pressing the [DOWN] switch once while the cumulative

time 2 is displayed changes the display to the
cumulative time 3 (Motor).

- 53 -
(7) Setting the clock

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to select the clock

setting mode.

Press the [SET] switch to change to the time changing

screen (hour).

Press the [UP] or [DOWN] switch to adjust to the current

time (hour).

Clock shows the time up to 24 hours.

Set 19 (hours) if it is 7 o’clock PM.

- 54 -
Press the [SET] switch to change to the time changing
screen (minute).

Press the [UP] or [DOWN] switch to adjust to the current

time (minute).

Press the [SET] switch to complete the setting.

- 55 -
14.2 User setting mode
Following items are displayed with the user setting mode. In the following figure, the [DOWN] switch progresses the
changes while the [UP] switch reverses the sequence.

Minimum power operation time setting mode

This function inhibits the unit from being
stopped with the thermostat OFF till the
setting time elapses after starting the
drive with the sub-engine or motor in
order to optimize the frequency of start
and stop, and to prevent flat battery.
Setting range is 4~30 minutes, which can
be changed minute by minute. (This is
set at 4 minutes at shipping from factory.)
User setting mode
See page 58

Minimum power stop time setting mode Celsius, Fahrenheit display setting mode
This function inhibits the unit from Selects the unit of temperature (°C or °F).
operating till the setting time elapses (°C is selected at shipping from factory.)
after stopping the driving power when the
sub-engine or motor has been stopped
with the thermostat OFF, in order to
optimize the frequency of start and stop
and to save the fuel consumption during
the automatic start/stop operation.
Setting range is 1~30 minutes, which can
be changed minute by minute.
See page 60 (This is set at 8 minutes at shipping from See page 75
factory.)

Maximum power stop time setting mode Inside container temperature control setting mode
When the cooling or heating operation Used to set the following temperature controls.
conditions are not satisfied after the Return air, supply air temperature control
(At shipping from factory):
setting time has elapsed following the Controls using both the return air temperature
power stop by the thermostat OFF during sensor and the supply air temperature sensor.
the auto start/stop operation, this Return air temperature control:
function resets the operation inhibition Controls with the return air temperature sensor
forcibly and restarts the operation. only. With this setting, the automatic start/stop
Setting range is 10~240 minutes, which operation is selected forcibly.
Supply air temperature control:
can be changed minute by minute. Controls with the supply air temperature sensor
(This is not set at shipping from factory.) only. With this setting, the continuous operation is
See page 62 See page 73 selected forcibly.

Thermostat resetting temperature difference setting mode Operation pattern selection setting mode
Sets the cooling or heating thermostat Operation pattern selection setting is used to
conditions for the automatic start/stop select the continuous operation when the setting
temperature is within the preset continuous
operation.
operation selecting temperature range or the
Setting temperature range is +1~-+6°C, automatic start/stop operation if it is out of the
which can be changed in the unit of range. If this function is set to auto select, these
0.5°C. operations are automatically selected overriding
(This is set at 2°C at shipping from the setting of the CONT./AUTO changeover
factory.) switch.
Continuous setting temperature range is –30 ~-
+25°C, which can be changed in the unit of 0.5°C.)
(At shipping from factory, the lower limit value is
See page 64 See page 70 0°C and the upper limit value is 3°C.)

Forced thermostat resetting temperature difference setting mode Out of adequate temperature thermostat setting mode
If the setting temperature difference is If the inside container temperature entered
reached while the operation is inhibited once in the range of thermostat reset
by the restriction with the minimum temperature difference after starting the
power stop time during the automatic operation but it becomes higher or lower
start/stop operation, this function cancels than the out of adequate temperature, this
the operation inhibition and restarts the function makes flicker the “ ” mark
operation. on the control panel LCD.
Setting temperature range is +2~-+10°C, Setting temperature range is +2 ~ +6°C,
which can be changed in the unit of 0.5°C. which can be changed in the unit of 0.5°C.
(This is set at 4°C at shipping from (This is set at 4°C at shipping from
See page 66 factory.) See page 68 factory.)

- 56 -
 At each step of setting change operation, a push on the [MODE] switch scrolls back to the last
previous step. If this scroll back is operated, the subsequent setting changes become invalid. When
a setting change is aborted on the way, foregoing setting change is not reflected so that the previous
setting remains valid.

Freezing protection setting mode Cumulative time 1 reset setting mode

To protect cargoes loaded close to the Function to reset the cumulative time 1
supply air outlet from freezing, this (Cumulative engine operation time).
function controls the supply air Reset the time after replacing engine oil
temperature and adjusts the capacity. and engine oil filter when the error code
The function operates only when the E075 (Engine maintenance demand)
setting temperature is set in the range has occurred.
of -5 ~ +5°C. It is set at enable or
disable.
(Enable is selected at shipping from
factory.)
See page 77 See page 92

LCD backlight setting mode Optional sensor setting mode

Turns on or off the backlight. Mode to enable or disable the optional
(This is set to turn on the backlight at sensor
shipping from factory.)
When it is on, the brightness is
adjustable in 3 steps.

See page 79 See page 89

Switch operation sound setting mode Forced low speed operation resume setting mode
Mode to turn ON/OFF the emission of Determines whether WHISPER
switch operation sound operation setting is used also at the
This setting selects the sound emission next startup or not. If it is set to enable,
or no sound. when the WHISPER operation was on
(Sound emission is selected at shipping at the end of unit operation, it operates
from factory.) with the WHISPER operation at the next
startup. If disable is selected, the
normal operation starts.
(Disable is selected at shipping from
factory.)
See page 81 See page 87

Operation log interval setting mode In-stop log interval setting mode
Sets the interval to record the log during Mode to set the interval to record the log
operation when the operation is stopped
Setting interval is 1~5, 10, 15, 20, 30 or Setting interval is 1~5, 10, 15, 20, 30, 60
60 minutes. minutes or OFF.
(It is set to 10 minutes at shipping from (It is set to OFF at shipping from
factory.) factory.)

See page 83 See page 85

- 57 -
(1) Setting the minimum power operation time

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [SET] switch to change to the minimum power

operation time setting screen.

- 58 -
Press the [UP] or [DOWN] switch to set the time.

Setting range is 4~30 minutes, which can be adjusted

minute by minute.

Press the [SET] switch to complete the setting.

- 59 -
(2) Setting the minimum power stop time

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the minimum power

stop time setting mode.

- 60 -
Press the [SET] switch to change to the minimum power stop
time setting screen.

Press the [UP] or [DOWN] switch to set the time.

Setting range is 1~30 minutes, which can be adjusted

minute by minute.

Press the [SET] switch to complete the setting.

- 61 -
(3) Setting the maximum power stop time

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the maximum

power stop time setting mode.

- 62 -
Press the [SET] switch to change to the maximum power
stop time setting screen.

Press the [UP] or [DOWN] switch to set the time.

Setting range is 10~240 minutes, which can be

adjusted minute by minute.

Press the [SET] switch to complete the setting.

- 63 -
(4) Setting the thermostat resetting temperature difference

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the

thermostat resetting temperature difference setting
mode.

- 64 -
Press the [SET] switch to change to the thermostat
resetting temperature difference setting screen.

Press the [UP] or [DOWN] switch to set the temperature.

Setting range is +1~+6°C, which can be adjusted

in the unit of 0.5°C.

Press the [SET] switch to complete the setting.

- 65 -
(5) Setting the forced thermostat resetting temperature difference

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the forced

thermostat resetting temperature difference setting
mode.

- 66 -
Press the [SET] switch to change to the forced
thermostat resetting temperature difference setting
screen.

Press the [UP] or [DOWN] switch to set the temperature.

Setting range is +2 ~ +10°C, which can be

adjusted in the unit of 0.5°C.

Press the [SET] switch to complete the setting.

- 67 -
(6) Setting the out of adequate temperature thermostat

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the out of

adequate temperature thermostat setting mode.

- 68 -
Press the [SET] switch to change to the out of adequate
temperature thermostat setting screen.

Press the [UP] or [DOWN] switch to set the temperature.

Setting range is +2 ~ +6°C, which can be adjusted

in the unit of 0.5°C.

Press the [SET] switch to complete the setting.

- 69 -
(7) Setting the operation pattern selection

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the operation

pattern selection setting mode.

- 70 -
Press the [SET] switch to change to the operation
pattern selection setting screen.

Press the [UP] or [DOWN] switch to set to Auto.

Press the [SET] switch to change to the continuous

operation thermostat lower limit value setting screen.

Press the [UP] or [DOWN] switch to set the temperature.

Setting range is -30 ~ +25°C, which can be

adjusted in the unit of 0.5°C.

Press the [SET] switch to change to the continuous

operation thermostat upper limit value setting screen.

- 71 -
Press the [UP] or [DOWN] switch to set the
temperature.

Setting range is -30 ~ +25°C, which can be

adjusted in the unit of 0.5°C.

Press the [SET] switch to complete the setting.

- 72 -
(8) Setting the inside container temperature control

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the inside

container temperature control setting mode.

- 73 -
Press the [SET] switch to change to the inside container
temperature control setting screen.

Press the [UP] or [DOWN] switch to select the control.

Setting items are Automatic setting (Auto) →

Return air (rEt) → Supply air (SUP).

Press the [SET] switch to complete the setting.

- 74 -
(9) Setting Celsius, Fahrenheit display

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the Celsius,

Fahrenheit setting mode.

- 75 -
Press the [SET] switch to change to the Celsius,
Fahrenheit setting screen.

Press the [UP] or [DOWN] switch to set the display.

Press the [SET] switch to complete the setting.

- 76 -
(10) Setting the freezing protection

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the freezing

protection setting mode.

- 77 -
Press the [SET] switch to change to the freezing
protection setting screen.

Press the [UP] or [DOWN] switch to set the

enable/disable.

Press the [SET] switch to complete the setting.

- 78 -
(11) Setting the LCD backlight

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the LCD

backlight setting mode.

- 79 -
Press the [SET] switch to change to the LCD backlight
setting screen.

Press the [UP] or [DOWN] switch to set.

Setting items are Always on (on) → 10 seconds on

with switch operation only (on_t) → Always off (off).

Press the [SET] switch to complete the setting.

- 80 -
(12) Setting the switch operation sound

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the switch

operation sound setting mode.

- 81 -
Press the [SET] switch to change to the switch operation
sound setting screen.

Press the [UP] or [DOWN] switch to set the

enable/disable.

Press the [SET] switch to complete the setting.

- 82 -
(13) Setting the operation log interval

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the operation

log interval setting mode.

- 83 -
Press the [SET] switch to change to the operation log
interval setting screen.

Press the [UP] or [DOWN] switch to set the log interval.

Setting times are 1~5 → 10 → 15 → 20 → 30 → 60

minutes.

Press the [SET] switch to complete the setting.

- 84 -
(14) Setting the in-stop log interval

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the in-stop

log interval setting mode.

- 85 -
Press the [SET] switch to change to the in-stop log
interval setting screen.

Press the [UP] or [DOWN] switch to set the log interval.

Setting times are 1~5 → 10 → 15 → 20 → 30 → 60

minutes → off.

Press the [SET] switch to complete the setting.

- 86 -
(15) Setting the forced low speed operation resume

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the forced

low speed operation resume setting mode.

- 87 -
Press the [SET] switch to change to the forced low
speed operation resume setting screen.

Press the [UP] or [DOWN] switch to set the

enable/disable.

Press the [SET] switch to complete the setting.

- 88 -
(16) Setting the optional sensor

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the optional

sensor setting mode.

- 89 -
Press the [SET] switch to change to the GPS setting
change setting screen.

Press the [UP] or [DOWN] switch to set the

enable/disable.

Press the [SET] switch to change to the optional sensor

1 setting screen.

Press the [UP] or [DOWN] switch to set the

enable/disable.

Press the [SET] switch to change to the optional sensor

2 setting screen.

- 90 -
Press the [UP] or [DOWN] switch to set the
enable/disable.

Press the [SET] switch to change to the optional

sensor 3 setting screen.

Press the [UP] or [DOWN] switch to set the

enable/disable.

Press the [SET] switch to complete the setting.

- 91 -
(17) Setting the cumulative time 1 reset

Press the [MODE] switch to select the current error display mode.

Press the [UP] or [DOWN] switch to display the user

setting mode.

Press the [SET] switch to change to the minimum power

operation time setting mode.

Press the [UP] or [DOWN] switch to select the

cumulative time 1 reset setting mode.

- 92 -
Press the [SET] switch to change to the cumulative time
setting value change screen.

Press the [UP] or [DOWN] switch to set the “rSEt”.

Press the [SET] switch to clear the cumulative time.

- 93 -
14.3 Service and maintenance mode
Hold down the [MODE] and [SET] switches simultaneously for 5 seconds on the normal display screen to select the
service and maintenance mode. Following items are displayed in the service and maintenance mode.
In the following figure, the [DOWN] switch progresses the changes while the [UP] switch reverses the sequence.

Special service screen (Initial screen)

Initial screen of the service, mainte-
nance mode. (In each mode, unless
any switch is operated for 10 seconds,
it returns to the normal display screen.
When starting up the controller while
the unit is stopped, the power supply
is turned off unless there is any switch
Normal display screen operation for 10 seconds.)
5 seconds
hold down

Software Ver. display mode Past alarm log display mode

Mode to display the software Mode to display the log of
version. error codes occurred in the
past.

See page 95 See page 112

ID code setting mode Thermistor temperature display mode

Mode to set optional Mode to display the value
identification codes. detected with the thermistor.

See page 96 See page 111

Calendar setting mode Analog sensor display mode

Mode to set the calendar. Model to display the sensor
value corresponding to
analog sensor inputs,
excluding the thermistor.

See page 99 See page 110

Electronic expansion valve output, test display mode Contactor, fuse status display mode
Mode to display the electronic Mode to display the sensor
expansion valve output status value corresponding to digital
and to check the operation of sensor input.
individual electronic
expansion valve outputs.
See page 101 See page 108

Relay output, test display mode

Mode to display the relay
output status and to check the
operation of individual relay
outputs.

See page 104

- 94 -
(1) Displaying the software version

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the software

version display mode.

Press the [SET] switch to display the software version.

Displays alternately.

Left-hand side: Right-hand side:

Main printed board Display printed board
software version software version

- 95 -
(2) Setting the ID code

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the ID code

setting mode.

Press the [SET] switch to display the ID code setting

screen.

Press the [UP] or [DOWN] switch to change to a desired

code.

- 96 -
Press the [SET] switch to display the 3rd and 4th digits
setting screen.

Press the [UP] or [DOWN] switch to change to a desired

code.

Press the [SET] switch to display the 5th and 6th digits
setting screen.

Press the [UP] or [DOWN] switch to change to a desired

code.

Press the [SET] switch to display the 7th and 8th digits
setting screen.

- 97 -
Press the [UP] or [DOWN] switch to change to a
desired code.

Press the [SET] switch to finalize the setting.

- 98 -
(3) Setting the calendar

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the calendar

setting mode.

Press the [SET] switch to display the calendar setting

screen.

Press the [UP] or [DOWN] switch to change the year,

which is displayed by the Christian Era (Gregorian
calendar).

- 99 -
Press the [SET] switch to display the month setting
screen.

Press the [UP] or [DOWN] switch to set the month.

Press the [SET] switch to display the date setting

screen.

Press the [UP] or [DOWN] switch to set the date.

Press the [SET] switch to finalize the date.

- 100 -
(4) Displaying the electronic expansion valve output

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the electronic

expansion valve output display/test mode.

Press the [SET] switch to display the current pulse

number.

- 101 -
(5) Testing the electronic expansion valve output

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the electronic

expansion valve output display/test mode.

Press the [SET] switch to display the current pulse

number.

Press the [DEFROST] switch to display the operation

test screen.

- 102 -
Press the [UP] or [DOWN] switch to conduct the test
operation.

Press the [UP] switch to fully open (240 pulses) the

electronic expansion valve or [DOWN] switch to
fully close (0 pulse) the electronic expansion valve.

Press the [MODE] or [SET] switch to return to the electronic expansion valve output screen.

- 103 -
(6) Displaying the relay output

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the relay

output display/test mode.

Press the [SET] switch to display the relay output

display/test screen.

Press the [UP] or [DOWN] switch to select the relay output to see. See the list on next page for the relay
outputs displayed.

- 104 -
Relay output display list
Display Symbol Relay Symbol

AR MO

AR SOL

AR HS

BZ

SV2-1

SV2-2

SV3

SV4

SV5

AR SR

AR PH

SOL RS

AR MCL

AR DCS1

AR DCS2

GU

- 105 -
(7) Testing the relay output

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the relay

output display/test mode.

Press the [SET] switch to display the relay output

display/test screen.

Press the [UP] or [DOWN] switch to select the relay

being put to the relay test.

- 106 -
Press the [DEFROST] switch to change to the relay
output test screen.

Press the [UP] or [DOWN] switch to change to “on” or

“off”.

Press the [SET] switch to finalize the change.

The relay output test can be carried out only when having started the controller by pressing the
[MODE] switch (the unit is stopped). Outputs cannot be tested while the unit is operating.

- 107 -
(8) Displaying the contactor, fuse status

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the contactor,

fuse status display mode.

Press the [SET] switch to display the contactor, fuse

status display screen.

Press the [UP] or [DOWN] switch to select a contactor or fuse to see. See the list on next page for the
contactors and fuses which can be seen.

- 108 -
Contactor, fuse status display list

Left 7-segment Display Right 7-segment Display

Display Symbol Contactor, Fuse Name

MC Power on Power off

AR AC Power on Power off

OCR Abnormal Normal

HPS Abnormal Normal

OPS Movement Normal

WTS Abnormal Normal

LM Door open Door close

OLS Abnormal Normal

F2 Fuse blown Normal

F3 Fuse blown Normal

F4 Fuse blown Normal

F8 Fuse blown Normal

SW M Movement Normal

SWCONT Continuous operation Auto start/stop

SWD-E Motor drive Engine drive

- 109 -
(9) Displaying the analog sensor

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the analog

sensor display mode.

Press the [SET] switch to display the analog sensor

display screen.

Press the [UP] or [DOWN] switch to select a sensor to see. Following t analog sensors and values are
displayed:

Engine speed 0～9990 min-1 Battery voltage 0.0～16.0 V

High pressure -999～9990 kPa Alternator L terminal voltage 0.0～16.0 V
Low pressure -999～9990 kPa

- 110 -
(10) Displaying the thermistor temperature

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the thermistor

temperature display mode.

Press the [SET] switch to display the thermistor

temperature display screen.

Press the [UP] or [DOWN] switch to select a sensor to see.

Following thermistors are displayed:

TDS THD1-1 ATS Not used Spare 1

EVT THD1-2 Not used Not used Spare 2
TH1 Not used Not used RTH

For a “Not used” sensor, “- - - - ” is displayed at the right 7-segment.

When the inside container temperature is lower than the lower limit, “ ” is displayed on the right
7-segment.
When the inside container temperature exceeds the upper limit, “ ” is displayed on the right 7-segment.

- 111 -
(11) Displaying the past alarm log

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the past

alarm log display mode.

Press the [SET] switch to display the past alarm log

(Error codes displayed in the past).
Starting from the latest error code, it displays alarm
codes one by one at 2 seconds interval.

- 112 -
(12) Erasing the past alarm log

Press the [MODE] and the [SET] switches simultaneously for 5 seconds to select the service and
maintenance mode.

Press the [UP] or [DOWN] switch to select the past

alarm log display mode.

Press the [SET] switch to display the past alarm log.

Hold down the [UP] and the [DOWN] switches

simultaneously for more than 3 seconds to erase the
log.

- 113 -
15. INSPECTION 15.2 Periodic inspection
Implement the periodic inspections for necessary items at the
15.1 Daily inspection
following intervals. For details, see page 126 in addition to
Check the following items with the daily inspection.
the followings. (Also see the Check Sheet of page 132.).
For details, see page 121.
1. Inspection at installation
CAUTION
2. At every 250 hours
Before starting inspection, make sure to turn the main Inspection and cleaning of air cleaner
switch to “OFF” to put the refrigeration unit in the
3. At every 500 hours
stopped condition, disconnect the power supply plug,
and confirm that there is no dangerous condition. Replacement of air cleaner/fuel filter and greasing on
door latches and hinges
1. Inspection of the sub-engine oil quantity 4. At every 1000 hours
2. Inspection of the cooling water quantity and leakage Replacement of cooling water; inspection/cleaning of
injection nozzle; inspection/adjustment of valve
WARNING
clearance (at about 50 hours for initial inspection only);
cleaning of evaporator coil/drain outlet;
When inspecting or replenishing cooling water and oil,
inspection/retouch of painting of main unit; inspection of
wait till the temperature drops sufficiently. Cooling
water and oil are in higher temperatures immediately damaged rubber cushion; inspection of electromagnetic
after stopping the sub-engine. There is risk of burns. clutch; inspection of sub-engine governor lever link;
inspection at around solenoids; inspection of alternator;
3. Inspection of the refrigeration unit indicator lamps retightening of unit installation bolts; inspection
4. Inspection of battery charge condition retightening of mounting bolts; inspection of gas leakage
5. Inspection of refrigerant on refrigerant system; inspection of cooling; inspection
6. Inspection of belt tension of defrost operation; confirmation of motor drive
Inspect 4 pieces of belt for tension (see the operation/inspection of insulation resistance; inspection
illustration). Also check the belts visually for of loose electronic wiring terminals/damaged wire cover;
abnormalities such as cracks, eccentric wear, etc. If movement check of high-pressure switch/door switch and
any belt is found slack, adjust it to the specified inspection of compressor oil for contamination
tension (see the illustration). 5. At every 1500 hours
Replacement of sub-engine oil (at 100 hours at initial
inspection only); replacement of oil filter (at about 100
Alternator belt tension: Fan belt tension: hours at initial inspection only); inspection of starter;
(New belt) 500+100N (New belt) 800+100N
[50+10kgf] [80+10kgf]
water draining from fuel tank/cleaning of fuel pump;
(Re-use belt) 350+50N (Re-use belt) 560+50N inspection (noise) of bearings for idling pulley / tension
[35+5kgf] [56+5kgf] pulley / electromagnetic clutch / fan shaft; and
Reservoir tank replacement of belt (alternator)
6. At every 4000 hours
Replacement of belts (other than alternator); replacement
of bearings for idling pulley / tension pulley /
electromagnetic clutch / fan shaft; replacement of fan
shaft seal; replacement of alternator brush and inspection
of centrifugal clutch shoe for wear
7. At every 6000 hours
Replacement of engine stop solenoid, pre-heater; and
replacement of standby motor bearing, alternator bearing
8. At every 10000 hours
Replacement of starter, engine high solenoid; and
overhaul of sub-engine
9. 1-month inspection and 6-month inspection.
(a) Inspection of sub-engine oil quantity
(b) Inspection of sub-engine oil and fuel for leakage
Compressor belt tension: Water pump belt tension: (c) Inspection of interference with moving sections
(New belt) 1200+100N (New belt) 500+100N
[120+10kgf] [50+10kgf] (d) Cleaning of condenser coil and radiator coil
(Re-use belt) 840+50N (Re-use belt) 350+50N (e) Inspection of cooling water quantity and leakage
[84+5kgf] [35+5kgf]
(f) Inspection of sub-engine speed
(g) Inspection of color and fluid level in the refrigerant
sight glass

- 114 -
 (h) Inspection of belts for slackness and damage To adjust, remove the engine fuel injection pipe,
(i) Inspection of battery nozzle, suction indicator and also the engine head
(j) Inspection of centrifugal clutch for noise and slip cover.
(k) Cleaning of evaporator coil and drain outlet (7) Cleaning of condenser coil, radiator coil, evaporator
(l) Inspection of rubber cushion for damage coil and drain outlet
(m) Inspection of solenoid clutch To clean, wash with water and brush or blast dust
(n) Inspection of sub-engine governor lever link and with compressed air.
related matters
(o) Inspection at around solenoids CAUTION
(p) Inspection of alternator Never use a high pressure washing machine because
(q) Retightening of unit installation bolts it could collapse the condenser fins. Also prohibited is
(r) Inspection, retightening of mounting bolts the steam cleaning because it raises excessively the
pressure in the equipment so much as it is dangerous.
(s) Inspection of gas leakage from refrigerant system
(t) Inspection of cooling
(8) Inspection, retouch of main unit painting
(u) Inspection of defrost operation Inspect metal sections for paint chips, rust, etc.
(v) Check of motor drive operation and inspection of Retouch if necessary.
insulation resistance
(9) Inspection of damaged rubber cushion
(w) Inspection of loose electronic wiring terminals Inspect rubber cushions and replace if damaged. For
and damaged wire cover replacement, see page 116, (34).
(x) Movement check of high-pressure switch, door
(10) Inspection of electromagnetic clutch (abnormal noise,
switch vibration)
(y) Inspection for compressor oil for contamination If abnormal noise, vibration, etc. is detected on the
(z) Replacement of sub-engine oil
electromagnetic clutches, replace. For replacement,
(aa) Replacement of oil filter see page 117, (36).
(ab) Inspection of starter (11) Inspection of sub-engine governor lever link and
(ac) Inspection of idling pulley, tension pulley and
related sections
bearings (12) Inspection at around solenoid
Inspect fouling, movement, etc. on the solenoid
15.3 Inspection and service/repair methods plunger. Check also if the link and related sections
(1) Inspection, replacement of air cleaner operate smoothly or not.
Remove the dust cap from the unit front and inspect (13) Inspection of alternator (abnormal noise)
or replace. Judgment of the replacement interval Inspect the alternator for any abnormal noise. If
could be done by observing the suction indicator found, remove and replace together with the
(optional part) mounted on the sub-engine suction alternator mounting bracket.
manifold. (14) Retightening of unit installation bolts
(2) Replacement of fuel filter (15) Inspection, retightening of parts mounting bolts
Replace it from the unit front. Inspect and retighten mounting bolts of major parts
(3) Greasing of door latches and hinges (sub-engine, compressor, compressor head, motor,
(4) Replacement of cooling water alternator, rubber cushion, pulley, electromagnetic
Remove the radiator cap, slacken the air vent and the clutch, fan, solenoid, fan shaft bearing, etc).
engine cooling water drain bolt and drain cooling (16) Inspection of gas leakage from refrigerant system
water. After draining completely, tighten the drain Inspect for bleeding of oil. When a bleeding spot is
bolt and inject cooling water to the specified quantity. discovered, further inspect carefully with a gas
Positively bleed air and then tighten the radiator cap detector.
and the air vent. (17) Inspection of cooling (inspection of temperature
Then, while running the sub-engine, inject cooling display, high/low pressure)
water from the cooling water inlet port to the “MAX” Check the difference between the temperature shown
position indicated on the reservoir tank (see page on the display and actual temperature inside
114). container. If the difference is larger, inspect the
After replacing cooling water, while running the high/low pressure.
refrigeration unit (with sub-engine running), (18) Inspection of defrost operation
replenish cooling water again from the cooling water Lower the inside container temperature to 0°C or
inlet port. Replenish cooling water to the “MAX” below and check if the defrost solenoid valve trips in
position on the reservoir tank. to start the defrosting when the defrost switch is
(5) Inspection, cleaning of injection nozzle turned on manually. Also check if it drains properly.
Check the nozzle for interference and damage. If it is (19) Motor operation check, inspection of insulation
defective, replace as an assembly. resistance
(6) Inspection, adjustment of valve clearance (at 50 Check the continuity with a tester, etc.
hours for initial inspection)
- 115 -
(20) Inspection of slackened electronic wiring terminals, of about 20mm between the centrifugal clutch
broken wire cover main unit at the engine side and the pulley at the
Closely check for slackened wiring terminals and poor compressor side. Remove any dust, etc. found in
insulation because these could cause short-circuit or the housing.
startup malfunction. (g) Returning the compressor, tighten bolts to the
(21) Operation check of high-pressure switch, door switch specified tightening torque.
Run the unit with a gauge attached on the compressor (h) Using the tension pulley, adjust the tension to
discharge operation valve and shielding the return air the specified value. (Center bolt tightening
inlets of two condensers with pieces of paper. Confirm torque: 44N･m [4.5kgf･m])
that, when the high pressure reaches 3.18MPa (i) Mounting the alternator belt, adjust the tension
(32.5kgf/cm2), the unit stops, the error lamp lights and within the range of specified value.
“ ” is displayed. Also confirm that the unit does (j) Install the battery.
not operate if the unit cover is left open.
<Between motor and fan shaft>
(22) Inspection of contaminated compressor oil
(a) Slacken the tension pulley.
Inspect oil through the compressor sight glass and, if (b) Remove the baffle plate from top of right
the color is changed, replace oil. condenser.
(23) Replacement of sub-engine oil (including inspection of (c) Remove the bell-mouth from within the right
oil leakage; at 100 hours for initial inspection only) condenser shroud.
Drain oil by removing the drain bolt under the oil pan (d) Remove/reinstall the belt.
at the front of sub-engine. Replace the oil filter at the (e) Mount the bell-mouth and baffle plate.
same time. Refill oil from the orange oil cap provided (f) Using the tension pulley, adjust the tension
at right in front of the sub-engine. within the range of specified value. (Center bolt
(24) Replacement of oil filter (at about 100 hours for initial tightening torque: 44 N･m [4.5 kgf･m])
inspection only)
<Engine fan belt>
(25) Inspection of starter
(a) Slacken the tension pulley.
Inspect the starter current, revolving condition, extent
(b) Remove/reinstall the belt.
of wear on brush, gap, etc. (c) Using the tension pulley, adjust the tension
(26) Water draining from fuel tank, cleaning of fuel pump within the range of specified value. (Center bolt
Inspect the condition of water drain from fuel tank and tightening torque: 44 N･m [4.5 kgf･m])
clean if necessary. Clean also the fuel pump. (30) Replacement of bearings for idling pulley, tension
(27) Inspection (noise) of bearings for idling pulley, tension pulley, electromagnetic clutch and fan shaft
pulley, electromagnetic clutch and fan shaft (31) Inspection of wear on centrifugal clutch shoe
Inspect each pulley and bearing for abnormal noise. If the clutch shoe is worn excessively, replace.
(28) Replacement of belts (alternator) (32) Adjustment of sub-engine speed
Slacken the alternator tension bracket to replace. Later, Adjust at the engine throttle lever section in front of
adjust the belt tension to the specified value. (Refer to the unit.
the nameplate attached to the unit.) See page 118 for (33) Replacement of battery
the adjustment of belt alignment. When replacing battery, if the power supply is
(29) Replacement of belts (other than alternator) interrupted for more than 3 hours, the clock built in
See page 118 for the adjustment of belt alignment for the controller is delayed. Replacement must be
each belt. performed as quickly as possible.
(34) Removal/reinstallation of sub-engine
<Between compressor and motor, between motor and
(a) Disconnect the connection to battery (+) terminal.
alternator>
(b) Separate the compressor (compressor housing)
(a) Remove the battery from the unit. (If the battery is and engine. For details, refer to the section (29)
removed for more than 3 hours, the clock built in for the replacement of belt between compressor
the controller is delayed. Reset the clock after the and motor.
work. See page 54.) (c) Remove the exhaust pipe, fuel hose, water hose
(b) Slacken the alternator tension bracket and remove and wiring, etc.
the alternator belt. (d) Remove the cushion bracket at engine top and
(c) Slacken the tension pulley between the compressor the tension pulley bracket.
and the motor. (e) Spread a blanket in the clearance between the
(d) Remove mounting bolts (6 pcs.) between the sub-engine and the flame (10mm).
sub-engine flywheel housing and the compressor (f) Remove engine fixing bolts from bottom of
housing. Support the bottom of compressor with frame.
sleepers, etc. (g) Lift the sub-engine at one side each and insert a
(e) Move the compressor to the left, facing it, by about sleeper of 15 – 20mm in thickness. Remove the
80mm. rubber cushion. Take care at this time not to
(f) Remove and install the belt through the clearance damage the oil pan, frame, etc.
- 116 -
 (h) After placing a pallet in front of the frame with a (w) Pull out the fan shaft, evaporator fan and casing
forklift truck and pull out the sub-engine. to the inside container side.
(35) Replacement of compressor, compressor pulley (x) Pull out the right and left condenser fans
After closing the operation valve and recovering forward and remove.
refrigerant from compressor, remove pipes, etc. and
<To reassemble, reverse the steps of above
then remove the compressor with housing.
procedures. At the reassembly, observe the
Use a new gasket for the operation valve at the
following items faithfully.>
reassembly.
• Take care not to deform the fan by undue stress.
(36) Removal/reassembly of fan shaft and related parts
• Tighten all bolts to respective tightening torques.
(a) Remove the crown cover and right/left side upper
• Adjust the position of casing in a manner that the
covers.
tip clearance will be homogeneous between the
(b) Remove baffle plates from right/left sides of
evaporator fan and the casing.
condenser top.
• Position the shaft seal ASSY securely in a manner
(c) Remove right/left condenser fan bell-mouths and
that the centers of rubber seal and shaft center are
bell-mouth fixing brackets.
aligned.
(d) Slacken and remove the belt.
• Adjust strictly the air gap on the electromagnetic
(e) Remove left condenser fan hub fixing center bolt
clutch armature. For details, refer to the
and fan fixing bolts.
following.
(f) Pull out the fan hub from the shaft using a special
jig and take it out from between the fan and the <Measure the air gap at 4 points in the following
shaft. Take care to recover the woodruff. figure.>
(g) Move the left condenser fan to the back of Top
condenser.
(h) Remove the left bearing unit.
(i) Remove the evaporator fan supply air outlet panel.
(j) Remove bolts fixing the evaporator fan and the
This side Depth
evaporator fan hub.
(k) Remove the fixing bracket from this side of
evaporator fan casing.
(l) Disconnect the evaporator fan casing from a pair of
Bottom
brackets located at the depth and turn toward front
by approximately 90°.
(m) Removing shaft seal ASSY fixing bolts, separate Step 1
it from the heat insulating wall. Turn the shaft (armature plate) at the (This side)
(n) Removing right condenser fan fixing bolts, move position, and put a mark on the circumference of
the fan to the back of condenser. armature plate when the air gap becomes the smallest.
(o) Remove the electromagnetic clutch armature Step 2
ASSY. Take care to recover shims. Adjust the marking on the armature plate at each
(p) Remove the electromagnetic clutch harness. measurement position and measure the air gap.
(q) Removing bolts fixing the electromagnetic clutch Step 3
to the housing, remove it from the frame. When the dispersion in the gaps at 4 measurement
(r) Pull out the fan shaft to the right. positions exceed 0.4mm, slacken the housing fixing
(s) Remove a snap ring from the back of clutch bolts, and adjust by moving the housing in the
housing using an off-the-shelf snap ring remover. direction that reduces the dispersion (move in the
(t) Remove the electromagnetic clutch and the housing direction where the gap is larger). Adjust also shims
ASSY from the fan shaft. Take care that the outer so as to make the minimum gap at 0.3～0.5 mm
circumference of bearing and the clutch house are
likely to tilt because O ring is press-fit for the
anti-creep bearing.
(u) Pull in the left end of fan shaft to the inside
container side of heat insulation wall.
(v) Pull out the left end of fan shaft together with the
casing to a position avoiding the leading end at the
inside container side of heat insulation wall. At
this time, rotate the fan shaft on the fulcrum of the
section penetrating the right side of heat insulation
wall.

- 117 -
(37) Adjustment of belt alignment (Between motor and alternator)
Adjust the belt miss-alignment so that it will After adjusting between the sub-engine～compressor
become less than 1mm. Moreover, adjust the tilt of ～motor, adjust alternator by moving ① based on
each pulley shaft at less than 0.35°. However, the the location of motor. (Adjust the tension at ②.)
tilt of shaft between the motor pulley and the
tension pulley at the condenser fan side must be less
than 0.5°.

Less than 1mm

Less than 0.35° (0.5°)

15.4 List of flare nut and bolt tightening

torque
(Between compressor and motor)
Move the motor to the right or the left based on the (1) Standard tightening torque of flare nut
location of sub-engine/compressor. Position the Copper Tube Tightening Torque N·m (kgf·m)
motor while pressing it against the guide plate
ø6.35 9.9～14.7 (1.0～1.5)
provided at the back of frame mounting face.
ø9.52 19.6～29.4 (2.0～3.0)
ø12.7 34.3～44.1 (3.5～4.5)
ø15.88 49.0～58.8 (5.0～6.0)
ø19.05 58.8～68.6 (6.0～7.0)

Flywheel housing 2mm (2) Tightening torque of general bolts

end face N·m (kgf·m)
Material SS400 S45C SUS304
Thread Head △or 7
Dia. Mark None or 4 None
0.8 + 0.2 1.15 + 0.35 0.9 + 0.1
M3 (0.08 + 0.02) (0.12 + 0.04) (0.09 + 0.01)
1.25 + 0.25 2.0 + 0.5 2.16 + 0.25
M4 (0.13 + 0.03) (0.20 + 0.05) (0.22 + 0.03)
2.16 + 0.25 3.9 + 0.5 3.9 + 0.5
M5 (0.22 + 0.03) (0.40 + 0.05) (0.40 + 0.05)
3.95 + 0.45 7.1 + 0.7 7.1 + 0.7
M6 (0.40 + 0.05) (0.72 + 0.07) (0.72 + 0.07)
9.1 + 0.7 17.2 + 1.5 17.7 + 1.5
M8 (0.93 + 0.07) (1.76 + 0.15) (1.81 + 0.15)
18.3 + 1.3 34.4 + 3.0 35.6 + 2.7
(Between motor and fan shaft) M10 (1.87 + 0.13) (3.51 + 0.31) (3.63 + 0.28)
After adjusting between compressor and motor, 31.3 + 2.1 58.8 +4.9 61.1 + 4.7
M12 (3.19 + 0.21) (6.00 + 0.50) (6.23 + 0.48)
adjust the distance from frame (14mm) as shown
50.0 + 3.4 94.7 + 7.4 98.1 + 7.4
below. M14 (5.10 + 0.35) (9.66 + 0.76) (10.01 + 0.76)
78.9 + 5.4 149.1 + 11.8 154.2 + 11.5
M16 (8.05 + 0.55) (15.21 + 1.20) (15.73 + 1.17)

N·m (kgf·m)
Material SS400

Forward
Head Mark
Thread diameter
8 11

M8 30 34
14mm (3.06) (3.47)

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15.5 Greases and oils
Oil, Antifreeze coolant Capacity
Sub-engine fuel Diesel fuel
(Intense cold season: cold weather fuel) −
Sub-engine oil Type API Class CE or higher 10W-30 13.5L
Refrigeration
machine oil Diamond Freeze MA32R 2.4L

* Antifreeze coolant Fuso Diesel Long Life Coolant Total capacity

(Incl. antifreeze coolant, reservoir tank)
Cooling water Soft water with fewer impurities 7.8L

* Use the antifreeze coolant with the following concentrations according to the lowest outdoor temperature.

Antifreeze coolant concentration (%) 30 35 40 45 50 55 60

Mixed antifreeze coolant amount (L) 2.34 2.73 3.12 3.51 3.9 4.29 4.68

Lowest outdoor temperature (°C) -10 -15 -20 -25 -30 -35 -40
Setting at
shipment

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15.6 Methods of refrigerant recovery, evacuation and refrigerant charging
Since the refrigerant system is closed by solenoid valves, check valves, etc. at the unit operation stop, observe the following
items at the refrigerant recovery, evacuation and refrigerant charge.
(1) Refrigerant recovery
Recover the refrigerant and evacuate system simultaneously from 3 places including 2 service ports at compressor
suction/discharge valves and the check joint provided at the downstream side of dryer.
(2) Refrigerant charge
•Make sure to measure the specified quantity of liquid refrigerant before charging.
•After the evacuation, charge the specified quantity from the service port at compressor discharge valve and the check
joint provided at the downstream side of dryer.
Make sure at that time to open the condenser inlet solenoid valve (SV4) and defrost solenoid valve (SV2-1) according
to 14.3 (7) “Testing the relay output” (page 106, 107). Unless the defrost solenoid valve (SV2-1) is opened, refrigerant
will not be fed to the low-pressure pipe side so that the operation cannot be started because the controller detects a
pressure error.
•When the specified quantity of refrigerant cannot be charged, run the unit and charge the remaining refrigerant
gradually from the suction operation valve. Use at that time the safety charger, etc. not to damage the compressor by
the liquid compression.

CAUTION
It is strictly prohibited to charge liquid refrigerant from the suction operation valve when the unit is stopped.
Otherwise, it will damage the compressor by the liquid compression.

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15.7 Cautionary points for daily inspection
Orient the user to perform the following items:
Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
1 Gas leakage Sight glass allows 1. Refrigerant quantity 1. Shortage of refrigerant 1. Check and repair the
check checking the Inspect if the refrigerant quantity is quantity leaking place, recover
refrigerant quantity normal by referring the section 11.18 on ○ Poor or no refrigeration the refrigerant, evacuate
and the presence of page 25. ○ Abnormal rise of the system, measure
water in the 2. Water inclusion discharge gas and refill the specified
refrigerant. Check If the check color is green, the refrigerant temperature quantity of refrigerant.
these during daily is proper. If it is yellow, the refrigerant is 2. Moisture invasion 2-1. Recover the
inspection. improper containing water. See 11.18 on ○ The expansion valve is refrigerant, replace

To a servicing shop
page 25. clogged. the dryer, evacuate
○ The dryer is clogged. the system, measure
and refill the
specified quantity of
refrigerant.
2-2. Check, also, the oil
level in the
compressor, and
refill the oil in the
same procedure as
above.
2 Condenser coil To prevent the heat The coils should be washed with tapped 1. The condenser coil is Clean the coils off dirt
and radiator exchanger efficiency water by using brush, because the fins of dirty. HPS is operated, frequently.
coil cleaning drop caused by coil the coils will be possibly deformed by and the refrigerating
contamination. pressurized water poured directly. capacity drops.
2. The radiator coil is dirty.
Failure will be induced
by the engine overheat.

3 Paint on main Corrective action to Corrosion, due to stone hit marks, scratch, 1. Hole or crack in the 1. If rust generation is
body paint scaled off or etc. on the painted surfaces, has grown up panel. observed, clean the
corrosion appeared on without awareness. The initial corrosion 2. Fall off of the panel. subjected area with sand
the metallic areas, can be prevented from growing up by paper at the earliest
when the unit is touch-up paint. convenience, and repair
operated for a the area with touch-up

To a servicing shop
considerable long time. paint.
2. Replace a part on
which rust is grown
up to holes or cracks.

4 Precaution for To take sufficient care 1. To prevent oil, water, or other foreign The centrifugal clutch is 1. If possible, do not pour
centrifugal to prevent pressurized materials from sticking to the power thermally seized or the pressurized water to
clutch during water from splashing transmitting surface (shoe and drum) of damaged due to slip or heat the centrifugal clutch.
washing a truck on the centrifugal the centrifugal clutch. generation. If oil or water 2. If washing water sticks to
clutch, when washing 2. To prevent washing water from entering sticks to the contact the centrifugal clutch, dry
truck body or van. and sticking during washing truck. To surfaces between the clutch it completely before
close the clearance between the clutch shoe and drum, the operation.
and engine, by inserting waste cloth or frictional coefficient will 3. If oily material sticks to
news paper prior to washing. rapidly drop. the clutch shoe, replace the
3. To prevent oily material from sticking clutch shoe. Clean the
during inspection of the unit. inner wall of the drum
completely with
degreasing detergent.

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 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
5 Sub-engine To maintain proper 1. To check for cooling water quantity. To 1. Overheat (causing 1. Check cooling water
overheat function of the cooling check cooling water piping system and revolution speed drop and quantity and refill if
system to prevent any radiator for water leakage. output drop). necessary.
failure caused by 2. To check belt for looseness. 2. Thermal seizure on the Check the clamps on the
overheat. 3. To check radiator fin for dirtiness and sliding areas of the cooling water hose
clogging. crankshaft, piston, etc. connection for looseness,
3. The unit stops due to and retighten the clamp.
failure. 2. Tighten the belt to proper
tension.
3. Clean and wash the
radiator fins.

6 Air cleaner Intake air amount 1. To remove and clean or replace the air 1. Revolution speed drops 1. Clean the air cleaner
element insufficient. cleaner element at the specified time. and output drops. element at the specified
2. If the air filter is clogged, oxygen in the 2. The centrifugal clutch is time. (Air blow)
combustion chamber becomes thermally damaged. 2. Replace the air cleaner
insufficient, and the injected fuel can not 3. Refrigerating capacity is element if the dirt is
be completely burned. insufficient. extreme.
4. Exhaust gas color is
improper.
5. Carbon is deposited on
the surrounding areas of
the intake/exhaust valve,
piston top and
combustion chamber.

7 Custody of fuel To prevent the 1. To make sure to use the specified fuel. 1. Revolution speed drops Be sure to use the specified
sub-engine from Diesel fuel (Intense cold season: cold and output drops. fuel for refilling.
failure caused by usage weather fuel) 2. Exhaust gas color is
of improper fuel. 2. To take care to prevent rain water or improper, and starting
dust from entering into the fuel port. action is poor.
3. Deposition of carbon on
the combustion chamber
increases. (The valve seat
surface becomes rough,
and the piston ring is
thermally seized.)
4. Fuel injection pump or
injection nozzle is worn
or seized.

8 Fuel filter In addition to dust in 1. Check the fuel filter periodically, and 1. Poor sub-engine 1. The fuel filter is a filter
the fuel, moisture is, replace if necessary. operation due to failed paper element cartridge
also, accumulated in 2. When replacing the fuel filter, make combustion. type. Replace the cartridge
the fuel filter. sure to purge air. 2. Poor starting ability. periodically (every 1500
hours or yearly). (Replace
even within 1500 hours or
yearly, if excessively
dirty.)
2. Purge air securely until
any bubble disappears
completely.

- 122 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
9 Control of Check and control the 1. Be sure to use the specified lubricant. 1. Overheating. 1. Check the lubricant
engine oil engine oil quantity, ○ API service division, Class CE or 2. Thermal seizure on the quantity every day as the
contamination, higher. piston. daily inspection.
deterioration, etc. ○ Viscosity 3. Thermal seizure on the 2. Make sure to change the
Summer: 20°C or higher connecting rod. lubricant every 1500 hours
SAE30 or 10W-30 4. Thermal seizure on the (100 hours for the first
Spring and Autumn: crank-shaft. time).
5 to 20°C 5. High oil consumption. 3. For refilling and change,
SAE20 or 10W-30 6. Excessive blow-by gas. use the lubricant specified
Winter: 5°C or lower in the left.
SAE10W-30 4. It is desirable to use the
2. Check with the gauge attached to the oil same brand lubricant
inlet cap (see illustration) of engine oil continuously.
pan on the unit front. Check when the oil
inlet cap is completely screwed in. If the
engine oil decreases below the allowable Oil inlet
quantity while the sub-engine is running,
the sub-engine could seize. Check the oil
quantity every day and confirm that oil is Oil level gauge
reserved at around the upper limit on the
oil level gauge. (However, overcharge
must be avoided.)

10 Lubricant filter Replace the lubricant 1. When removing the filter, place waste 1. Abnormal wear and 1. Replace the lubricant filter
filter periodically. cloth to prevent oil remained in the filter thermal seizure on the at the specified interval.
from spilling on the sub-engine's main sliding area of the First Second time and
body or each part of the unit. sub-engine. time subsequence
2. Before installing new filter, clean the 2. Excessive blow-by gas. 100 Every
hours 1500 hours
filter seat surface completely. 3. Excessive oil
3. Replace the filter packing (O-ring) with consumption. When the
new one. oil filter is clogged, the
4. After the filter is replaced, make sure to contaminated oil before
run the engine in order to verify that oil filtering will flow in the
does not leak. main gallery from the
by-pass valve. In this
case, the sliding area is
rapidly worn. Moreover,
if any metallic chip enters
the switch by oil
pressure, it will cause
improper activation or
malfunction.

- 123 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
11 Oil leakage Early finding and The oil seals and gaskets are used on some 1. Excessive oil 1. If looseness is found
remedy for oil leak on area of the sub-engine in order to seal the consumption. on any drain plug or
any area of the lubricant. Since the sealing ability may 2. When oil leakage is bolt of the gear case,
sub-engine. become poor as the operating time excessive, the oil quantity rocker cover, etc,
increases, this will result in oil leakage. decreases and the oil retighten any loose one.

To a servicing shop
Check the whole of the sub-engine pressure drops, and the 2. Replace any damaged
sufficiently during inspection in order to unit will stop abnormally. gasket.
find oil leakage as early as possible. (The sliding area of the 3. If leakage is found on
sub-engine is thermally the oil seal area, replace
seized.) the seal. Check the lip
3. The sub-engine and unit contact area on the shaft
will become dirty. side. Replace the oil
seal if worn.

12 Abnormal sub- Abnormal noise often Since a large failure has often been 1. Crankshaft or main If any area which

To a servicing shop
engine noise sounds as the previously prevented by finding an bearing is worn. generates abnormal
symptom, before a abnormal noise, usually be accustomed to 2. Bearing of connecting noise is isolated, take the
large engine trouble normal running noise and combusting rod is worn. suitable remedy. (Part
occurs. noise with your sense. Take care for any 3. Piston or piston pin is replacement, adjustment,
noise during inspection. worn. etc.)
4. Valve working system of
the camshaft is worn.
5. Any bearing worn.

13 Precaution for 1. When it is not used When the unit is not used for a long time, 1. When the compressor
halt of a long for a long time, run the unit approximately 15 minutes halts for a long time,
time refrigerant must be every 3 to 4 days. (If the unit is stopped for liquid refrigerant is
prevented from more than 2 weeks, the unit is protectively internally accumulated.
migrating into the operated automatically.) When the unit starts, this
compressor. Oil must will cause improper
be prevented from lubrication to thermally
running short on the seize the compressor.
shaft seal. Moreover, refrigerant gas
2. Prevention of leakage may result from
dewing and rusting shortage of oil on the
in the sub-engine. shaft seal area.
2. When the sub-engine,
also, halts for a long time,
the oil film will be
broken on each sliding
area and dew will be
generated on the inner
wall of the cylinder. This
will lead to rusting.

- 124 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
14 Precaution for Prevention of When the unit is utilized as a substitute of The drain pipe will be
usage of defrosting failure, the refrigerator, melt frozen ice by raising clogged failing drainage
refrigerator when utilizing the unit the inside container temperature up to plus and ice will grow up
truck as a as a substitute of a temperature one time every week. progressively due to frozen
substitute of a refrigerator for a long defrosting water. This may
refrigerator time, for the storage of cause to crush the
pre-refrigerated cargo defrosting pipe and cooling
or refrigerated extra coil.
cargo at night.

15 Cargo loading 1. When loading cargo, Especially important dimensions are as 1. The temperature 1. The uneven temperature
method in van keep sufficient shown below. distribution is sometimes distribution will be
clearance to circulate largely uneven between reduced as the clearance
air in the container. Refrigeration unit the top and bottom or dimensions are larger.
300~400m Lower than supply air outlet
2. When cargo is between the front and 2. Keep a clearance of 30
loaded or unloaded rear areas. mm or more on both sides
Minimum
with the door 100mm 2. When the door is opened of cargo.
opened, the unit must with the air circulated, 3. Provide waterproof
Evaporator supply
be stopped. air outlet the cold air will be measures for cargoes,
Minimum 100mm
3. If cargoes must be replaced with the outdoor which must be protected
Evaporator supply air outlet
protected from air to rapidly rise the from wetting with water.
Minimum Minimum
wetting with water, 300mm 300mm temperature in the
place a waterproof container.
sheet over the cargo 3. Depending on the extent
placed near the Minimum 50mm of frost on the evaporator
supply air outlet. coil, some water may be
Dimensions vary depending on the size of splashed after defrosting.
trailer trucks.

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15.8 Cautionary points for periodical inspection
Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
1 Solenoid Clean the solenoid When inspecting the solenoid, remove the 1. Solenoid binding. Check every inspection.
plunger and apply plunger. If it is dirty or rusted, clean it with 2. Solenoid thermally
grease on it. waste cloth. Apply a thin coat of grease on damaged.
the whole. 3. Improper sub-engine
revolution.
4. Centrifugal clutch
thermally damaged.

Adjust the adjusting When adjusting the sub-engine revolution Thermal damage and Check the contact point.
rod. speed, activate the solenoid to verify that defective contact point.
the contact point of the pull-in coil is The pull-in coil and
surely opened. holding coil are provided in
Contact point the solenoid. Since much
of pull-in current flows in the pull-in
coil, it will be thermally
It must be opened damaged if the current
when the solenoid
is activated. flows for a certain time or
more.

Rust preventive spray When the sub-engine revolution speed is 1. When the adjusting rod Clean the adjusting rod and
for adjusting rod. adjusted, the adjusting rod is always used is rusted, it could be spray rust inhibitor on the
(for adjusting). Take care to prevent difficult to adjust the rod during inspection.
rusting. sub-engine revolution
speed.
2. If the engine runs at the
low revolution speed due
to the above, the
centrifugal clutch will be
thermally damaged.

2 Centrifugal Check the wear degree Remove the centrifugal clutch every 4000 1. Centrifugal clutch 1. Once the centrifugal
clutch of the power hours, and check the clutch shoe for wear. thermally damaged. clutch slips, the generated
transmission surface If it is worn to the limit, replace the shoe 2. Refrigerating capability heat slips the clutch
(shoe) of the set. When the shoe is worn by 2 mm (the reduced. further.
centrifugal clutch clearance between the shoe and drum is 3. Alternator charge failed. 2. The wear limit for the
coupled on the 2.1 to 2.4 mm), it is the limit line. New drum is 0.5 mm.
sub-engine. shoe is 4 mm thick.

3 Dryer Prevention of dryer Dryer is sealed. Do not open the seal till Contamination of dryer
installation contamination just before the mounting. with moisture or foreign
matters (Dryer could
absorb moisture contained
in air or being
contaminated with foreign
matters, etc.)

- 126 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
4 Water-proof Check the breakage 1. Coil thermally damaged. 1. The water-proof cover
cover check for degree of rubber boot Water-proof Solenoid
2. Improper suction. must close tightly the
solenoid boot covers provided on the Solenoid boot 3. Operation failed due to joining surfaces of the
front and rear areas of clogging. metallic sheet cover.
the solenoid. 4. Contact point becomes 2. Replace any torn and
1. The breather port rough. holed cover.
must face downward.
2. The wire lead-out hole
must face downward.

5 Governor lever Link and related parts Since they are influenced by rain water and 1. Improper sub-engine Check the adjusting lever
link and related of the governor lever dust, take care for dirtiness and rusting. stopping. shaft of the link section
parts shaft adjusting rod, etc. Verify that the link and related parts from 2. Revolution speed drop or periodically, and clean and
do not operate the solenoid to the governor lever shaft too low. lubricate the lever shaft.
properly. operate smoothly. 3. Solenoid thermally
damaged.

6 Sub-engine Since each part of the 1. Using the tachometer, adjust the speed 1. Cooling capability Refer to page 21 for
revolution unit is designed to to the proper value specified in the insufficient. adjustment procedure.
speed match the specified manual (it is possible to verify the 2. Centrifugal clutch worn
adjustment revolution speed, revolution speed by using the control early.
various failures may panel). 3. Crack in pipe.
result if the revolution 2. Verify that the contact point of the 4. Chattering, tearing and
speed goes wrong. pull-in coil of the solenoid is opened, breakage.
after adjusting the revolution speed. 5. Excessive fuel
consumption.

7 Belt tightness Adjust the tension of 1. Adjust the belt tension by using the 1. Excessively loose. Refer to page 116 for proper
belts used on the tension meter. ○ Belt slippage tension.
engine, motor, 2. Since a new belt is initially elongated, ○ Capability reduced.
compressor, alternator retighten the belt after an initial ○ Alternator failed to
and fan. operation of approximate 10 hours. generate.
2. Excessively tight.
○ Pulley bearing failure.
○ Belt wear early.
○ Sub-engine crankshaft
broken.
○ Motor shaft broken.

8 Refrigerating Precaution when using 1. The refrigerating machine oil (Diamond Clogging may occur in Do not use refrigerating
machine oil refrigerating machine Freeze MA32R) has an extremely high each section if refrigerating machine oil that has been
oil for charging to the absorbency, so work quickly when machine oil exposed to air exposed to air for a long
compressor. handling it. for a long time is used. time.
2. Never use leftover oil. Always dispose
of it.

- 127 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
9 Refrigerating When the compressor 1. Refrigerant circuit flushing 1. Improper cooling. HCFC141b is refrigerant for
circuit flushing is replaced due to some (1) Fill HCFC141b and circulate it with 2. Expansion valve washing purpose.
and cleaning compressor trouble, another pump. After washing the clogged.
check the refrigerant circuit, recover HCFC141b and 3. Dryer clogged.
and oil for evacuate the circuit. Fill, then, 4. Symptoms on the
contamination. refrigerant. compressor.
If necessary, flush and 2. Cleaning operation ○ Thermal seizure
clean the circuit. (1) Replace with a new compressor, occurs.
evacuate the circuit and charge gas. ○ Remaining oil is
Run the cooling operation approx. one almost black with
hour (approx. 15 minutes for heating). metallic chips included.
(2) Recover the refrigerant and replace ○ Sliding areas on the
the dryer. Change the compressor cylinder, piston, rod,
refrigeration oil, evacuate the circuit etc. are worn and much
again, and charge gas. scored.
The above procedure will prevent a failure
from a recurrence in the compressor. If any above symptom
occurs in the compressor,
the refrigerant circuit may
be dirty. Accordingly, even
after the compressor is
replaced, some similar
failure may recur in a short
time.

10 Commercially Precaution for usage of Commercially available parts must not be 1. If any bearing of a Replace with genuine parts.
available parts commercially available easily used, even if the size and capacity different sealing structure
parts. are verified. (non-contact seal type) is
used as the tension pulley
bearing, a failure will
occur in a short time after
replacement.
2. If any fuse or fusible link
of different
characteristics is used,
protection will become
ineffective or it will
result in malfunction.

11 Repair for Early remedy for areas If generation of rust is ignored, it will 1. Panel or similar has A part on which rust has
painted areas rusting by paint grow up further to result in a secondary holes or is cracked. developed to hole or crack
peeling on any metallic damage. Remove rust using wire brush, 2. Panel drops. must be replaced to prevent
part of the unit. emery paper, etc. and clean the areas drop of the part or other
completely. Then touch up paint or take a troubles during driving.
suitable repair.

- 128 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
12 Refrigerant ○ Penetration of 1. Work on piping connection under a roof, 1. Clogging of water and 1. Investigation of
piping moisture avoiding a rainy day. dust in the expansion abnormality of expansion
○ Penetration of dust 2. Because copper dust may enter the pipe valve and, clogging of the valve on no freezing
from its cut and flared area, perform dryer. reveals that many of the
○ Be most sure to
air-blow (N2 blow) after processing. causes are due to sticking
keep moisture and
3. Do not place piping materials (copper of copper dust.
dust from entering
pipe) on the floor, ground etc, where it is 2. Perform evacuation after
the piping in order to
dusty. applying pressure in order
avoid the refrigerant
4. When glazing, pass N2 gas into the to check for gas leakage
cycle from being
piping. from glazed area, etc. To
damaged by them.
5. Perform evacuation for more than 60 check for leakage after
minutes, and reaching of evacuation glazing, leave the pipe
should be over –0.1 MPa (750 mmHg). alone for 5 minutes to
6. Do not use the copper pipe which has maintain –0.1 MPa (750
been left alone for long and inside of mmHg).
which is rusted. 3. Plug the cut of the
refrigerant piping during
storage.

13 Low pressure Insulate from heat the Apply insulation to the low-pressure Rising of suction gas Apply insulation to the
piping piping from the piping. temperature low-pressure piping in order
evaporator outlet to the ↓ to keep the suction gas
suction pipe of Rising of discharge gas temperature from rising.
compressor. temperature
(excluding hose) ↓
Early deterioration of
compressor oil
↓
Breaking of compressor

14 Wire harness Wiring process inside 1. Before wiring works, disconnect the 1. If it is energized during 1. Verify that the battery
(electrical unit and connecting battery terminal. working, it will lead to terminal is disconnected.
wiring) battery etc. short circuit troubles, etc.

2. Take care of polarity of battery wiring. 2. If the polarities (+) and 2. Replace the damaged part.
(-) are reversely
connected, the electrical
parts will be damaged
(burnt).

3. Select a place of 80°C or less ambient 3. Cable sheath may be 3. Avoid placing it near the
temperature for wire routing. subjected to damage or engine exhaust pipe and
fire. high-pressure piping.

4. Clamp cable at 500 mm or less intervals 4. Interference with other

to avoid unnecessary sags. equipment 500mm or less

Wire harness

- 129 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
14 Wire harness Wiring process inside 5. Do not clamp together with the high 5. Temperature of high 5. Clamp the wire harness
(electrical unit and connecting pressure gas pipe. pressure gas pipe alone.
wiring) battery etc. becomes high, causing
damage to the cover and
fire.

6. Use the clamp according to the 6. Broken wire and poor

No biting
thickness of the harness. And when contact
pulled lightly, it should not be slid or Wire harness
pulled out. Also be sure that the tip of the
clamp does not bite the wire harness or
crush it. Clamp the harness to the
convenient direction. Holding of Clamp
body, etc.
by screw.

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

Water traveling the harness

drops down by the trap.

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.
sheath thermal damage (Negligence is prohibited.
which is caused by It has been reported that
insufficient wire capacity. fire actually happened
owing to the negligence.)
9. Use the compression terminal or solder 9. Unit may be subjected to
type terminal to connect the cable. fire owing to heating and
(Solder onto caulking section of crimp firing caused by increase
terminal. Hand-twisting and of the contact resistance.
tape-retaining alone are prohibited.)

10. Check the electrical wiring for 10. Fire may happen on the 10. Clamp cable securely.
interference with any vibratory object on damaged sheath of cable.
the way.

11. Insert the connector with lock until it 11. The connector may be 11. Select the cable
makes "click" sound. Here, do not removed by vibration connection area which is
tighten the connector lock with a ty-rap. free from oil or fuel
sticking.

- 130 -
15.9 Installation and test run check sheet
Van manufacturer
Customer Signature Unit installation company
Refrigeration Model Delivery date
unit Serial No. Inspection date
Model Inspection date
Vehicle
Serial No. Inspector
Inspection
Inspection Item Remarks
Result

Check if the refrigeration unit is installed at the proper position.

Check if pipes/wires are arranged properly.

Inspect sealant is applied completely at the root of mounting bolts.

Inspect if mounting bolts are tightened properly.

Inspect if the fuel and drain hoses are connected securely, or clamped properly.

Inspect if sealant is applied completely at bores where pipes/wires pass through.

Inspect if electric wires are clamped properly.

Inspect if proper quantity is reserved for engine oil/cooling water/fuel.

Inspect drive belts for slackness.

Inspect for leakage of gas from refrigerant system or oil/fuel/ cooling water.

Inspect for interference with movable sections. (Between fan/pulley/belt, etc. and pipes/wires)

Inspect for abnormal noise/vibration.

Inspect if the engine operation sound is normal or fan speed is normal.

Inspect the color on the sight glass and the extent of flush.

Check if high/low pressure is normal.

Check if the thermostat starts/stops the sub-engine properly.

Inspect the display temperature for correctness.

Check if the defrosting cycle operates properly.

Check if the high-pressure switch operates properly.

Clean the inside of container.

Time
Item
Cooling inspection

Inside container Ambient temperature °C

temperature °C
Note) Operate till it cools down
High pressure
below the setting temperature.
MPa (kgf/cm2)
Low pressure
MPa (kgf/cm2)
Remarks

- 131 -
15.10 Periodic inspection check sheet

Customer Customer’s signature

Model Delivery data
Inspection interval Refrigeration unit
Serial No. Inspection date

inspection
Model Inspection company
1500 hrs

1000 hrs

500 hrs

Vehicle Serial No. Inspector

Every

Every

Every

Daily

Inspection Item Inspection Result Remarks

○ Sub-engine oil quantity
○ Fuel quantity
○ Sub-engine oil, fuel leakage check
○ Inspection of interference with moving sections
○ Cleaning of condenser coil, radiator coil
○ Inspection of cooling water quantity, leakage (water hose, radiator, water pump)
○ Sub-engine revolution speed check
○ Inspection of refrigerant sight glass color, refrigerant quantity
○ Inspection of slackened belt, damage on belt
○ Battery check (fluid quantity, specific gravity, terminals, wiring)
○ Inspection of noise from, slip of centrifugal clutch
○ Draining of water separation filter
Inspection, cleaning of air cleaner (at every 250hrs.)
○ Replacement of air cleaner
○ Replacement of fuel filter
○ Greasing of door latch, hinge, etc.
○ Replacement of cooling water
○ Inspection, cleaning of injection nozzle
○ Inspection, adjustment of valve clearance (at about 50 hrs. after start of use only at initial inspection)
○ Cleaning of evaporator coil, drain port
○ Inspection, retouch of painting on main unit
○ Inspection of damage on rubber cushion
○ Inspection of electromagnetic clutch (noise, vibration)
○ Inspection of sub-engine governor lever link and related parts
○ Inspection at around solenoid
○ Inspection of alternator (noise)
○ Retightening of unit mounting bolts
Inspection, retightening of mounting bolts (sub-engine, compressor, compressor head, motor,
○ alternator, rubber cushion, pulley, electromagnetic clutch, fan, solenoid, fan shaft bearing, etc.)
○ Inspection of gas leakage from refrigerant system
○ Inspection of cooling (inspection of temperature display on the display, high/low pressure)
○ Inspection of defrost operation
○ Check of motor-driven movements, insulation resistance
Inspection of slackened electronic wiring terminals, damage on wire cover (battery harness,
○ starter harness)
○ Motion check of high-pressure switch, door switch
○ Inspection of dirty compressor oil
Replacement of sub-engine oil (including inspection of oil leakage: at 100 hrs. at initial
○ inspection only)
○ Replacement of oil filter (at about 100 hrs. at initial inspection only)
○ Inspection of starter
○ Water draining from fuel tank
Inspection of idling pulley bearing, tension pulley bearing, fan shaft bearing,
○ electromagnetic clutch bearing (noise)
○ Replacement of belt (alternator)
Replacement of belts (other than alternator), alternator, idling pulley bearing, tension pulley bearing,
electromagnetic clutch bearing, fan shaft bearing, fan shaft seal (at every 4000 hrs.)
Inspection of wear on centrifugal clutch shoe (at every 4000 hrs.)
Replacement of engine stop solenoid, pre-heater, standby motor bearing, alternator bearing,
fuel hose, cooling water hose (at every 6000 hrs.)
Replacement of starter, engine high solenoid (at every 10000 hrs.)
Overhaul of sub-engine (at every 10000 hrs.)

- 132 -
15.11 Standard operating pressure list

2.45(25)

2.35(24)
Inside container
2.26(23) temperature -18°C

2.16(22)

2.06(21)
Inside container
High pressure MPa (kgf/cm2)

1.96(20) temperature 0°C

1.86(19)

1.77(18)

1.67(17)

1.57(16)

1.47(15)

1.37(14)
Inside container
1.27(13) temperature -29°C

1.18(12)

1.08(11)

0.98(10)

0.88(9)

0.78(8)

Inside container Inside container Inside container

temperature 0°C temperature -18°C temperature -29°C
Low pressure MPa (kgf/cm2)

0.25(2.5)

0.20(2.0)

0.15(1.5)

0.10(1.0)

0.05(0.5)

0(0)
10 15 20 25 30 35 40
Condenser inlet air temperature °C
(Ambient temperature)

- 133 -
16. TROUBLESHOOTING
16.1 Troubleshooting of refrigerant system
(1) Abnormality and its cause of refrigerant system

Abnormality

Compressor does not maintain the suction pressure

Float does not rise in the lower sight glass of the

Refrigerating capacity is not observed

receiver or the sight glass is flushing

Compressor generates noise

Compressor does not suck
Pump down is impossible

Defrosting is impossible
High pressure is higher

Suction pipe is frosted.

Low pressure is higher
High pressure is lower

Low pressure is lower

Cause

○ ○ ○ Refrigerant is overcharged.

○ ○ ○ ○ ○ Refrigerant is insufficient, leaking

○ ○ Temperature of inlet air of the condenser is excessively high.

○ Condenser is clogged.

○ ○ ○ Temperature of inlet air of the condenser is excessively low.

○ ○ ○ Air is mixed in the refrigerating cycle.

○ Condenser fan stops.

○ ○ ○ Evaporator coil is clogged.

○ ○ ○ Evaporator coil is frosted.

○ ○ ○ Refrigerant leaks on the discharge valve of the compressor.

○ ○ ○ ○ ○ ○ Refrigerant leaks on the suction valve of the compressor.

○ An excessive amount of refrigerator oil circulates.

○ ○ ○ ○ ○ ○ ○ Compressor piston and cylinder are defective.

○ Compressor bearing is defective.

○ ○ ○ ○ ○ ○ ○ Valve plate of the compressor is broken.

○ ○ ○ Improper mounting of evaporator outlet temperature sensor EVT

○ ○ ○ ○ Expansion valve is excessively opened.

○ ○ ○ Expansion valve is excessively closed.

○ ○ ○ Expansion valve is clogged.

○ ○ ○ The low-pressure side is clogged.

The high-pressure side is clogged. (Defective of condenser inlet
○ ○ solenoid valve and check valve, etc.)
○ ○ ○ Evaporator fan is stopped. (During cooling operation)

○ ○ ○ Defective defrost solenoid valves SV2-1, 2-2

- 134 -
(2) Cooling is insufficient.

Trouble cause Countermeasure

(1) Airflow is insufficient.
(a) The evaporator coil is frosted. (a) Reset the time on the defrost timer.
(b) Defective fan shaft solenoid clutch (b) Check the clutch operation or inspect the air gap.
(2) Since an opening exists on the refrigeration van, Check for opening, and repair to eliminate the opening.
air enters from outdoors through the opening.
(3) Float is not floating in the lower sight glass of the Inspect for gas leakage and replenish refrigerant after repair.
receiver or the sight glass is flushing.
(4) Condenser coil is dirty. Wash with water. Take care of the fins which may be deformed if rubbed
with hard-haired brush.

WARNING

• If the high-pressure washer is used, the condenser fins will be

deformed. Be sure to prevent using the washer.
• Avoid using the steam washer because the pressure in the equipment
will abnormally rise and it is very dangerous.

(5) When Items (1)～(4) are normal. (a) Connect the gauge manifold, and start engine. Check that the engine is
(a) The expansion valve is clogged. turning by high-speed rotation (2100min-1). The expansion valve or dryer
may be clogged if a slightly lower value is indicated as the pressure on the
high-pressure side and the pressure indicated on the lower side is lower
than the value shown in page 133.
1) Expansion valve may be clogged if moisture freezes at and blocks the
hole of expansion valve outlet. Check the aperture with the controller.
See page 101. If it differs largely from the aperture shown by the table
at left after operating for a while, the expansion valve is stuck. Inspect
Ambient temperature 30°C (Pulse) and replace if necessary.
Inside Container 2) Recover the refrigerant if moisture is mixed. Then replace the dryer.
Temperature After completely removing the moisture with the "repeated evacuating
0°C -20°C
Drive method", replace the refrigerant. Furthermore when the dryer is
clogged, the low-pressure gauge may also show the lower value than
Sub-engine drive the normal operating condition. In the worst case, the dryer and
(High speed) 200±10 145±10
subsequent tubing will be covered by heavy frost. If it is slightly
clogged, the temperature difference is observed between before and
Motor drive after the dryer. (Replace)
(50Hz) 145±10 110±10

(b) When the pressure on the low-pressure side is high together with the
(b) Expansion valve is excessively opened.
low-pressure valve of the compressor frosted, the expansion valve is
excessively opened and refrigerant enters into the compressor in liquid
state. Check whether the EVT is not afloat. The expansion valve is
sometimes seized.

- 135 -
 Trouble cause Countermeasure
(c) Defective evaporator outlet temperature (c) To judge whether LPT is good or not, compare the value shown on the
sensor EVT, low-pressure sensor LPT control display with the gauge manifold.
To judge whether EVT is good or not, measure the temperature on the pipe
located near EVT and compare the result with the value shown on the
control display.
When checking the pipe temperature, closely contact the temperature
sensor to the pipe and cover them with insulation material.

(d) Compressor valve is defective (d) If the pressure difference between the high and low pressure is small, the
compressor valve may be defective or the expansion valve may be
excessively opened.
The excessive opening is detected by article (b). The defective valve of the
compressor is detected by keeping the gauge manifold connected and
checking whether the pressure difference between low and high pressure is
proper or not.

(e) Excessive refrigerant (e) If the float is floating in the upper sight glass of the receiver or the high
pressure is high, refrigerant is overcharged. Recover refrigerant once and
then re-charge the specified quantity.

(f) Much air is mixed in the equipment. (f) If the high-pressure gauge shows a fairly high value and cooling is poor,
air is mixed. It is necessary to recover refrigerant and evacuate system.

(3) Abnormal noise is heard.

Trouble cause Countermeasure
(1) Improper mounting work Check, repair or retighten.

(2) Compressor
(a) Metallic noise is heard from the internal. (a) Disassemble for internal check. Repair or replace, if necessary.
(b) Oil is excessively filled. (b) Drain oil to the specified amount.

(3) Belt is loose. Retighten to the specified tension.

(4) Sub-engine muffler is clogged. Replace the muffler.

(5) Fan interference Inspect and repair if necessary.

(6) Liquid compression in the compressor Check expansion valve and quantity of refrigerant.

(4) High pressure is too high.

Trouble cause Countermeasure
(1) Mixing of air in the equipment Recover refrigerant, and evacuate the equipment.

(2) Dirty condenser coil Clean the condenser coil.

(3) Excessive refrigerant amount Recover refrigerant once and re-charge the proper quantity.

(4) Defective condenser fan Inspect.

(5) Condenser inlet solenoid valve (SV4) does not open. Repair or replace if necessary.

- 136 -
 Trouble cause Countermeasure

(6) Clogged pipe on the high-pressure side Repair or replace if necessary.

(7) Condenser coil is damaged. Repair.

(8) Ambient temperature is high. Move the unit into the shade or to a cool airy place.

(9) Belt slip Adjust the tension. For the proper tension, see page 114.

(5) High pressure is too low.

Trouble cause Countermeasure

(1) Refrigerant quantity is insufficient. Repair the leakage area and recharge the refrigerant.

(2) Valve breakage or leakage on the compressor Replace.

(3) Clogged dryer Replace.

(4) Service valve is not open sufficiently. Open service valves completely.

(5) Defrost solenoid valves (SV2-1, 2-2) are open. Repair or replace if necessary.

(6) Ambient temperature is low. Not abnormal

(7) Frosted evaporator coil Inspect and conduct the defrosting operation.

(6) Low pressure is too high.

Trouble cause Countermeasure
(1) Compressor valve is damaged. Replace.

(2) Refrigerant quantity is excessive. Recover refrigerant once and then re-charge the proper quantity.

(3) Defrost solenoid valves (SV2-1, 2-2) are open. Repair or replace if necessary.

(4) Ambient temperature is high. Move the unit into the shade or to a cool airy place.

(5) Expansion valve is open excessively. Inspect evaporator outlet temperature sensor and replace if expansion
valve is seized.

(7) Low pressure is too low.

Trouble cause Countermeasure

(1) Refrigerant quantity is insufficient. Repair the leakage area and recharge the refrigerant.

(2) Frosted evaporator coil Inspect and conduct the defrosting operation.

(3) Clogged dryer Replace

(4) Ambient temperature is low. Not abnormal

(5) Clogged pipe on the low pressure side Inspect and repair.

(6) Expansion valve is clogged or closed excessively. Recover refrigerant and evacuate system if moisture freezes. Replace if
expansion valve is seized.

- 137 -
16.2 Troubleshooting of sub-engine and related components
(1) Sub-engine troubles and their causes

Contamination of engine oil by foreign object

Black or white exhaust smoke during start-up

Black or white exhaust smoke after start-up

Excessive fuel consumption, contamination

Abnormality

Improper oil pressure (OPS trips, E20)

Excessive vibration, abnormal noise

Excessive engine oil consumption

Battery charging is insufficient.
Starter does not start to rotate.

Unstable rotation, hunting

Sub-engine does not start.

Overheat (abnormal stop)

Cause

○ ○ Improper clearance of suction･discharge valve.

○ ○ ○ B B Seizure of suction･discharge valve.

○ ○ Pressure leakage from cylinder head gasket.

○ W W ○ Wear of piston ring or cylinder.

○ ○ ○ Seizure of crank pin or shaft bearing.

○ ○ Wear of crank metal and journal metal.

W ○ Wear of suction･discharge valve guide..

○ ○ B B ○ Pressure leakage from valve seat..

○ ○ Crack in cooling water jacket.

B ○ Shortage of cooling water.

B ○ Faulty thermostat function.

○ ○ Usage of inadequate engine oil.

○ Leakage from engine lubrication system.

○ Insufficient engine oil quantity.

W ○ Excessive engine oil quantity.

B･W B･W Usage of inadequate fuel.

○ B Injection timing is too early at fuel injection pump.

W W ○ Injection timing is too late at fuel injection pump.

○ Insufficient fuel supply to fuel injection pump.

○ ○ B･W B･W Irregular injection volume from fuel injection pump.

B ○ ○ ○ Excessive fuel injection.

○ Clogging of fuel filter.

B B Clogging of air filter.

○ ○ ○ ○ Trouble of wiring.

○ ○ ○ Defective battery. (Flat battery)

○ ○ Defective starter.

Note. B: Black, W: White

- 138 -
(2) Shortage of output

Trouble cause Countermeasure

(a) Insufficient compression
1) Improper valve clearance 1) Adjust the valve clearance.
2) Pressure leakage from valve seat 2) Removing the cylinder head, grind out the valve.
3) Seized valve stem 3) Repair or replace.
4) Deteriorated or broken valve spring 4) Replace the valve spring.
5) Pressure leakage from cylinder head gasket 5) Replace the gasket.
6) Stuck or broken piston ring 6) Replace the piston ring.
7) Worn piston ring, cylinder 7) Overhaul the engine.

(b) Defective fuel injection system

1) Improper injection timing 1) Adjust the injection timing.
2) Defective nozzle 2) Adjust or replace the nozzle.
3) Cylinder head, nozzle hole are clogged with carbon. 3) Remove carbon.

(c) Defective fuel system

1) Clogged fuel filter element 1) Replace the fuel filter element.
2) Mixing of air in fuel system 2) Bleed air from each pipeline.
3) Contaminated fuel tank 3) Clean the fuel tank.
4) Deteriorated fuel pump function 4) Disassemble or replace the fuel pump.
5) Improper injection amount from injection pump 5) Adjust by referring the Engine Service Manual.
6) Insufficient injection amount due to improper 6) Adjust by referring the Engine Service Manual.
governor adjustment

(d) Insufficient intake air volume

1) Clogged air cleaner 1) Replace the element.
2) Larger valve clearance 2) Adjust the valve clearance.

(e) Overheat
1) Inadequate engine oil 1) Replace with the specified oil.
2) Shortage of cooling water 2) Replenish cooling water.
3) Worn or broken belt 3) Adjust or replace.
4) Faulty thermostat function 4) Replace the thermostat.
5) Faulty water pump function 5) Repair or replace the water pump.
6) Clogging of or water leakage from radiator 6) Clean, repair or replace in case of water leakage
7) Defective nozzle 7) Adjust or replace.

- 139 -
(3) Higher engine oil consumption
Trouble cause Countermeasure
(a) Loose oil pan drain plug Tighten the drain plug or replace the gasket.

(b) Loose oil pan set bolt Tighten the set bolt.

(c) Loose timing gear cover Tighten the set bolt or replace the gasket.

(d) Defective cylinder head cover gasket Replace the gasket.

(e) Loose bolt (for oil filter setting) Tighten the set bolt or replace the gasket.

(f) Broken oil filter body gasket Replace the gasket.

(g) Worn valve, stem guide or broken oil seal Replace the oil seal.

(h) Improper piston ring abutment position Adjust the piston ring position.

(i) Worn piston ring Replace the piston ring or piston.

(j) Worn piston and cylinder Replace the piston or cylinder liner.

(k) Excessive lubricant spray over bore, piston Oil is charged excessively. Reduce to the specified quantity.

(4) Faulty startup

Trouble cause Countermeasure

(a) Startup speed is slow.

1) Engine oil is too dense. 1) Replace with the specified oil.
2) Discharge or deteriorated capacity of battery 2) Charge or replace the battery.
3) Poor contact of starter cable and grounding band 3) Clean, retighten terminals, or replace the cable.
4) Defective starter 4) Repair or replace.

(b) Defective injection system

1) Fuel leakage from injection pipe 1) Tighten or replace the pipe.
2) Defective nozzle 2) Repair or replace the nozzle.
3) Mixed air 3) Bleed air.
4) Delayed injection timing 4) Adjust the injection timing.
5) Defective governor link 5) Adjust or replace.

(5) Engine knock

Trouble cause Countermeasure

(a) Diesel knock

1) Faulty nozzle spray or improper spray pressure 1) Clean, adjust or replace.
2) Inadequate fuel 2) Use the specified fuel.
3) Insufficient compression pressure 3) Overhaul the engine.
4) Inadequate injection timing 4) Adjust the injection timing.
5) Super cooled or overheated engine 5) Warm up the engine or replace cooling water.
6) Irregular injection volume 6) Adjust the injection volume on the injection pump of each cylinder.
7) Improper valve clearance 7) Adjust the valve clearance.

- 140 -
(6) Faulty idling revolution
Trouble cause Countermeasure

(a) Injection pump and related matters

Irregular injection volume from injection pump Adjust the injection volume from injection pump.

(b) Nozzle
Irregular injection volume or irregular injection Adjust or replace the nozzle.
pressure from each nozzle

(c) Engine main unit

1) Improper valve clearance 1) Adjust the valve clearance.
2) Poor adhesion of valve seat 2) Grind the valve.
3) Too slow engine speed 3) Adjust the idling speed.
4) Seizure of crank metal or shaft bearing 4) Overhaul the engine.

Engine noise
In many cases, engine noise is considered to generate as a result of combined effects related to respective
revolving sections, sliding sections, combustion, noise, and so forth. It is necessary therefore to identify the cause
of noise resulting from each factor. Check them after stopping the injection by such measures as disconnecting
wiring of stop solenoid and so on.

(7) Starter does not start to rotate

Trouble cause Countermeasure

(a) Defective battery (Flat battery) 1) Charge the battery.
2) Replace the battery if the specific gravity does not increase over 1.3 after
charging.

(b) Blown fuse “FL1” Replace the fuse.

(c) Trouble of wiring (poor contact) (removal, 1) Check plus (+) terminal of battery, S terminal (8D line) and B terminal
disconnection) (2L line) of starter. Fix if any slack is found.
2) Check if battery voltage is detected on B terminal (2L line) of starter.
Disconnection of 2L line is suspected if no voltage is found.
3) Check if 12V is detected on S terminal (8D line) at 15 seconds after
operation switch is on. Trouble on starter relay (ARSR) is suspected if 12
V is not detected.
4) Check if 12V is detected at the contact side of ARSR relay (2F line).
Disconnection between FL1 ~ ARSR is suspected if 12V is not detected.

(d) Defective starter relay (ARSR) 1) Check if 12V is detected on 7A7 line of ARSR relay at 15 seconds after
operation switch is on.
2) Check if ARSR relay is grounded.
3) Defect of main board or disconnection of relay wiring is suspected if
ARSR relay does not operate after the check of 1) and 2).

(e) Defective starter Defective starter is suspected if no problem is found after investigation of (a)
through (d). Replace the starter.

- 141 -
(8) Others
Trouble cause Countermeasure

(a) Crankshaft and bearing metal

1) Excessive oil clearance due to wear on metal 1) Replace the metal.
2) Eccentric wear on crankshaft journal 2) Repair or replace the journal.
3) Burning, peeling of crankshaft metal 3) Replace the metal.

(b) Connecting rod and bearing metal

1) Wear on connecting rod metal 1) Replace the metal.
2) Bent connecting rod 2) Repair or replace the rod.
3) Burning, peeling of connecting rod metal 3) Replace the metal.

(c) Piston, piston pin and piston ring

1) Excessive clearance due to wear on cylinder 1) Overhaul the engine.
2) Worn piston or piston pin 2) Replace the piston or piston pin.
3) Seized piston 3) Replace the piston and piston ring, and inspect respective sections of the
engine.
4) Broken piston ring 4) Replace the piston ring, inspect and clean respective sections of the
engine.

(d) Others
1) Wear on timing gears such as idler gear and 1) Replace the gear.
camshaft gear
2) Wear on rocker arm 2) Replace the rocker arm.
3) Excessive valve clearance 3) Adjust the valve clearance

- 142 -
16.3 Troubleshooting of electrical components
(1) Detail of alarm code
Alarm Code Alarm Lamp Measures

Flicker
(Unit continues When the blown F3 (30A) has been detected for more than 5 seconds.
operation with Fix the engine speed at the low speed.
some restrictions.)

On
When the blown F2 (10A) has been detected for more than 5 seconds.
(Unit stops with
Inspect F2 fuse and replace if it is blown.
abnormal stop.)

Flicker When AR AC OFF and MC auxiliary contactor OFF and Alternator generation voltage ≦ 4.0 V
(Unit resets have been detected for more than 1 second during motor operation.
automatically.) Check electric power source.

When the high-pressure switch has tripped 10 times during operation.

(1) Opening the panel and check the condenser fan drive belts (ribbed belt, 2 pcs.) for
abnormal condition.
(2) If the condenser coil is fouled, clean by washing with water.
On
(Unit stops with
abnormal stop.) WARNING
• Never use a high pressure washing machine because it could collapse the condenser fins.
• Also prohibited is the steam cleaning because it raises excessively the pressure in the
equipment so much as it is dangerous.

Flicker When the high-pressure switch has tripped.

(Unit resets When it has elapsed for more than 3 minutes after the high-pressure contactor ON and the error
automatically.) detection, it resets automatically.

When it has detected +145°C ≦ Discharge gas temperature ≦ +160°C for more than 5 seconds.
Flicker
When it has detected +140°C ≦ Discharge gas temperature ≦ +160°C for more than 60 seconds.
(Unit resets
When it has detected Discharge gas temperature ≦ +100°C and it has elapsed for more than 3
automatically.)
minutes after error occurred, it resets automatically.

When, while the unit is stopped, it has detected Low pressure ≦ 0.03MPa (0.3kgf/cm2) for
On
more than 5 seconds with High pressure ≦ 0.05MPa (kgf/cm2) (It does not detect if Ambient
(Unit stops with
temperature＜–10°C and Inside container temperature＜–10°C).
abnormal stop.)
Inspect the leakage of refrigerant.

When any error has occurred 5 times on the low pressure during operation. Or, when broken
On
coil or short-circuit has occurred on the low-pressure sensor.
(Unit stops with
This error shows that the refrigerant pressure at the compressor suction side has dropped to the
abnormal stop.)
protective pressure. Inspect the refrigerant quantity and the low-pressure sensor.

Low pressure ≦ 0MPa (0kgf/cm2) has been detected for more than 60 seconds when the
Flicker
sub-engine or motor is operating.
(Unit resets
It resets automatically at Low pressure＞0MPa (0kgf/cm2) and more than 3 minutes after the
automatically.)
error detection.

On
Broken coil or short-circuit has occurred on the high-pressure sensor.
(Unit stops with
Inspect the high-pressure sensor.
abnormal stop.)

- 143 -
Alarm Code Alarm Lamp Measures

When OLS OFF and OPS ON have been detected for more than 5 seconds at 20 seconds after
On detecting Engine speed ≧ 700min-1. When the oil pressure of engine is lower than 0.05 MPa
(Unit stops with (0.5 kgf/cm2).
abnormal stop.) Replenish engine oil (for diesel: 10W30, CE or CF-4) till the oil level rises to between Lo～Hi
on the level gauge.

When the cooling water high temperature error has been detected more than 10 times during
operation.
On
Engine water temperature switch is turned on. Inspect cooling water quantity in the
(Unit stops with
reservoir tank and replenish if necessary. (Antifreeze coolant concentration 50%wt).
abnormal stop.)
Inspect and clean the fouling on the radiator (the heat exchanger found at right when
seeing the unit from the front) at the same time.

Flicker WTS ON has been detected for more than 5 seconds.

(Unit resets It is the cooling water high temperature error.
automatically.) It resets automatically at WTS OFF and as more than 3 minutes elapse.

When, after detecting the Engine speed ≧ 700min-1, it has detected 300min-1 ≦ Engine speed
Flicker
≦1000min-1 for more than 10 seconds.
(Unit resets
This is the abnormal engine speed drop.
automatically.)
It resets automatically 30 seconds after the abnormal stop.

On When the abnormal engine speed drop has been detected 10 times during operation.
(Unit stops with Inspect the fuel tank to check the remaining fuel.
abnormal stop.) If sufficient fuel is reserved, bleed the fuel of air.

When the engine startup has failed 5 times consecutively (the engine speed does not pick up
On higher than 700min-1).
(Unit stops with When the microcomputer has reset while power is supplied to the starter motor.
abnormal stop.) Inspect the fuel tank to check the remaining fuel.
If sufficient fuel is reserved, inspect the battery.

On
When Engine speed ≧ 3000min-1 has been detected for more than 1 second.
(Unit stops with
Adjust the engine high speed.
abnormal stop.)

Flicker
When LM OFF is detected with the operation switch ON.
(Unit resets
If LM ON is detected for more than 5 seconds, it resets automatically.
automatically.)

When OCR auxiliary contactor ON has been detected for more than 1 second during motor
Flicker
operation.
(Unit resets
If OCR auxiliary contactor is OFF and more than 3 minutes have elapsed after the error
automatically.)
detection, it resets automatically.

On When the battery voltage＜11V and the alternator power generation voltage ≦ 3 V have been
(Unit stops with detected for more than 5 seconds while the sub-engine or motor is running.
abnormal stop.) Alternator is not charged properly. Inspect the alternator.

Flicker
(Unit operation When Alternator voltage ≦ 3 V has been detected for more than 5 seconds with Battery
continues without voltage≧ 11V, at Engine speed ≧ 700min-1 or during motor operation.
restriction.)

- 144 -
Alarm Code Alarm Lamp Measures

When it detected a broken wire or short-circuit on the return air temperature sensor.
Flicker
Broken wire: Return air temperature sensor＜-60°C
(Unit continues
Short-circuit: Return air temperature sensor＞+80°C
operation with
It changes forcibly to the supply air temperature control.
some restrictions.)
If and have been detected, the unit stops.

Flicker
When Engine speed ≦ 200min-1 has been detected at the throttle solenoid OFF→ON.
(Unit continues
When a broken wire or short-circuit has been detected in the throttle solenoid circuit.
operation with
Engine speed is fixed to the low speed operation.
some restrictions.)

When the high-pressure switch does not reset even if more than 30 minutes have elapsed after
Flicker
the high-pressure switch has tripped.
(Unit resets
When the high-pressure switch has tripped at 0.5Mpa ≦ High-pressure sensor ≦ 2.5MPa.
automatically.)
This is the high-pressure switch error. Inspect the high-pressure switch.

When a broken wire or short-circuit has been detected on the discharge gas temperature sensor.
Flicker
Broken wire: Discharge gas temperature sensor＜-30°C has been detected for more than 60
(Unit continues
seconds at Engine speed ≧ 700min-1 or during motor operation (it does not detect
operation with
at the ambient temperature＜-20°C).
some restrictions.)
Short-circuit: Discharge gas temperature sensor＞+180°C

On When OPS ON and OLS ON are detected for more than 10 seconds consecutively at 20
(Unit stops with seconds after detecting Engine speed ≧ 700min-1.
abnormal stop.) Engine oil pressure switch is faulty. Inspect the switch.

Flicker
(Unit operation When OPS OFF and OLS ON are detected for more than 10 seconds at Engine speed ≧
continues without 700min-1.
restriction.)

On During PTI engine startup check, when Alternator power generation voltage ≧ 3V has been
(Unit stops with detected for more than 10 seconds at Engine speed＜700min-1.
abnormal stop.) Inspect the engine speed sensor.

Flicker
When the engine operation time has exceeded 1500 hours.
(Unit operation
Replace engine oil and engine oil filter.
continues without
After the replacement, reset the H1 cumulative time (For details, see page 92.)
restriction.)

On When MC auxiliary contactor ON and OCR auxiliary contactor ON have been detected for
(Unit stops with more than 5 seconds.
abnormal stop.) Inspect the over current relay.

When it failed to establish the regular communication for more than 30 seconds between the
Flicker
main PCB and the display PCB.
(Unit resets
When the event communication failed to establish between the main PCB and the display PCB
automatically.)
after 5 retries.

On When the communication error (communication error between the main PCB and the display
(Unit stops with PCB) has been established 10 times.
abnormal stop.) Inspect connectors and wiring between the main PCB and the display PCB.

- 145 -
Alarm Code Alarm Lamp Measures

When AR AC ON, MC auxiliary contactor ON, OCR auxiliary contactor OFF and Alternator
On
power generation voltage＜4V have been detected for more than 5 seconds during motor
(Unit stops with
operation.
abnormal stop.)
Inspect the contactors.

Flicker
When AR AC ON and MC auxiliary contactor OFF have been detected for more than 5
(Unit operation
seconds during motor operation.
continues without
Check commercial power supply facility.
restriction.)

On
When the blown F4 (10A) has been detected for more than 5 seconds.
(Unit stops with
Inspect F4 fuse and replace if it is blown.
abnormal stop.)

Flicker
(Unit operation When the blown F8 (5A) has been detected for more than 5 seconds.
continues without Inspect F8 fuse and replace if it is blown.
restriction.)

On When Low pressure＞0MPa (0kgf/cm2) has been detected for more than 60 seconds after
(Unit stops with initiating the pump-down during PTI.
abnormal stop.) Inspect compressor and solenoid valves.

Flicker
When OLS OFF has been detected for more than 60 seconds.
(Unit operation
Amount of engine oil is short. Replenish engine oil (10W-30 for diesel engine, CE or CF-4)
continues without
until the indication comes between Lo and Hi of level gauge.
restriction.)

Flicker
When Engine speed＜1250min-1 or Engine speed＞1650min-1 has been detected for more than
(Unit operation
60 seconds at Engine speed ≧ 700min-1 and the throttle solenoid at OFF.
continues without
Adjust the engine speed.
restriction.)

Flicker
When Engine speed＜1900min-1 or Engine speed＞2300min-1 has been detected for more than
(Unit operation
60 seconds at Engine speed ≧ 700min-1 and the throttle solenoid at ON.
continues without
Adjust the engine speed.
restriction.)

When Engine speed ≦ 100min-1 (engine stop) has been detected 5 times consecutively after
On
detecting Engine speed ≧ 700min-1.
(Unit stops with
Inspect the fuel tank to check the remaining fuel.
abnormal stop.)
If sufficient fuel is reserved, bleed the fuel of air.

When a broken wire or short-circuit has been detected on the evaporator outlet temperature
Flicker
sensor.
(Unit continues
Broken wire: Evaporator outlet temperature sensor＜-60°C
operation with
Short-circuit: Evaporator outlet temperature sensor＞+80°C
some restrictions.)
Electronic expansion valve is controlled with the low-pressure sensor only.

When a broken wire or short-circuit has been detected on the supply air temperature sensor 1.
Broken wire: Supply air temperature sensor 1＜-60°C
Flicker Short-circuit: Supply air temperature sensor 1＞+80°C
(Unit continues It controls with the supply air temperature sensor 2 as the representative supply air
operation with temperature.
some restrictions.) If the supply air temperature sensor 2 is also in error, it changes forcibly to the return air
temperature control.
If and are detected, the unit stops.

- 146 -
Alarm Code Alarm Lamp Measures

When a broken wire or short-circuit has been detected on the supply air temperature sensor 2.
Broken wire: Supply air temperature sensor 2＜-60°C
Flicker
Short-circuit: Supply air temperature sensor 2＞+80°C
(Unit continues
It controls with the supply air temperature sensor 1 as the representative supply air temperature.
operation with
If the supply air temperature sensor 1 is also in error, it changes forcibly to the return air
some restrictions.)
temperature control.
If and are detected, the unit stops.

Flicker
When a broken wire or short-circuit has been detected on the ambient temperature sensor.
(Unit continues
Broken wire: Ambient temperature sensor＜-60°C
operation with
Short-circuit: Ambient temperature sensor＞+80°C
some restrictions.)

When the low pressure protection control has been detected 5 times with the defrost solenoid
Flicker
valve 1 at ON.
(Unit continues
When a broken wire or short-circuit has been detected.
operation with
When any error is detected with PTI.
some restrictions.)
It operates with the defrost solenoid valve 1 at OFF.

When the low pressure protection control has been detected 5 times with the defrost solenoid
Flicker
valve 2 at ON.
(Unit continues
When a broken wire or short-circuit has been detected.
operation with
When any error is detected with PTI.
some restrictions.)
It operates with the defrost solenoid valve 2 at OFF.

Flicker
When a broken wire or short-circuit has been detected on the unloader solenoid valve.
(Unit continues
When any error is detected with PTI.
operation with
It operates with the unloader solenoid valve at OFF.
some restrictions.)

On
When the high-pressure switch has tripped while operation was going on in the state of .
(Unit stops with
Inspect SV4.
abnormal stop.)

When the high-pressure switch has tripped within 60 seconds after Engine speed ≧ 700min-1
Flicker or AR MO ON.
(Unit continues When the high-pressure switch has tripped within 10 seconds after changing the unloader
operation with solenoid valve from ON to OFF during operation.
some restrictions.) When any error is detected with PTI.
It continues in the operation mode of the minimum capacity.

Flicker
When a broken wire or short-circuit has been detected on the liquid bypass solenoid valve.
(Unit continues
When any error is detected with PTI.
operation with
It operates with the liquid bypass solenoid valve at OFF.
some restrictions.)

On When a broken wire or short-circuit has been detected on EEV.

(Unit stops with When any error is detected with PTI.
abnormal stop.) Inspect EEV.

Flicker
(Unit continues When a broken wire or short-circuit has been detected on the external buzzer circuit.
operation with It operates with the buzzer OFF.
some restrictions.)

On
When a broken wire or short-circuit has been detected on the stop solenoid circuit.
(Unit stops with
Inspect the stop solenoid circuit.
abnormal stop.)

On
When a broken wire or short-circuit has been detected on the starter circuit.
(Unit stops with
Inspect the starter circuit.
abnormal stop.)

- 147 -
Alarm Code Alarm Lamp Measures

On
When a broken wire or short-circuit has been detected on the standby motor drive circuit.
(Unit stops with
Inspect the standby motor circuit.
abnormal stop.)

On
When a broken wire or short-circuit has been detected on the pre-heater drive circuit.
(Unit stops with
Inspect the pre-heater drive circuit.
abnormal stop.)

Flicker When the battery voltage value＜12V has been detected for more than 60 seconds while the
(Unit operation sub-engine or motor is stopped.
continues without Battery voltage is low.
restriction.) If the battery is aged, replace with a new one.

On
When the battery voltage value＜12V has been detected for more than 5 seconds with PTI.
(Unit stops with
Replace with a new battery.
abnormal stop.)

- 148 -
17. INSTALLATION PROCEDURE
17.1 Reference illustration for installation
Refrigeration unit

※ Battery ※ Fuel tank

General view of installation

Note:
(a) Parts number, name, etc. referred to here are listed on page 160.
(b) Parts indicated with ※ (battery, fuel tank) are not MHI standard accessories.
(c) Refrigeration unit mounting section on the van shall be constructed with a sufficient strength as the refrigeration
vehicle.
(d) When modifying the vehicle or manufacturing the van, assure the limit dimensions and structures as specified here
after with care to ensure that the unit and its components can be installed securely.
(e) Determine the installation position of each unit to be able to secure the applicable vehicle rollover stability angle
of each country.
(f) Read carefully and follow strictly the precautions on next page to secure safety before installation.
(g) Inspect using the installation and test run check sheet (page 131) after installation. Moreover, be sure to open
(back seat) the compressor suction valve and discharge valve before test run.
(h) Adjust calendar and clock setting on the controller before test run. (See page 99 and page 54.)

- 149 -
17.2 Safety precautions at installation

WARNING Safety precautions for installation

Failure to observe the following items could lead to trouble or accidents. Be sure to read
the following carefully before starting installation and follow strictly the instructions.

1. Preparation of vehicle before installation

(a) When modifying or manufacturing the van, secure the limit dimensions given in the installation procedure
illustrations and provide sufficient strength. Always follow the installation procedure illustrations when installing.
(b) Installations must always be done by installation technicians or qualified personnel to prevent damage to the unit or
injury.
(c) Securely chock the front and rear wheels and apply the side brakes to prevent the vehicle from moving during the
work. Failure to do so could lead to accidents such as worker injury from the vehicle advancing or retracting due to
mistaken operation.
(d) Completely remove the van from the tractor head during the installation work.

2. During unit installation

(a) Make it clear to all persons related to the work that work is in progress. If work is being carried out jointly, an effort
should be made so that the workers involved understand the other’s work.
(b) Taking care sufficiently of the unit’s weight and center of gravity position, utmost attention must be paid not to drop
the unit, getting caught hands or feet or hurting the lower back of body during transportation or installation. The unit,
especially, weighs approx. 800kg, which is too heavy to support or push away by human power when it went off
balance or dropped. Always secure a safe place during the work. If necessary, secure safety by carrying out the work
with several workers.
(c) Take care of the hazardous parts such as edges on the vehicle and refrigeration unit to avoid injuries. If necessary,
wear helmets, gloves and protective covers during the work.
(d) Use adequate tools and the specified tightening tools when installing the unit. Tighten the parts to the designated
tightening torques (indicated in this manual). Have other workers help if necessary, in order to avoid working in
dangerous postures.
(e) Make sure that the installation sections on the van for the refrigeration unit have sufficient strength and rigidity. If the
strength is insufficient, the unit could break and drop off, leading to a serious accident.
(f) Install fuel pipes and harnesses avoiding interference with high temperature sections or edges. Provide adequate
protective means as required. (Make sure the tractor head will not interfere when connecting.)
(g) Do not attach or remove terminals or harness connectors with wet or oily hands. Failure to observe this could lead to
electric shocks, poor contact or corrosion of terminals.
(h) When carrying out the work indoors, sufficiently ventilate the area to prevent accidents such as oxygen deficiency, or
other.

- 150 -
3. Check items for test run
(a) Before starting the test run, inspect to see if the unit has been installed properly as instructed by this manual.
(b) Securely chocks the front and rear wheels and apply the side brakes to prevent the vehicle from moving during the
work. Failure to do so could lead to accidents such as worker injury from the vehicle advancing or retracting due to
mistaken operation.
(c) Make sure that no tools, instruments or other parts have been left in the refrigeration unit or chassis before starting
the refrigeration unit.
(d) Confirm that there are no workers on all sides of the vehicle or under the vehicle body, and warn workers in the area
that the refrigeration unit is to be started.
(e) Be sure to open the compressor suction valve and discharge valve before starting the test run.
(Compressor operation valves are closed when shipping from the factory.)
(f) Always securely close all covers before the test run.
(g) Whenever any abnormal operation, noise or error display has occurred during testing, stop the unit immediately and
inspect.
(h) To drive the motor, use only the rated power supply of 400V, 50Hz.
(i) Protect electrical parts from splash of water. It could cause short-circuit or electric shocks.
(j) Do not operate the control panel of refrigeration unit with wet hands.
(k) When there is risk of touching live parts such as terminals, etc. when checking electric circuits, sufficient care must
be taken to avoid electric shocks or short-circuit.
(l) Take special care to prevent body parts, hands or legs from getting caught by rotary devices (pulleys, drive belts,
condenser fan and evaporator fan).
(m) Avoid bringing an object within the range of revolving component. It could lead to accidents if the component
breaks.
(n) Take care sufficiently not to touch high temperature sections such as the engine exhaust system, cooling system, high
pressure refrigerant pipes, etc.
(o) Do not open the radiator cap during engine operation or until the engine has cooled down after operation. There is
risk of getting burns by boiling cooling water.
(p) Do not wash the refrigeration unit with pressurized water or steam. Highly pressurized water could collapse the heat
exchanger fins or high temperature steam could raise the internal pressure of refrigeration unit to dangerously high
pressure.
(q) Always use the designated brands of refrigerant, refrigeration machine oil, engine oil, antifreeze coolant and fuel.
(r) Take care of the leakage of refrigerant, cooling water, engine oil, etc. Directly touching these substances could result
in frostbite or burns.
(s) When refrigerant leaked, take care to protect eyes or not to inhale the gas.
(t) Discharging refrigerant to the atmosphere is prohibited.

- 151 -
17.3 Cautionary and requested points during installation
Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
1 Clamp mounting Installation of pipes on When the screw hole for the clamp is 1. Unless blocked by Application of sealer to the
for pipe the body with clamp drilled to the body, be sure to coat sealer. It sealer, water infiltrates clamp and screw is not
and screw. is recommended that seal will be swelled into the insulated material helpful for the body already
out when the screw is tightened. of the body through the infiltrated by water.
Do not clamp together with the high clearance to cause
pressure gas pipe. no-cooling.
2. The seal plays the role of
Neo-sealer preventing the screw
from loosening.

Prepared hole on the

wall of the body

2 Fuel pipe Prevention of defect 1. When routing fuel pipe at the time of 1. Fuel pipe is holed to leak 1. When routing the fuel
due to leakage from installation, keep it from contacting other fuel. pipe, provide the clamps
pipes related to fuel parts and high temperature area. 2. It is dangerous that fire and use the rubber sheet as
and sucking of air 2. Tighten securely the connection of fuel results from the above. necessary to prevent the
pipe (Negative pressure side sucks air). 3. Air is sucked into the pipe from interference with
fuel to cause reduced or vibration from any other
revolution speed or poor part.
engine running. 2. Use the specified hose
bands and securely fasten
the pipe.

3 Countermeasure Prevention of rain When the hole is produced on the trailer 1. Rain water enters the Verify that the hole or
for the passing water from entering side and any clearance is produced on the trailer through the hole or clearance is wholly and
hole on the trailer the trailer, and hole with the refrigeration unit, mounting clearance, and the thermal securely sealed.
prevention of the bolts, refrigerant pipe, electric wiring, insulator is moistened.
refrigerating capacity drain hose, etc. in the outfitting process, 2. Thermal load enters
from dropping. close the hole or clearance by coating through the clearance of
sealer. the thermal insulator and
is moistened to cause
poor cooling.

4 Wire harness Wiring process 1. Before wiring works, disconnect the 1. If it is energized during 1. Verify that the battery
(electrical wiring) connecting remote battery terminal. working, it will lead to terminal is disconnected.
monitoring equipment short-circuit troubles, etc.
and its sensors etc.
2. Select a place of 80 °C or less 2. Cable sheath may be 2. Avoid placing it near the
atmospheric temperature for wire subjected to damage or engine exhaust pipe and
routing. fire. high-pressure device.

3. Clamp cable at intervals of 500 mm or 3. Interference with other 3. 500mm or fewer

fewer to avoid unnecessary sags. equipment.

Wire harness

4. Use the clamp matching to the thickness 4. Broken wire and 4. No biting
of the harness. And be sure that it does ineffective contact.
not slide or pull out when slightly pulled. Wire harness
Also be sure that the tip of the clamp
does not cut into or crush the harness.
Clamp

Holding of body, etc. by

screw

- 152 -
 Possible Corrective action
No. Item Explanation Precaution for service
failure (Remarks)
5 Tightening When tightening the (Observe the following tightening torques) 1. Gas leaks on the Periodically retighten the
torques of flare bolts and nuts, refrigerant piping system. bolt and nut, and check that
nuts, general observe the 1. Standard tightening torques for flare nuts they are tightened to the
bolts and nuts following tightening Applicable Tightening torque specified torques.
torques. copper pipe N·m (kgf·m)
ø6.35 9.9～14.7 (1.0～1.5) (Take sufficient care for
over tightening.)
ø9.52 19.6～29.4 (2.0～3.0)

ø12.7 34.3～44.1 (3.5～4.5)

ø15.88 49.0～58.8 (5.0～6.0)

ø19.05 58.8～68.6 (6.0～7.0)

2. Tightening torques of general bolts 2. General bolts and nuts
N·m (kgf·m) ○ If over tightened, the
bolt may break owing
Material SS400 S45C SUS304 to the excessive
elongation.
Head mark No mark ○ If insufficiently
Thread
diameter
or 4 △ or 7 No mark
tightened,
0.8 + 0.2 1.15 + 0.35 0.9 + 0.1 looseness may
M3
(0.08 + 0.02) (0.12 + 0.04) (0.09 + 0.01) lead to troubles.

1.25 + 0.25 2.0 + 0.5 2.16 + 0.25

M4
(0.13 + 0.03) (0.20 + 0.05) (0.22 + 0.03)

2.16 + 0.25 3.9 + 0.5 3.9 + 0.5

M5
(0.22 + 0.03) (0.40 + 0.05) (0.40 + 0.05)

3.95 + 0.45 7.1 + 0.7 7.1 + 0.7

M6
(0.40 + 0.05) (0.72 + 0.07) (0.72 + 0.07)

9.1 + 0.7 17.2 + 1.5 17.7 + 1.5

M8
(0.93 + 0.07) (1.76 + 0.15) (1.81 + 0.15)

18.3 + 1.3 34.4 + 3.0 35.6 + 2.7

M10
(1.87 + 0.13) (3.51 + 0.31) (3.63 + 0.28)

31.3 + 2.1 58.8 +4.9 61.1 + 4.7

M12
(3.19 + 0.21) (6.00 + 0.50) (6.23 + 0.48)

50.0 + 3.4 94.7 + 7.4 98.1 + 7.4

M14
(5.10 + 0.35) (9.66 + 0.76) (10.01 + 0.76)

78.9 + 5.4 149.1 + 11.8 154.2 + 11.5

M16
(8.05 + 0.55) (15.21 + 1.20) (15.73 + 1.17)

N·m (kgf·m)

Material SS400
Head mark
Thread 8 11
diameter
30 34
M8 (3.06) (3.47)

- 153 -
17.4 Unit hanging procedure
(1) Remove both upper and lower side covers before hanging.
(2) Please prepare the hanging jig that corresponds to the center of gravity of the unit. The hanging jig shall have sufficient
strength and stiffness to the unit weight (860kg).

<In case of using M16 hanger bolt>

(Applicable to the units with serial numbers from 869400001BL to 869400101BL.)

Jig
(To be supplied by the installation company.)

M16 hanger bolt (2 pcs.)

(To be supplied by the installation company.)

<In case of using hook hole>

(Applicable to the units with serial number of 869400102BL and after.)

Jig
(To be supplied by the installation company.)

- 154 -
 17.5 Appearance and dimensions of the unit
King pin center
Note:
1755 (Hanger bolt hole) MAX 111 1. Center of gravity and weight are as follows.
1659 Center of Gravity Weight
Model

1600
MIN 28 908 (Hook hole) MIN 80(*1)
(*1) A B C (kg)
TFV2000D-E 50 1310 195 857
Unit accessory − − − 3
MIN 526(*1)

(Above weight includes refrigerant, cooling water and oil.)

MIN 837 (*1)

430
MAX 830
Parts to be supplied by Weight
Remarks

MAX 1358
the installation company (kg)
Installation anchor bolt (8 pcs.) 1.6 MHI TSJ911B002
Upper side cover
(Left and right) Battery 21.5 GS Yuasa TW-115D31L (or equivalent)

Lower side cover Fuel tank 28 To be supplied by installation company.

(Left and right) Fuel tank bracket 50 To be supplied by installation company.
Lower center cover
2. When providing new installation bolts at the van side, bore holes at
positions “a” (5 places) and “b” (3 places).
2000 (Use the installation holes at “c” position for re-installation only.)
3. *1 shows the minimum dimension to remove/install the resin cover.
4. Do not place any projection such as rivet on the front wall where the
frame shown on the Frame rear-view will be located.
5. Dimensions are shown in (mm).

1616 100
B

2-φ30 430

106
(Hook hole) 151

15
2138

200

opening dimension)
dimension) (Supply air outlet
(Return air inlet
167

1150
520
181

35
A
AC Socket
In case of mounting under the unit 119 395
frame, (See 17.8 on page 159.)

C
1778
546 606
(Supply air outlet 11-φ16
opening dimension) a
201 137
180
117

a a 80 1768

80
35
1011

157

a a
75
1239
2035
117
576

c b
102 c
918

174
114

164 192
c 1629 74.5
(Return air inlet dimension)
70

b b
Bolt by-pass hole for old position at re-installation.
Frame, rear-view
(Never fix the unit here. Bolt must be added at “b” positions on the van.) (See Note 4)

- 155 -
17.6 Specifications required for the van

(Must be the minimum.)

More than 180
1778+1.0

889+1.0

117+1.0
79+1.0

Provide waterproof
(Opening)
1168+3.0

means at the cross

1011+1.0

1128+1.0
section of opening.

697+1.0
325+1.0

1929+1.0
6-φ4.9～5.0
Prepare rivet holes.
110

Make a hole on the van

body.
879+1.0 235 235 Seal this portion with
item 22 (sealer).

1697+3.0

(Opening)
(6 pcs.)

Van opening dimensions, mounting bolt position

(Seeing from the front of van)

(When the unit installing face is flat.) (When there are protrusions
such as rivets, etc.)
To be 40～45

Spacer (To be supplied by van maker)

(Place spacers at all bolts and all along the
fitting surface of the unit gasket to obtain
uniform height.)
Unit installation bolt:
M14x2 (See Note 2.)

Unit installation bolt (8 places), detail

Note:
1. Van maker is requested to provide a structure with sufficient strength and rigidity for the front wall of van, mounting
face of refrigeration unit (weight: 860kg), opening and unit installation bolt fixing position.
2. For unit installation bolts, use genuine MHI products or use bolts that meet the following conditions. Embed these bolts
at right angle against the wall of van.
1) Tensile strength – 800N/mm2 or higher (81.6 kgf/mm2)
2) Electro-galvanized (Plating film thickness – 5µm or more)
3. Dimensions are shown in (mm).

- 156 -
 300～400
Select positions of opening and mounting bolts to make the
gap between van ceiling and supply air outlet minimum.

Supply air

1400*
Rear door spacer

More than 100

More than 100

Floor rail Side air rib
Height: more than 50
150～250

Bulkhead (To be supplied by van maker)

50～75
(Shall cover full inside width and shall prevent
force on the unit.
The part between * must be easily removable.)

Required dimensions for van inside

Member of bulkhead support

(Fixed to the wall of van)
Supply air outlet

Bulkhead (To be supplied by van maker)

Sponge rubber

Hinge or bolted
Member of air passage

Example of bulkhead

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17.7 Installation view of the unit

Seal entire periphery of gasket to avoid

Fix to the van at the location leaking of water into the container.
avoiding interference with the
compressor.

Pass the drain hose through

holes of the unit frame
before installation to the van.

(Thick washer exclusive to 7 places

the center mounting position) Tightening torque
150～160N·m
(15.3～16.3kgf·m)
Tightening torque
150～160N·m
(15.3～16.3kgf·m)

(2 pcs. x 2 places)
(2 pcs. x 2 places)

(2 places) Fix with glue.

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17.8 Fuel system･electrical system connection, refrigerant system handling drawing

Fuel pipe at the Fuel filter assy

(straight pipe O.D. 9.8)

Return to
fuel tank
Fuel pipe at the unit side From
(straight pipe O.D. 5.9) fuel tank

View A <Case①> (Using plastic hoses. Refer to Note 6)

(See Note 6)
Do not mistake
polarities
Clamp at intervals
Open suction valve and of about 500mm
discharge valve of compressor
(2 pcs.)
(19 pcs.)
(2 pcs.)
(37 pcs.)
(2 pcs.)
(6 pcs.)
(6 pcs.)

(5 pcs.)
(2 pcs.)
(Shift to the right) A Fuel outlet pipe

Fuel return pipe

(USE BY CUTTING TO THE DESIRED LENGTH)

Protect the hose passing the through hole of joist with
120
105 Grommet (to be supplied by installation company).
60
(2 pcs.)
73

(8 pcs.)
5-φ4.9～5.0 AC Socket
Prepare rivet holes. In case of mounting
Make a hole on the van under the unit frame
body. Return to
Seal this portion with LEAD WIRE DIAMETER･･･φ3.7 mm fuel tank From
item 22 (sealer). (SECTION AREA･･･8 mm2)
fuel tank
CABLE DIAMETER･･･φ18.5 mm～φ24 mm
150 (Remove
existing pipes) (Remove
B L2 L3 existing pipes)

View A <Case②> (Using rubber hoses. Refer to Note 6)

φ73
95

L1 PE
B B-B
Plug installation drawing TERMINAL POSITION

Note:
1. Fuel tank and fuel filter (for water drain) can be mounted at either side of chassis.
2. Do not mistake the polarities of battery. Reverse connection of (+) and (–) will destroy electric
components of the unit.
3. Separate the fuel tank fill port and gas breathing port more than 200mm from exposed electric terminals and electric
switches.
4. Connect the (–) battery terminal after the work to prevent troubles by short-circuit.
5. Be sure to open the compressor suction valve and discharge valve.
6. When using plastic hoses for fuel hoses, all the parts downstream of hose connectors (items 108, 109) should be
supplied by the installation company. (See <Case ①> above.)
When using rubber hoses for fuel hoses, utilize alternative fuel hose set (TFV-FH). If necessary, separately purchase
from MHI. (See <Case ②> above.)
7. Dimensions are shown in (mm).

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17.9 Parts list for installation
(1) Unit accessories
No. Part No. Name Q’ty Remarks
1 TMA116A002 Support 1
2 TMA116A003 Support 1
4 TSJ423J008 Drain port 2
5 SSA937A946 Hose clamp 1
6 TSJ937A013G Clamp 7 ø14
7 TSJ937A013M Clamp 5 ø22
9 SSA911D214A Bolt & washer 2 For support (M8 x 20 large washer)
10 SSA911M219 Bolt 8 For bottom cover (M6)
11 TMA911M001 Bolt 2 For battery (M8 x 270)
12 W010D05X016 Tapping screw 10 For drain hose, for fuel hose (M5 x 16)
1 For unit installation (M14)
13 SSA915A121 Washer (Center portion, rear side of motor)
14 W200G14 Washer 7 For unit installation (M14)
15 W200G08 Washer 2 For battery (M8)
18 N351L08 Wing nut 2 (M8)
19 SSA914A032 Nut 8 For unit installation (M14 x 2)
22 SSA971G015F Sealer 1
23 TMA623A001 Filter assy, fuel 1
26 W220G14 Spring washer 8 For unit installation (M14)
27 SSA566B054 Plug socket 1
28 TMA011H008A Caution label 1 Caution automatic operation
29 TMA111A001 Bottom cover 1
30 SSA911D207CB Bolt & washer 2 For socket bracket (M8 x 25)
31 TMA141A005 Baffle plate 1

32 SSA917A005L Rivet 6 ø 4.8 7.1

33 SSA917A005M Rivet 5 ø 4.8 10.3

34 SSA911D207BA Bolt & washer 1 For fuel hose (M16 x 16)

(2) Parts to be supplied by the installation company

No. Part No. Name Q’ty Remarks
101 TSJ911B002 Stud bolt for installation 8 MHI (M14 x 130)
102 ―― Battery 1 Automotive battery 90Ah or higher at 20 hour rate
103 ―― Fuel tank 1 To be supplied by installation company
104 ―― Fuel tank bracket (with bolts) 1 To be supplied by installation company
105 ―― Grommet (ø30) 10 To be supplied by installation company
2
Wire diameter - - ø3.7mm (Section area - - 8mm )
106 ―― Cable 1 Cable diameter - - ø18.5mm～ø24mm
108 ―― Fuel hose connector (ø10) 1 To be supplied by installation company
109 ―― Fuel hose connector (ø6) 1 To be supplied by installation company
110 ―― Fuel hose (ø10) 1 To be supplied by installation company
111 ―― Fuel hose (ø6) 1 To be supplied by installation company
※ Selection of specification and control of quality of the parts from 102 to 106 and from 108 to 111 should be performed under
the responsibility of the installation company.
(3) Alternative fuel hose set [TMA006A011: TFV-FH] (See page 159)
If necessary, separately purchase from MHI.
No. Part No. Name Q’ty Remarks
201 TSJ624A003C Fuel pipe 2 ø8 L = 80mm
202 P050Y08K000 Fuel hose 2 I.D. 8 L = 10000mm
203 SSA937A946 Hose clamp 4 For fuel hose
204 TSJ937A013G Clamp 38 ø14
206 W010D05X016 Tapping screw 19 For fuel hose (M5 x 16)

(4) Optional parts (See page 161 for the outline of installation)
No. Part No. Model Q’ty Remarks
301 TMA006A002 TFV-SG 1 Snow guard set
302 TMA006A008 TFV-ACI 1 Engine air cleaner service indicator set
303 TMA006A009 TFV-EFG 1 Evaporator fin guard set
304 TMA006A010 TFV-RCH 1 Remote control unit harness set

- 160 -
17.10 Optional parts installation outline drawing

Snow guard

To be supplied by the
Engine air cleaner installation company.
service indicator Consult with Mitsubishi Heavy
Printed RT Industries for the communication
Remote control board 2M
B1
protocol.
unit harness E3
(Snow guard)

Remote control
unit
72
(2138)

Evaporator
fin guard

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18. SATURATED TEMPERATURE PRESSURE TABLE (R404A)
Tem- Saturated Tem- Saturated Tem- Saturated Tem- Saturated Tem- Saturated
perature pressure perature pressure perature pressure perature pressure perature pressure
°C °C °C °C °C
2 2 2 2 2
MPa (kgf/cm ) MPa (kgf/cm ) MPa (kgf/cm ) MPa (kgf/cm ) MPa (kgf/cm )

–0.019 0.137 0.461 1.049 1.991

–50 –26 –2 22 46
(144.0mmHg) (1.4) (4.7) (10.7) (20.3)

–0.011 0.157 0.500 1.108 2.089

–48 –24 0 24 48
(79.5mmHg) (1.6) (5.1) (11.3) (21.3)

–0.001 0.177 0.539 1.177 2.197

–46 –22 2 26 50
(9.8mmHg) (1.8) (5.5) (12.0) (22.4)

0.010 0.196 0.579 1.245 2.295

–44 –20 4 28 52
(0.1) (2.0) (5.9) (12.7) (23.4)

0.020 0.226 0.628 1.314 2.412

–42 –18 6 30 54
(0.2) (2.3) (6.4) (13.4) (24.6)

0.029 0.245 0.667 1.393 2.520

–40 –16 8 32 56
(0.3) (2.5) (6.8) (14.2) (25.7)

0.039 0.275 0.716 1.461 2.638

–38 –14 10 34 58
(0.4) (2.8) (7.3) (14.9) (26.9)

0.059 0.304 0.765 1.550 2.766

–36 –12 12 36 60
(0.6) (3.1) (7.8) (15.8) (28.2)

0.069 0.334 0.814 1.628 2.883

–34 –10 14 38 62
(0.7) (3.4) (8.3) (16.6) (29.4)

0.088 0.363 0.872 1.716 3.020

–32 –8 16 40 64
(0.9) (3.7) (8.9) (17.5) (30.8)

0.098 0.392 0.923 1.804

–30 –6 18 42
(1.0) (4.0) (9.4) (18.4)

0.118 0.432 0.981 1.893

–28 –4 20 44
(1.2) (4.4) (10.0) (19.3)

- 162 -
19. ABBREVIATIOS AND CODES
AC Alternating current MCL Fan magnetic clutch
AH Ampere-hour MHI Mitsubishi Heavy Industries, Ltd.
API American Petroleum Institute MOS Metal oxide semiconductor
APR Opposite phase relay OCR Over current relay
AR AC AC power supply detection relay OLS Oil level switch
AR DCS1 DCS1(power supply 1 for external equipment) relay OP Option
AR DCS2 DCS2(power supply 2 for external equipment) relay OPB Display printed board
AR DH Drain heater relay OPS Oil pressure switch
AR HS Engine high solenoid relay PCB Printed circuit board
AR M Run switch relay PH Pre-heater
AR MCL Fan magnetic clutch relay PL C Cooling lamp
AR MO Motor relay PL D Defrost lamp
AR PH Pre-heater relay PL EM Alarm lamp
AR SOL Engine stop solenoid relay PL H Heating lamp
AR SR Starter relay PL M Run lamp
ASSY Assembly PL MOT Motor lamp
ATS Ambient air temperature sensor PTI Pre-trip inspection
BATT Battery PWB Printed wiring board
BZ Buzzer (unit) RCN Connector
CN Connector RCU Remote control unit
CON Power socket REC Recorder
DC Direct current RTB Remote terminal base
E6 Ground RTH Remote temperature sensor
EEV1 Electronic expansion valve SAE Society of Automotive Engineers
EVT Evaporator outlet temperature sensor SM Starter motor
F1 Control line fuse SOL Solenoid
F2 Relay circuit fuse SOL HS Engine high solenoid
F3 Engine high solenoid fuse SOL RS Engine stop solenoid
F4 Fan magnetic clutch fuse SV2-1 Defrost solenoid valve 1
F8 External load fuse SV2-2 Defrost solenoid valve 2
FET Field effect transistor SV3 Unloader solenoid valve
FH Fuel hose, Fuse holder SV4 Condenser solenoid valve
FL1 No.1 current fuse SV5 Liquid bypass solenoid valve
FL2 No.2 current fuse SW CONT Run mode change switch
FWS Flywheel sensor SW D-E Diesel-electric switch
GND Ground SW DEF Switch (defrost)
GPS Global positioning system SW DOWN Switch (down)
GU Alternator SW ENT Switch (enter)
GU B Alternator B terminal SW M Main switch
GU E Alternator ground SW MODE Switch (mode)
HPS High-pressure switch SW ON-OFF On-Off switch
HPT High-pressure sensor SW PTI Switch (PTI)
HS Throttle solenoid SW REM Remote control unit switch
LCD Liquid crystal display SW UP Switch (up)
LM Limit switch SW WISP Switch (whisper)
LPT Low-pressure sensor TDS Discharge gas temperature sensor
M Electrical motor TH1 Return air temperature sensor
MC Motor contactor THD1-1 Supply air temperature sensor 1
MC1 Motor contactor 1 THD1-2 Supply air temperature sensor 2
MC2 Motor contactor 2 WTS Water temperature switch
MCB Main printed board

- 163 -