Linda H.
How to troubleshoot problems with a Mitsubishi TU42DXB Transport Refrigeration Unit?
Troubleshooting steps for various issues are available.
The TU 42DXB is a transport refrigeration unit designed for truck applications, suitable for both frozen and refrigerated cargoes. The unit has a compact design which allows for easy installation and removal from the container. It features automatic start/stop and continuous operation modes, allowing for optimized fuel efficiency and temperature control. It uses a super thin evaporator unit that allows for more efficient use of the freezer space and operates at ambient temperatures ranging from -20 to +40°C, maintaining inside container temperatures between -30 to +25°C.
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MITSUBISHI TRANSPORT REFRIGERATION UNIT TU42DXB SERVICE MANUAL TU42DXB SERVICE MANUAL AIR-CONDITIONING & REFRIGERATION SYSTEMS HEADQUARTERS TRANSPORTATION REFRIGERATION DEPARTMENT 3-1, ASAHI, NISHIBIWAJIMA-CHO, KIYOSU, AICHI, 452-8561, JAPAN Phone : 052-503-9312 Fax : 052-504-7552 No.086 (2.2A) RO ’07 · TU-S · 002 Introduction This service manual describes the outline and maintenance procedures, etc., of the TU42DXB refrigeration unit, and is intended to be used by the service personnel of the unit. Read this manual thoroughly before starting to ensure quick and waste-less servicing and to maintain the performance of the refrigeration unit. Explanation of types TU42DXB - 25 - 4E Motor driving voltage 4: 380V, 50Hz Drive method and functions 25: Sub-engine drive exclusive for refrigeration unit, and motor drive Refrigeration and heating (without electrical heater) Model name X: Super thin type evaporator 00_TU42DXB.indd 1 2008/02/04 13:31:17 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 series 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. Never touch. Repairs and disassembly must be done by qualified personnel. WARNINGS (1) Never touch the high temperature sections such as the movable sections, exhaust pipe, and high pressure side piping while the refrigeration unit is operating. Failure to observe this could lead to burns. (2) Do not place flammable materials near the exhaust pipes. Failure to observe this could lead to fires. (3) Set the stop switch in the cabin controller and control box to "STOP", disconnect the battery terminal and the power supply plug before starting inspection and adjustment of the refrigeration unit. The sub-engine or motor could be stopped by the thermostat even when the operating switch is set to "RUN". The thermostat could activate during inspection causing operation to start automatically and lead to injuries. (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. 00_TU42DXB.indd 2 2008/02/04 13:31:18 WARNINGS (8) When installing the product 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 overheated, 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) When working on the evaporator fan motor, make sure to disconnect the fan motor connector beforehand. (13) Temperatures of engine oil and engine cooling water could become extremely higher. Wait till the temperatures drop sufficiently before starting inspection, refilling or exchange. (14) 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. (15) Do not load volatile or inflammable substances in the container. Failure to observe this could lead to explosions or fires. (16) Refrain from attempting any dangerous act such as riding on the unit, hanging on to, grasping, stepping on the unit, or others. (17) 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. (18) Do not insert fingers or rods in air intake and outtake ports. A fan is rotating at a high speed inside, and inserting fingers or rods could lead to injuries. (19) Do not place volatile or flammable matters in the room. Failure to observe this could lead to explosions or fires. (20) 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. (21) 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. (22) 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. 00_TU42DXB.indd 3 2008/02/04 13:31:18 WARNINGS (23) 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. (24) 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. (25) Do not use the cabin controller when driving the vehicle. It could cause trouble. (26) Do not leave combustible objects around the exhaust pipe. These could catch fire. (27) It is prohibited standing on, hanging down from, holding on or stepping on the refrigeration unit, or other similar acts. It could cause injury or trouble. (28) Do not use the refrigeration unit in explosive atmosphere. It could cause explosion, fire, or other accident. (29) 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. (30) Do not spill water, coffee, soft drinks, etc. on the cabin controller. It will cause a trouble or abnormality. (31) Do not run the motor at an incorrect voltage. Doing so could lead to faults in the refrigeration unit or to fires. 00_TU42DXB.indd 4 2008/02/04 13:31:19 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 120 AH or more. Failure to do so could lead to electric shocks or trouble. (4) Take care of the polarity of the battery wiring. Connecting the and poles in reverse could lead to electric shocks or trouble. (5) If using a commercial power supply to drive the motor, take current leakage measures for the power supply circuit. (6) 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. (7) Do not discharge a refrigerant in the atmosphere. It could cause environmental disruption. 00_TU42DXB.indd 5 2008/02/04 13:31:19 CONTENTS 1. FEATURES................................................ 1 2. SPECIFICATIONS...................................... 2 3. GENERAL DESCRIPTION........................ 3 3.1 Cabin Controller................................................. 3 3.2 Operation control................................................ 3 3.3 Defrosting........................................................... 3 3.4 Protective devices............................................... 4 4. COMPONENTS.......................................... 5 5. TEST OPERATION AND ADJUSTMENT ................................................................... 6 12.9 Dryer................................................................. 21 12.10 Sight glass......................................................... 21 12.11 Receiver............................................................ 22 12.12 Heat exchanger................................................. 22 12.13 Accumulator..................................................... 22 12.14 Fan motor for evaporator.................................. 22 12.15 Defrost completion thermosensor (DTS)......... 23 12.16 Inside container air temperature sensor (TH)... 23 12.17 Delivery temperature sensor (Td sensor).......... 23 12.18 Overcurrent relay (OCR).................................. 24 12.19 Alternator.......................................................... 24 12.20 Engine oil pressure switch................................ 25 12.21 Sub-engine solenoid switch.............................. 25 5.1 Check before test run.......................................... 6 12.22 Sub-engine speed sensor (FWS)....................... 26 5.2 Check during test run.......................................... 6 12.23 Limit switch...................................................... 26 5.3 Motor drive......................................................... 6 12.24 Setting value and revolution speed list............. 27 6. DAILY OPERATION................................... 6 12.25 Tension adjustment of belt................................ 27 6.1 Check before operation....................................... 6 13. WIRING DIAGRAM.................................. 28 6.2 Operation mode selection................................... 7 13.1 Ladder diagram................................................. 28 6.3 Operation sequence............................................ 7 13.2 Refrigeration unit wiring diagram.................... 29 7. CAUTIONARY POINTS DURING OPERATION............................................ 13 13.3 Description of operation................................... 30 13.4 Description of the thermostat operation........... 41 7.1 Check during operation.................................... 13 14. INSPECTION........................................... 43 7.2 Cautionary points during operation.................. 13 14.1 Daily inspection................................................ 43 8. CARGO LOADING................................... 13 14.2 Periodical inspection........................................ 43 8.1 Check before cargo loading.............................. 13 8.2 Cargo loading procedure.................................. 14 8.3 Cargo unloading............................................... 14 9. REFRIGERANT PIPING SYSTEM.......... 15 14.3 Additional requirements................................... 45 14.4 Mounting bolt tightening torque list................. 45 14.5 Cautionary points for daily inspection............. 46 14.6 Cautionary points for periodical inspection..... 51 14.7 Installation and test operation check sheet....... 55 9.1 Refrigerant piping system................................. 15 14.8 Periodical inspection check sheet..................... 56 9.2 Cooling cycle.................................................... 15 14.9 Standard working pressure graph..................... 57 9.3 Defrosting and heating cycle............................ 16 15. TROUBLESHOOTING............................. 58 10. DRIVE SYSTEM....................................... 16 15.1 Troubleshooting of refrigerant system............. 58 11. CONTROL SYSTEM................................ 17 15.2 Troubleshooting of sub-engine and related 12. DESCRIPTION OF MAJOR COMPONENTS........................................ 18 15.3 Electric circuit troubleshooting........................ 67 12.1 Compressor....................................................... 18 12.2 Sub-engine........................................................ 19 12.3 Centrifugal clutch............................................. 19 12.4 Motor................................................................ 19 12.5 High-pressure switch........................................ 19 12.6 Expansion valve................................................ 20 12.7 Solenoid valve.................................................. 20 components....................................................... 62 16. INSTALLATION PROCEDURE................ 78 16.1 Cautionary points during installation............... 78 16.2 Cautionary and requested points during installation........................................................ 79 16.3 Reference illustration for installation............... 84 17. Saturated temperature pressure table (R404A).................................................. 100 12.8 Multi-function valve......................................... 21 00_TU42DXB.indd 6 2008/02/04 13:31:19 1. FEATURES (1) The cabin has an advanced operation panel display function, which improves the visibility and the operability. Its data logging function allows outputting easily the temperature control record, etc. (2) Since the refrigeration unit is a compactly arranged separate type, it can be easily installed on and removed from the container. And it also has an advantage of setting up a vehicle tip-over angle. Furthermore, TU42DXB has a super thin evaporator unit that allows more efficient use of the freezer space. (3) The refrigeration unit is operable at an ambient temperature of -20 to +40°C, and the inside container temperature can be maintained at -30 to +25°C. (4) With the driving engine supported by vibrationproof rubber, the refrigeration unit can operate quietly with low noise. (5) Since the unit is driven by the exclusive engine or motor, it can be effectively used in garages, truck terminals, ferry boats, etc. (6) The exclusive sub-engine drive is provided with two selectable systems: the automatic start/stop system which saves fuel consumption and the continuous operation system which thinks much of the temperature distribution. Cooling and twospeed heating operation is provided. When the inside container temperature is higher than set, cooling is automatically selected, and when it is lower, heating is automatically selected. (7) The exclusive motor drive is provided with the same systems as above except the number of revolutions is only one-speed. (8) Defrosting is started with the automatic, timer or manual system as desired, being securely carried out by hot gas. (9) Environmentally friendly refrigerant R404A has been used. (10) The multi-function valve has the functions to control the high and low pressures, prevent the liquid from returning to the compressor and optimize the balance start of the different pressure, thus making the reliable operation possible in the high pressure range. Moreover, the low pressure is controlled to reduce the excessive load on the drive side. Cabin controller <Locate at driver's position> Fuel tank Fuel pump Evaporator unit TU42D AC power socket Condensing unit Battery —— 00_TU42DXB.indd 1 2008/02/04 13:31:20 2. SPECIFICATIONS Model Cooling capacity Item Conditions Engine drive Motor drive °C W (kcal/h) Function TU42DXB-25 Ambient temp. 35 Return air temperature -18 Return air temperature 0 2560 (2200) 4880 (4200) 1980 (1700) 3720 (3200) kW(PS)/min-1 cm3 Cooling and Heating -30 ~ +25 -20 ~ +40 1653 × 555 × 710 1477 × 128 × 591 288 32 Exclusive engine or motor Automatic Start/Stop or Continuous operation change-over system 4-cycle water-cooled vertical diesel engine L2E-31NCC <High speed> 6.25((8.5)/2400 <Low speed> 4.8 (6.5)/1900 635 Fuel consumption amount for continuous operation l/h <High speed> 1.9 <Low speed> 1.4 Ambient temperature 35°C Inside container temperature 0°C Bore × Stroke × No. of cylinders Oil capacity Fuel Cooling system Applicable revolution speed Model Delivery rate Bore × Stroke × No. of cylinders Applicable revolution speed Refrigerator oil filling amount Type Fan Fan revolution speed Type Fan Fan revolution speed Type Power Output Number of poles Refrigerant filling amount Sound power level Inside container temperature adjustment Operation control Defroster mm l ø76 × 70 × 2 Upper/lower limit 7.9/5.7 [Oil type API Class CD Grade] Diesel fuel, Under extreme cold weather (cold weather fuel) Water cooling type <High speed> 2400 <Low speed> 1900 CR2318LWL-C 182 ø45 × 38 × 3 <High speed> 2000 <Low speed> 1600 (In case of motor, 1100) Diamond Freeze MA32R, 1.0 Aluminum fin and copper tubes Centrifugal fan, motor direct connection × 3 2000 Aluminum fin and copper tubes Propeller fan <High speed> 1900 <Low speed> 1500 (in case of motor, 1000) Totally enclosed fan-cooled outdoor type 3-phase AC380V 50Hz 3.4 (50Hz) 6 R404A, 3.4 103 Electronic thermostat Electronic controller Automatic defroster with defrost timer Range of usage Equipment dimensions Weight of device Inside temperature Ambient temperature Condensing unit Evaporator unit Condensing unit Evaporator unit Motor Condenser Evaporator Compressor Sub-engine Drive system Operation system Type Rated continuous output Displacement °C mm kg min-1 cm3/rev mm min-1 l min-1 min-1 kW kg dB High pressure switch Cut out: 3.2 MPa (32.5 kgf/cm2) Cut in: 2.2 MPa (22.5 kgf/cm2) Engine oil pressure switch Cut out: 0.05 MPa (0.5 kgf/cm2) Engine water temperature switch Cut out: 111°C Fusible plug: 95°C, Motor overcurrent relay 11A Limit switch Molded case Circuit breaker Power supply capacity Isolating switch Power specifications (driven by motor) Safety device KVA 9.6 Switch capacity A 50 Over current circuit breaker Rated capacity A 40 Note: Though model TU42DXB-25 is provided with heating function, do not set such temperature as to require heating operation at the time. —— 00_TU42DXB.indd 2 2008/02/04 13:31:20 3. GENERAL DESCRIPTION (2) Motor drive These units are provided with the motor in addition to the same engine drive as above, and can be operated by the electric power (3-phase AC380V 50Hz) at garages, truck terminals or ferry boats, etc. By turning the change-over switch of the sub-engine or the motor on the control box, the same operation as the subengine drive is possible with motor drive. Here, they are operated at one speed when driven by motor. 3.1 Cabin Controller The Cabin controller improves the visibility and the operability with a large size LCD screen with backlight and can be accommodated neatly in the 1 DIN size space. It improves also the serviceability with the data logging function, which allows outputting easily the temperature control record, etc. 3.3 Defrosting 3.2 Operation control (1) Sub-engine drive The refrigeration unit is provided with the compressor and condenser fan, and are driven in the automatic start/stop system or continuous operation system (whichever is desired). The evaporator fan is driven by the original D.C. motor. ● In heating operation, high speed or low speed heating operation system can be selected. If heating is mainly intended, select the high speed heating operation and if cooling is mainly intended, select low speed heating operation. This makes it possible to arrange the inside container temperature more evenly. ● Automatic start/stop system The engine is run at 2 speeds. The operation switch on the control box and the thermometer start the engine. When the inside container temperature is higher than set by the thermostat, high speed cooling → low speed cooling is activated. When the inside container temperature reaches the set temperature of -1°C, it is automatically stopped. When the inside container temperature is lower than set by the thermostat, the high-speed heating or low speed heating is activated. When it reaches the set temperature of -1°C, it is automatically stopped. ● Continuous operation system This system is selected only for refrigeration but not for freezing. The operation switch on the control box or the thermometer starts the engine. Cooling will be carried out when the inside container temperature is higher than set, and heating will be automatically carried out when the inside container temperature is lower than set. Here, cooling, high speed heating and low speed heating will be continuously repeated to keep the inside container temperature at the set temperature. ● To prevent the refrigerating performance from dropping when frost builds up on the evaporator, the defrosting timer (set to 6 hours at the factory) functions to accurately defrost the unit. Here, the setting time on the defrost timer can be changed between 1 and 6 hours, depending on the load state and frosting speed. When the temperature of the evaporator which completes defrosting rises, the defrosting completion thermostat will switch the system into cooling mode. Moreover, during defrosting, the evaporator fan will be stopped in order to prevent the warm wind from going into the container. When much moistured cargo is loaded or when cooling in the inside container is slow, defrosting can be carried out in the manual mode. —— 00_TU42DXB.indd 3 2008/02/04 13:31:20 3.4 Protective devices (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) This refrigeration unit is provided with following protective devices: If the delivery pressure of the compressor becomes excessively high, the high-pressure switch will stop the engine or the motor. [3.2 MPa (32.5 kgf/cm2)] If the temperature and pressure become high because of fire, etc., the fusible plug will melt to release the refrigerant. [fusible at 95°C] If the hydraulic pressure of the sub-engine becomes low [below 0.05 MPa (0.5 kgf/cm2)], the oil pressure switch will stop the sub-engine to protect it from being seized up. If the sub-engine cooling water temperature becomes high [over 111°C], the water temperature switch will protect the engine from being over-heated. The over-current relay operates when unusually excessive electric current flows into the motor. The limit switch due to releasing of the service door. The fuse and the fuse cut-off indication operates when excessive current flows into the control circuit. The fuse and the fuse cut-off indication operates excessive current flows into the evaporator fan motor. The fuse and the fuse cut-off indication operates when excessive current flows into the sub-engine high speed solenoid or low speed solenoid. In case the engine starts running poorly 3 seconds after the starter motor has been energized with the revolution speed below 100 min-1. In case the engine starts running poorly 20 seconds after the starter motor has been energized with the revolution speed below 700 min-1. In case the engine starts running poorly 20 seconds after the engine has been started with the revolution speed below 1500 min-1. In case the sub-engine continues to run with the revolution speed below 1400 min -1 for more than 5 seconds while the sub-engine is running (after revolution speed has risen to 1500 min-1). In case the inside temperature sensor is disconnected, short-circuited or the connector is poorly contacted. In case the AC power supply fails during operation with motor drive. In case the controller (between cabin controller and control box) communication fails. In case the defrost solenoid valve operation is defective. When the above devices are activated, the abnormal indication lamps on the control box and cabin controller come on to stop the refrigeration unit automatically. Also when cabin controller change-over switch is turned to "ALARM", abnormal points will be indicated. Moreover, the unit is provided with other functions as follows: (1) Function to protect the battery from being fully discharged. ● In order to protect the battery from being fully discharged, the sub-engine should be continuously run for at least 3.5 minutes. In order to continue to run the engine for 3.5 minutes, cooling and heating operations should be repeated by the thermostat signal. (2) Function to delay evaporator fan motor to start ● In order to reduce the sub-engine load at the time of starting, the function delays to start the evaporator fan for 20 seconds after the sub-engine has completed to start. (3) Function for alternator delay generation control ● The generator circuit is formed approximately 20 seconds after the sub-engine starts. (4) Function to finish defrosting forcibly ● When defrosting time continues for long at low ambient temperature, it finishes forcibly the defrost operation in one hour. —— 00_TU42DXB.indd 4 2008/02/04 13:31:20 4. COMPONENTS (1) Evaporator unit (2) Condensing unit Evaporator fan AC power socket Control box (3) Details of condensing unit (4) Cabin controller (5) Control box MODE switch RUN/STOP switch UP switch Monitor display SET switch COOL HEAT DEFROST LO.HEAT RUN RUN ALARM CONT.RUN HI.HEAT ELEC. AUTO DIESEL STOP START/STOP Operation switch and lamp Hour meter (Sub-engine) Fuse box DEFROST switch Digital display area DOWN switch —— 00_TU42DXB.indd 5 2008/02/04 13:31:21 5. TEST OPERATION AND ADJUSTMENT 5.3 Motor drive Check the following items during test operation and adjustment, and enter the necessary items on the check sheet (page 56). (2) 5.1 Check before test run 6. DAILY OPERATION (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (1) Check the positions of the condenser, evaporator, battery and fuel tank. (See the installation figure.) Check whether the piping and wiring are properly clamped or not. (See the installation figure.) Check whether the end of the mounting bolts are completely sealed or not. (evaporator) Check whether the mounting bolts are tightened securely or not. Check whether the fuel hose, drain hose are securely connected and clamped or not. Check whether the area through which the piping and wiring pass is completely sealed or not. Check whether the electric wiring is properly clamped or not. Check whether the amount of the engine oil, cooling water and fuel are proper or not. Check the drive belt for slack. Check the refrigerant system for gas leakage, and oil, fuel and cooling water for leakage. Check the moving parts for interference (fans, pulleys, belts, etc. with the piping and the wiring) Check whether the operation valve of the refrigerant system is opened or not. (Check the gauge manifold for mounting.) Check the protector and the guard for mounting. Cleaning of room. 6.1 Check before operation 6.1.1 In case of sub-engine drive (1) 5.2 Check during test run (1) (2) (3) (4) (5) (6) (7) (8) (9) Check for abnormal noise and vibration. Check the sub-engine for proper running, and the fan motor for proper rotation. Check the color and flushing degree of the refrigeration sight glass. Check whether the high and low pressures are proper or not. Check whether the sub-engine start/stop (high/low speed switch) is properly control by the thermostat or not. Check the indication of the thermometer and the thermostat for proper working. Check the operation of the hourmeter. Check the operation of the defroster. Check the operation of the high pressure switch. Check the wiring of electric power. (Check the earth wire for poor insulation.) Check the motor for turning direction (automatically makes positive rotation). (2) (3) (4) (5) Engine oil amount check Be careful that if the engine oil decreases below the allowable level, it will result in thermal seizure of the sub-engine. The engine oil level must stand between the upper part of the level gauge mark and the lower tip. If the oil is heavily contaminated, replace it with new oil. (Caution) After three or more minutes have passed from starting the engine, stop the engine and inspect the oil amount. [Never use oil for gasoline engines.] Fuel amount check Fuel must be filled to the proper level in order to prevent fuel shortage on the way. Cooling water check Check whether cooling water is filled in the radiator and reservoir tank or not. Check engine oil, fuel and cooling water for leakage. Check the moving parts for interference and the belt for tightness. (Also see page 27.) —— 00_TU42DXB.indd 6 2008/02/04 13:31:22 6.1.2 In case of motor drive 6.2 Operation mode selection (1) The refrigeration unit can select automatic start/stop and continuous operation (selection system), and also the low/ high speed heating is selectable for the heating operation. (1) In case of loading frozen cargoes, it is recommended that the automatic start/stop mode be selected to save fuel. (2) In case of loading refrigerated cargoes, it is recommended that the automatic start/stop mode be selected when fuel saving is important, and that the continuous operation mode be selected when arrangement of the inside container temperature is important and that the low speed heating be selected when operated only by sub-engine drive. (3) When quick speed heating is desired, select the high speed heating mode (for sub-engine drive only). (2) After connecting the power, turn the engine/motor change-over switch to the motor side, and operate the start/stop switch momentarily to confirm that the motor can operate. (Even if the power is in the negative phase, the motor is always making a positive turn with a device to make a positive turn.) Check for abnormal vibration and noise. 6.3 Operation sequence 6.3.1 Functions of remote control box Heating operation lamp (Orange) Defrost indicator lamp Cooling operation lamp (Orange) (Green) Alarm indicator lamp COOL HEAT (Red) DEFROST LO.HEAT LO.HEAT/HI.HEAT changeover switch CONT.RUN/AUTO changeover switch Run indicator lamp (Green) RUN ALARM HI.HEAT RUN CONT.RUN ELEC. AUTO DIESEL ELEC./DIESEL changeover switch RUN/STOP switch STOP START/STOP Sub-engine hour meter Name Function A RUN/STOP switch (for emergency stop) The switch runs or stops the refrigeration unit. B Alarm indicator lamp (red) The lamp comes on or flickers and the engine or the motor stops when the lamp is lit. C Defrost indicator lamp (orange) The lamp is lit during defrosting. D Heating operation lamp (orange) The lamp is lit during heating. E Cooling operation lamp (green) The lamp is lit during cooling. F Run indicator lamp (green) The lamp is lit when the operation switch is turned to the operation side. G CONT.RUN/AUTO changeover switch The switch selects the automatic start/stop or continuous operation mode. H LO.HEAT/HI.HEAT changeover switch The switch selects the high-speed or low-speed heating mode. I Sub-engine hour meter The sub-engine's operating time is displayed. J ELEC./DIESEL changeover switch The switch selects the engine drive or motor drive. —— 00_TU42DXB.indd 7 2008/02/04 13:31:22 6.3.2 Functions of cabin control panel ① RUN/STOP switch ⑥ DEFROST switch Monitor display area ⑦ Digital display area ③ UP switch ② MODE switch ⑤ SET switch ④ DOWN switch (1) Switch names and functions ① RUN/STOP switch ② MODE switch ③ UP switch ④ DOWN switch ⑤ SET switch ⑥ DEFROST switch ⑦ Digital display area Turns the refrigeration unit RUN and STOP. Changes the screen display mode, etc. Changes the setting value of the temperature and time, etc. Changes the setting value of the temperature and time, etc. Registers a setting. Performs a manual defrost operation. Displays the setting temperature at the top, and the room temperature at the bottom. (2) Explanation of monitor display items This is the alarm indication. When trouble occurs, this symbol lights up (the backlight blinks) and blinks. This is the external communications status indicator. It lights up and blinks when the drive control switch is ON. This is the printer indicator. It lights up and blinks when data are being output to the printer, etc. This is the defrost indicator. It lights up during a defrost operation. This is the timer indicator. It lights up and blinks when there is a display or setting related to timer operation. This is the fix setting indicator. It lights up and blinks when prompting you to finalize a setting. This is the heating operation indicator. It lights up during a heating operation. This is the cooling operation indicator. It lights up during a cooling operation. This is the room temperature indicator. It lights up when the room temperature is being displayed in the bottom row of the digital display. It also blinks when the room temperature deviates from the setting temperature. —— 00_TU42DXB.indd 8 2008/02/04 13:31:22 6.3.3 Sub-engine drive operation sequence (all models) Operation mode Switch position and lamps 1 ELEC. Running ● Turn the ELEC./DIESEL changeover switch on the concent box to “DIESEL”. ● Select either the CONT.RUN/AUTO switch or continuous operating switch on the control box. DIESEL 2 CONT.RUN Select continuous operation only for refrigerated products, and do not select when the cargo is frozen products. AUTO START/STOP 3 LO.HEAT ● When heating is the main purpose, select high speed heating, and when refrigerating is the main purpose, select low speed heating. HI.HEAT 4 Select either the high speed heating or low speed heating changeover switch on the control box. Set the RUN/STOP switch on the control box to "RUN". 5 ● Starting the refrigeration unit Press the RUN/STOP switch on the cabin controller to switch the refrigeration unit “ON.” When the refrigeration unit is ON, the digital display switches from time display to show the temperature setting/inside container temperature. 6 ● Temperature setting/inside container temperature (1) Press either Up button or Down button, and the temperature in the digital display upper section flashes. By pressing the button again, you adjust the desired temperature. • Each press of the Up/Down button raises the temperature by 0.5 degree C increment. • Each press of the Up/Down button lowers the temperature by 0.5 degree C increment. Operation ● RUN STOP By pressing and hold the Up/Down buttons, the temperature changes more rapidly. (2) When the digital display shows the desired temperature, press the Set button. The cabin controller has a memory feature which stores the previous setting. Be certain to check the temperature in the digital display for proper operation. —— 00_TU42DXB.indd 9 2008/02/04 13:31:24 Operation mode Switch position and lamps Running 6 Operation The cabin controller has a memory feature which stores the previous setting. Be certain to check the temperature in the digital display for proper operation. Notes 7 ● Automatic defrosting When the evaporator is frosted, defrosting will be automatically executed. And after finishing to defrost, the cooling operation will be automatically carried out. 8 ● Stopping the refrigeration unit Press the RUN/STOP switch on the cabin controller for the second time to switch the refrigeration unit “OFF.” When the refrigeration unit is OFF, the digital displays show the time. Stopping Automatic defrosting When the inside container temperature is -29 degrees C or lower or 32 degrees C or higher, the display may not change by the 0.5 degree increment. This should not pose any problems for proper operation. Remarks (a) Precautions for operation If the RUN/STOP switch on the control box is changed over instantly, the unit may abnormally stop due to malfunctioning. (b) Unit operation The unit will start approximately two seconds after the RUN/STOP switch on the cabin controller is turned ON. (c) Starting of sub-engine ● The sub-engine will start automatically after the flow plug has been repeated for six seconds. ● If the sub-engine does not start within 20 seconds after the starter starts, the alarm indicator lamp will light, and the starter will stop automatically. Press the stop switch on the cabin controller once, and then press the RUN switch again. The subengine will automatically restart. (d) Air bleeding methods The refrigeration unit uses an automatic air bleeding system, so the air does not need to be bled. However, if air enters and the sub-engine cannot be started easily, set the start/stop switch to start, and then bleed the air from the fuel filter section. — 10 — 00_TU42DXB.indd 10 2008/02/04 13:31:24 (e) Automatic start-stop mode When the inside container temperature is higher than set on the thermostat, cooling will be activated, and when the inside container temperature is lower than set on the thermostat, heating will be automatically activated. (High speed heating or low speed heating is selectable.) Here, when the inside container temperature reaches the set temperature -1°C, the subengine will automatically stop and then the compressor, condenser fan and the evaporator fan will stop. However, when the temperature has reached -1°C from the set within 3.5 minutes of sub-engine run, the sub-engine will be automatically switched to the continuous operation to prevent the battery from being fully discharged. In case of cooling, when the temperature has reached -2°C from the set within 3.5 minutes of sub-engine run, the sub-engine will stop. And in case of heating, the engine will stop after the temperature has reached the set temperature. Here, no heating operation can be made if the set temperature is under "-7°C". If the inside container temperature reaches the set temperature within 3.5 minutes, the battery fail prevention circuit may function and heating operation may start even during refrigerating operation. The temperature width recorded on the recorder mounted on the refrigeration unit may widen in some cases, but there is no problem if the changes are not great. (f) Continuous operation mode When the inside container temperature is higher than set on the thermostat, cooling will be activated, and when the inside container temperature is lower than set on the thermostat, heating will be automatically activated. In order to keep the inside container temperature to the set, continuous operation will be made by repeating cooling and heating. (High speed heating or low speed heating is selectable for heating.) 6.3.4 Motor drive operation sequence Operation mode Switch position and lamps 1 ELEC. Operation sequence ● Turn the ELEC./DIESEL changeover switch on the control box to "ELEC.". ● Connect the motor drive power at the AC power socket, and then turn the power on. DIESEL 2 When connecting the power, confirm that the RUN/STOP switch on the cabin controller or the control box is turned "STOP". AC power socket Operation 3 CONT.RUN ● Select either of the automatic start-stop/continuous operation switch on the control box. Select continuous operation only for refrigerated products, and do not select when the cargo is frozen products. AUTO START/STOP 4 RUN ● Turn the RUN/STOP switch on the control box to “RUN”. STOP 5 ● ● Starting the refrigeration unit Press the RUN/STOP switch on the cabin controller to switch the refrigeration unit “ON.” When the refrigeration unit is ON, the digital display switches from time display to show the temperature setting/inside container temperature. As for the RUN/STOP procedures to be followed, carry out the same procedure as started on the sub-engine drive, item 5 thru 9 . — 11 — 00_TU42DXB.indd 11 2008/02/04 13:31:25 Remarks (a) Unit operation The unit will start approximately two seconds after the RUN/STOP switch on the cabin controller is turned “RUN”. (b) The motor drive operation is operated by one speed to make cooling or heating. (c) In case of selecting automatic start/stop mode When the inside container temperature is higher than the set temperature on the thermostat, cooling will be activated, and when the inside container temperature is lower than the set temperature, heating will be automatically activated. Here, when the inside container temperature reaches the set, the motor will automatically stop and then the compressor, the condenser fan and the evaporator fan will stop. No heating operation can be made if the set temperature is less than “-7ºC”. During motor drive, the battery fail prevention circuit will not function. (d) In case of selecting continuous operation mode When the inside container temperature is higher than the set on the thermostat, cooling will be activated, and when the inside container temperature is lower than the set, heating will be automatically activated. In order to keep the temperature to the set, continuous operation will be made by repeating cooling and heating. 6.3.5 Operation of MAN.DEF (manual defrost) switch When the evaporator is frosted during the cooling operation, defrosting will be automatically executed. However, when cooling of the inside container becomes slow with watery cargoes loaded, manual defrosting is available. Operation mode Switch position and lamps Operation sequence ● Turn the DEFROST switch “ON” during refrigerating operation. The defrost indicator will light during defrosting. ● When the unit is defrosted, cooling will be automatically activated. Defrosting ● — 12 — 00_TU42DXB.indd 12 2008/02/04 13:31:25 7. CAUTIONARY POINTS DURING OPERATION 7.1 Check during operation (1) Observe the digital display on the cabin controller to check whether the inside container temperature is kept at the set temperature or not. (2) Confirm that no abnormal noise is heard from the refrigeration unit. If any abnormal noise is heard, stop the refrigeration unit, and check the area generating the noise and take suitable countermeasures (repair, assurance of the cargo temperature, etc.) Check storage of the fuel. When the automatic start/stop is selected, if the inside container temperature reaches the set temperature in short time, the circuit to protect the battery from being fully discharged will be activated, and heating will start even during cooling operation, but this is not abnormal. Also, the temperature recorded on the recorder which is installed on the refrigerator vehicle sometimes varies, but not abnormal unless it varies largely. (3) (4) 7.2 Cautionary points during operation (1) (2) (3) When operating the refrigeration unit with the vehicle parked, avoid direct sunlight and select a well-ventilated area. The temperature indication on the display of the cabin controller may sometimes flicker owing to the wireless transceiver (of own or other vehicle). In this case, stop the vehicle once, restart and confirm the operation. Do not spill water, coffee, soft drinks, etc. on the cabin controller, or it will cause a trouble or abnormality. 8. CARGO LOADING 8.1 Check before cargo loading (1) (2) Carry it out according to the "check before test run" in page 6. Clean the container — 13 — 00_TU42DXB.indd 13 2008/02/04 13:31:25 (3) (4) Before loading the cargo, be sure to execute pre-cooling until the inside container temperature reaches the set temperature. (Carry it out according to the "operation sequence" in page 9.) It is necessary to pre-cool the body to transport and deliver the cargo properly. It sometimes rises to 60°C inside the body under direct sunlight in the summer. If any cargo is directly loaded in such a hot container it will surely result in abnormal temperature for transportation. Check the sight glass during operation and confirm that the refrigerant circulation amount (must be no foaming) and the check color (must be green) are normal. Sight glass Check color Green → Normal Yellow → Abnormal 8.2 Cargo loading procedure (1) 180mm About (2) (3) (4) Load the cargo into the refrigerator that has been cooled down beforehand to the specified temperature by another refrigerator. (If any warm or hot cargo is cooled down after it is loaded, the refrigeration unit will be over-loaded. Be sure to avoid such an operation.) When loading, stop the refrigeration unit and finish loading cargo as shortly as possible. Arrange the cargo so that cooled wind may be circulated every nook and corner. Keep the clearance of the cargo to the container wall as follows: Clearance,not to be piled up with loads. (5) (6) Rear door spacer Bulkhead Railings 50 ~ 75mm 500mm 100mm or more 100mm or more Make the upper surface of the cargo as flat as possible. Operate the refrigeration unit after loading. 8.3 Cargo unloading (1) Stop the refrigeration unit to unload the cargo. (2) Keep the door open for the shortest possible time. (3) To prevent ambient air from coming in and the cold air going out, always use a curtain when loading and unloading. Caution If loading or unloading is carried out while the refrigeration unit is running, the unit may abnormally stop. (In this case, the abnormality indication lamp will light. If the abnormality indication switch is pressed “ ” may display.) In this case, the defrost solenoid valve is not defective, so press the stop switch, and then press the start switch again. The refrigeration unit will start again. — 14 — 00_TU42DXB.indd 14 2008/02/04 13:31:26 9. REFRIGERANT PIPING SYSTEM 9.1 Refrigerant piping system Evaporator unit High pressure line Hot gas line Drain hose Low pressure line Condensing unit Accumulator 9.2 Cooling cycle Condenser coil Receiver Dryer Sight glass Low pressure switch Defrost solenoid valve (close) Condenser inlet solenoid valve (open) Heat exchanger Evaporator coil Evaporator unit High pressure switch Compressor Condensing unit Multi-function valve Accumulator Expansion valve Fan motor — 15 — 00_TU42DXB.indd 15 2008/02/04 13:31:27 9.3 Defrosting and heating cycle Defrost solenoid valve (open) Evaporator unit Condenser inlet solenoid valve (close) Condensing unit 10.DRIVE SYSTEM — 16 — 00_TU42DXB.indd 16 2008/02/04 13:31:28 11.CONTROL SYSTEM DTS FM1 FM1 FM1 Frame ground(E) Battery Ground Return air temp. sensor(TH) (E) (PE) Battery Return air temp. sensor connector <MC1> <OCR> DTS View A (M) (M) (F) 2P (M) A 3P (F) 3P (F) (M) 3P (F) 20P (F) Cabin controller HTS-overheat thermostat (E) Grommet 2P (F) Control box (F) 10P (M) (+) (-) Chassis ground Pre-heater PH Battery B Water temperature switch WTS Condenser inlet solenoid valve SV1 Alternator GU Defrost solenoid valve SV2 Engine speed sesnsor FWS High pressure switch HPS Sub-engine Starter motor SM Condensing unit Motor M Limit switch LM Compressor Control box Oil pressure switch OPS Discharge temperature sensor TDS Control box (3P) (PE) (E) Frame ground(B) FWS FWS OPS Frame round(A) (2D) (L) (14A) (14B) (2) (S) (PE) (7C1) (E) (7C1) (E) (8G) (2B) (8H6) (E) (8H1) (E) (12P) (2D) (B) (2) (S) PH WTS (PE) TDS (2P) (8C) (8H3) (E) HPS LM SWF SV1 SV2 TDS M (B) GU (E) SOL HS SOL RS SM (8H2) View B (8B4) (E) (8B3) (8B5) E Sub-engine (8C,8B5) (2P) (3P) Internal wiring of codensing unit — 17 — 00_TU42DXB.indd 17 2008/02/04 13:31:29 12.DESCRIPTION OF MAJOR COMPONENTS (3) Lubrication system Lubrication oil is supplied forcibly to respective bearings, pistons, tank shaft pins and shaft seals by the oil pump. 12.1 Compressor (1) Structure and function outline Driven by the motor or the sub-engine, the compressor sucks and compresses the refrigerant with the reciprocating motion of the piston. Schematic diagram of lubrication system Cross-sectional view of compressor (2) Note: The compressor oil has a high water absorbency, so after charging the oil, control the oil content carefully. (Refer to page 53 for details.) (4) Service valve The compressor is equipped with the suction service valve and deliver service valve. Specifications Model CR2318LWL-C Displacement 182cm3/rev Bore × Stroke × Number of cylinders ø45mm × 38mm × 3 Applicable revolution speed Engine type High speed 2000 min-1, Low speed 1600 min-1 Motor type 1100 min-1 (50Hz) Lubrication method Refrigerator oil Service valve Forcible lubrication Type Diamond Freeze MA32R Filling amount 1l (a) Back seat ●Closed between C and A, B. Open between A and B. (b) Front seat ●Closed between A and B, C. Open between B and C. (c) Intermediate seat ●A, B and C are opened to each other. Note: Before attaching the gauge to the service port, be sure produce the back seat state, and remove the plug. — 18 — 00_TU42DXB.indd 18 2008/02/04 13:31:29 12.2 Sub-engine 12.4 Motor Specification The unit can be operated in a garage, ferry boat, etc. with the motor driven by 3-phase electric power. Model L2E-31NCC (4-cycle water-cooled vertical diesel engine) Rated continuous output 6.25kW (8.5PS)/2400 min-1 (high speed) 4.8kW (6.5PS)/1900 min-1 (low speed) Displacement Motor specifications 635cm3 Fuel consumption amount for continuous operation. High speed 1.9l/h Low speed 1.4l/h Bore × Stroke × Number of cylinders ø76mm × 70mm × 2 Oil capacity 9.0l Fuel Diesel fuel, Under extremely cold weather (cold weather fuel) Cooling system Water cooling type Revolution speed High speed 2400 min-1 Low speed 1900 min-1 3-phase AC380V 50Hz Electric power Speed of revolution 1100 min-1 Specified output 3.4 kW 12.5 High-pressure switch When the compressor delivery pressure becomes excessively high, it is dangerous. Thus, the high-pressure switch is activated to stop the system. Factory-set value at delivery CUT OUT 3.2 ± 0.05 MPa (32.5 ± 0.5 kgf/cm2) CUT IN 2.2 ± 0.15 MPa (22.5 ± 1.5 kgf/cm2) <Automatic resetting> Unadjustable type 12.3 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 the pulley. Thus, the pulley will start 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 to the pulley in order to drive the compressor. Moreover, when the motor runs, the sub-engine will be kept to stop by this centrifugal clutch. Specified speed (setting value) 1100 ± 50 min-1 (1) If the pulley does not run even though the sub-engine revolution speed reaches 1100 min-1 or if the pulley starts together when the engine starts to run, the clutch is defective so repair it. High-pressure switch Judgment to be proper or not (1) Attach the high-pressure gauge to the refrigeration unit, and operate it. Make the heater exchange poor by blocking the air inlet of the condenser with paper. The high pressure will gradually increase as the time elapses. Observing the high-pressure gauge, consider that the switch is defective if the unit does not stop even though the pressure becomes 3.2MPa (32.5 kgf/ cm2). In this case, replace the switch assembly. (2) Measurement with the tester (proper) It is proper if the continuity is produced for the operational pressure of 2.2MPa (22.5kgf/cm2) or more during stop. Centrifugal clutch — 19 — 00_TU42DXB.indd 19 2008/02/04 13:31:29 12.6 Expansion valve 12.7 Solenoid valve The valve detects overheat at the outlet of the evaporator so that proper amount of refrigerant can flow into the evaporator, and make an automatic adjustment. When adjusting, turn the adjusting screw at a revolution of 1/4 and then 1/2 little by little, and see low much heated it is. (1) Condenser inlet solenoid valve (SV1) It opens during cooling operation and flows refrigerant into the condenser side. ● During defrosting, the solenoid valve is closed. ● The solenoid valve will, when electrified, close the refrigerant circuit and open it (plunger is upper side) when not electrified. ● Expansion valve Fix the thermo-sensitive cylinder securely, because the flowing amount of the refrigerant varies, depending on how it is fixed. Installation position Judgment to be proper or not When the sucking pressure of the valve during operation is lower than the one shown in page 57, the valve is considered to be clogged. Remove the thermo-sensitive cylinder from the sucking pipe and worm it up by hand. The expansion valve is normal if sound of the refrigerant going thru can be heard and the sucking pressure rises. If the refrigerant does not go thru, it is considered that either the needle in the valve is clogged or the gas in the thermo-sensitive cylinder is leaking. In case the needle valve is stuck, disassemble and clean it. And in case of leakage in the thermo-sensitive cylinder, replace the assembly. In order to check for gas leakage, warm and cool the thermo-sensitive cylinder to check the difference in the amount of the refrigerant going thru. (This is, however, the case when the needle is not stuck.) It is normal if there is any difference. It is defective if there is no difference. Do not try to make an adjustment excessively with the adjusting screw. In case of adjustment, remember the first position of the adjusting screw and make a quarter or a half turn to check the amount of the refrigerant going thru (sucking pressure). (2) Condenser inlet solenoid valve How to determine defective or not defective: When continuity of the lead between A and B is measured, the coil if normal if there is continuity and if not, it is defective. Before the coil is electrified, the temperature at the inlet and outlet of refrigerant is the same. So if the temperature becomes the different after the coil is electrified, the plunger is operating normally. If the temperature is the same the plunger is stuck. Easy way to find out the problem: When you electrify the coil with your hand touching the solenoid valve, it is normal if your hand feels a shock as the plunger goes down with a click sound. Defrost solenoid valve (SV2) It is installed in order to flow hot gas into the evaporator side when defrosting and heating operation. Defrost solenoid valve — 20 — 00_TU42DXB.indd 20 2008/02/04 13:31:30 How to determine defective or not defective: When continuity between the terminals is measured, the coil if normal if there is continuity and if not, it is defective. Before the coil is electrified, the temperature at the inlet and outlet of refrigerant is the same. So if the temperature becomes the different after the coil is electrified, the plunger is operating normally. If the temperature is the same the plunger is stuck. Easy way to find out the problem: When you electrify the coil with your hand touching the electromagnetic valve, it is normal if your hand feels a shock as the plunger goes down with a click sound. 12.8 Multi-function valve The multi-function valve features the following. (1) At the abnormally high pressure, the suction pressure is controlled to allow the unit to operate without any abnormal stop (high-pressure cutting). (2) Since the main valve of the multi-function valve is closed when the unit is stopped, the liquid does not return. This eliminates a danger of liquid compression to improve the reliability of the compressor. (3) The pressure equalizing hole of the multi-function valve makes the pressure difference early balanced soon after the unit is stopped. This will reduce the starting torque. (4) If the suction valve is high during operation, the subengine is overloaded. In this case, the suction valve will be kept to be so suitable that it can be operated at the preset pressure or less. Factory-set pressure at shipment High pressure side: 2.9 ± 0.05MPa (29.5 ± 0.5kgf/cm2) Low pressure side: 0.25 ± 0.02MPa (2.5 ± 0.2kgf/cm2) Note: (1) Since the multi-function valve was factory-set at shipment, don't adjust it at the site. If the adjusting screw is turned, the setting will become disturbed to cause a poor operation. (2) When installing the multi-function valve and connecting the pipe, don't apply any shock to the multi-function valve. Otherwise, it will cause gas leakage or improper operation. 12.9 Dryer Moisture and foreign materials are eliminated from the refrigerant. If the desiccant (molecular sieve) in the dryer can not remove moisture (the check color of the sight glass becomes yellow), replace the drier assembly. Also if inside of the dryer is clogged during operation, there will be a difference in temperature between the inlet and the outlet, and the outlet side becomes cool. Dryer When the dryer is replaced, replace it quickly. Here, when installing the dryer, pay heed to its direction and install it on the unit with the arrow mark aligned to the flow of the refrigerant. 12.10 Sight glass The sight glass is provided to allow observation of the circulation amount of the refrigerant and the existence of moisture in the refrigerant. (1) Judgment of refrigerant amount Sufficient refrigerant amount Insufficient refrigerant amount Check color Several bubbles moves or no bubble is observed. Check color Many bubbles are observed. If the refrigerant is extremely insufficient, it looks white. Sight glass Multi-function valve If the refrigerant is insufficient, repair the leakage area and charge the refrigerant gas. — 21 — 00_TU42DXB.indd 21 2008/02/04 13:31:30 (2) 12.13 Accumulator Judgment for moisture amount Moisture amount Judgment Refrigerant Refrigerant temperature 24°C temperature 38°C Green Normal 15 ppm or less 30 ppm or less Yellow green Slightly abnormal Yellow Abnormal Check color 15 ~90 ppm In order to prevent the refrigerant liquid from being sucked into the compressor, the refrigerant liquid and gas are separated. (To compressor) 30 ~140 ppm 90 ppm or more 140 ppm or more OUT (From evaporator) If it is yellow, moisture is mixed. Replace the dryer and evacuate the system. 12.11 Receiver Contains the refrigerant which was liquefied with the condenser. The receiver has a plug which melts down and release the refrigerant into atmosphere when the temperature rose excessively to prevent accident. Replace the plug when it melted. A three-way control valve is mounted at the outlet of refrigerant and it is used at the maintenance. Accumulator 12.14 Fan motor for evaporator The evaporator fan uses a long-life brushless fan motor. Voltage Number of revolution Rating DC12V 2000min-1 70W Fan Fan motor Rotated direction Receiver 12.12 Heat exchanger The refrigerating capacity is increased by exchanging the heat between the high-temperature liquid refrigerant and the low-temperature gas refrigerant. Fan Evaporator fan motor assembly Heat exchanger — 22 — 00_TU42DXB.indd 22 2008/02/04 13:31:31 12.15 Defrost completion thermosensor (DTS) (Unit: kΩ) The temperature of the evaporator coil is detected to indicate that defrosting is ended. Operation temperature OFF : 7.0 ± 1.5°C ON : 1.5 ± 1.5°C Judgment to be proper or not (1) Remove the lead cables of the thermistor sensor at the connector to check the continuity between the lead cables. (2) The negative resistance characteristic value of the thermistor temperature is shown on the right side. (3) In case the resistance value is widely out of range, remove the sensor at the connector and replace it. °C Minimum Standard Maximum -30 25.293 26.316 27.376 -20 15.125 15.572 16.031 -10 9.342 9.524 9.709 0 5.940 6.000 6.060 10 3.810 3.882 3.955 20 2.505 2.573 2.644 25 2.049 2.113 2.179 30 1.687 1.746 1.808 40 1.163 1.213 1.265 50 0.819 0.860 0.903 12.16 Inside container air temperature sensor (TH) The inside container air temperature sensor detects the evaporator suction air temperature so as to maintain the set temperature of the cabin controller. Here, the thermistor specifications are the same as those of the defrost completion thermosensor. Defrost completion thermosensor Negative resistance characteristic value of temperature 12.17 Delivery temperature sensor (Td sensor) The delivery temperature of the compressor is detected. If the delivery temperature rises, the refrigeration unit is stop. ● When the temperature reaches 150°C or more, the refrigeration unit is stopped. (1) Sensor Delivery temperature sensor Unit stop:150°C Unit operation:100°C — 23 — 00_TU42DXB.indd 23 2008/02/04 13:31:32 Judgment to be proper or not Disconnect the connector and measure the resistivity value. Resistivity value in normal state 200°C 0.430kΩ 100°C 5.228kΩ 175°C 0.738kΩ 25°C 80.470kΩ 115°C 3.352kΩ (3) The following diagram shows the operation. Circuit diagram 12.18 Overcurrent relay (OCR) When an excessive current flows into the motor during motor operation, the relay will stop the motor to protect it. It is required more than 1 minute to reset by automatic resetting. Setting value 11A Overcurrent relay 12.19 Alternator (1) The alternator is driven by the sub-engine or motor by belt, and generates electricity for charging battery. (2) The alternator is provided with a built-in IC regulator and its control section consists of a micro-integrated circuit. (4) Normal operation (a) When key switch is ON The voltage is applied to the terminal thru resistance, which MIC detects and the IC regulator will be in stand-by state. 1) Tr1 and Tr2 are interrupted by the transmission signal from MIC, and the initial excitation current which has been restrained in the field coil flows. 2) Since the alternator is not yet generating electricity, the voltage of the terminal is low, which MIC detects and turns on Tr3. (electricity not yet generating) (b) After starting of sub-engine As the alternator generates electricity, the voltages of terminals and rise to move on to next control. 1) As the voltage of terminal rises, the voltage of the terminal (voltage of battery terminal) rises. When it exceeds a specified adjusted voltage, MIC detects to turn off Tr2, which reduces the electric current of the field coil and in turn the power generation voltage, that is the voltage of the terminal will be lowered. And when the voltage of the terminal becomes lower than the adjusted voltage, the voltage will be kept constantly by the reverse action. 2) On the other hand, MIC detects from the voltage of the terminal that the alternator's power generation voltage is properly controlled, and turns off Tr3. (Normal electric generation) (5) Abnormal operation (a) Trouble diagnosis warning operation 1) When the field circuit is open When the field circuit is opened by some cause (breaking of field coil, wear of brush, etc.) the alternator will not generate electricity and the voltage of the terminal will be lowered. MIC detects the abnormality and turns on Tr3 to indicate the abnormality. Alternator — 24 — 00_TU42DXB.indd 24 2008/02/04 13:31:32 2) When the voltage is excessive When the alternator's power generation voltage becomes abnormally excessive, MIC detects it from the voltage of the terminal and turns on Tr3 to indicate abnormality. 3) When the alternator terminal is off If the alternator terminal comes off by some cause, the battery will not be charged and the battery voltage, that is the voltage of the terminal , will be lowered. when the voltage becomes lower than a specified value, MIC detects it and turns on Tr3 to indicate abnormality. 4) When the terminal is off If the terminal (S) comes off by some cause, voltage will not be applied to the terminal . MIC detects it and turns on Tr3 to indicate abnormality. Also, in this case, MIC moves on to the voltage detection control of the terminal to prevent abnormal rise of power generation voltage. In case of abnormal operation as shown in the item (5), the abnormality indication lamp of the cabin controller flickers to indicate the code "E32" on the display. (6) Specifications Rating Continuation Voltage DC12V Cold: 65 A (5000 min-1) Output capacity Rated number of revolution Hot: 52A(5000 min-1) 5000 min-1 Weight 5.5 kg 12.20 Engine oil pressure switch The oil pressure switch is installed at the side or top of the oil pump. If the oil pressure of the lubrication system drops to 0.05 MPa (0.5 kgf/cm2) during ordinary operation, the switch will be turned on to stop the sub-engine. 12.21 Sub-engine solenoid switch The sub-engine speed is changed to the high speed or low speed rated speed or is stopped by this solenoid. (1) To check the sub-engine speed while the refrigeration unit is operating, press the time indication switch and abnormality indication switch on the cabin controller simultaneously. The speed will display on the digital display section. Abnormality display section COOL HEAT SET POINT OUT OF RANGE ALARM MAN.DEF HOURS DISPLAY STOP RUN °C Time display switch The sub-engine speed (240 for high speed running and 170 for low speed running in the upper three digits) is displayed. If the sub-engine speed largely fluctuates on the display, make sure to check it on the speed indicator and carry out the following adjustment work. (2) Engine speed adjustment procedure (a) Adjustment of high speed revolution 1) Loosen the high speed set bolt e, and temporarily tighten it at the position where the clearance between the high speed set bolt e and speed control lever c is 2 mm or more when the speed control lever c is pressed in (toward solenoid side) by hand. 2) Run the sub-engine at the high speed operation, adjust the adjusting rod b, and set the speed to 2400 min-1. Make sure that the speed control lever c does not contact the high speed set bolt e during this adjustment. 3) Set the clearance of the high speed set bolt e and speed control lever c to 0.2 mm to 0.5 mm while the sub-engine is running at a high speed, and then fix the high speed set bolt e with a nut. d Low speed set bolt e High speed set bolt c Speed control lever Return spring b Adjusting rod Oil pressure switch — 25 — 00_TU42DXB.indd 25 2008/02/04 13:31:33 (b) Return 0.8 to 1.2 mm (2/3 turn) from the place where the speed sensor slightly hits. (Refer to the illustration below.) (b) Adjustment of low speed revolution 1) After adjusting the high speed rotation, run the sub-engine at the low speed. Set the speed to 1700 min-1 with the low speed bolt d, and fix with a nut. Note (1) In case of adjusting the engine speed, be sure that the solenoid and the return springs are securely mounted. (2) As for the solenoids (for both high and low speed), the solenoid shaft must be fully pulled in when electrified. The engine solenoid fuse will be melted if it is kept electrified without being fully pulled in. (3) After installation and adjustment, be sure to make a test run and check to see that it operates and stops. (2) 12.22 Sub-engine speed sensor (FWS) The engine speed sensor detects the engine speed and inputs to the controller (c) Secure the speed sensor to the bracket by the hexagonal nut. Tightening torque: 29.4 ± 4.9N·m (3 ± 0.5kgf·m) Inspection (a) Speed sensor gap inspection As shown in the above figure, it cheeks whether the gap between ring gear is a setting value. Setting value: 1 ± 0.2mm (b) Speed sensor inspection A Black line B Yellow line Speed sensor (1) Speed sensor installation procedures (a) Assemble the speed sensor to the bracket and keep turning until it slightly hits the ring gear. (Refer to the illustration below.) Disconnect the connector and measure the resistivity value between A and B. Resistivity value in normal state: 2.3 ± 0.2kΩ 12.23 Limit switch During refrigeration unit operation, the switch stops refrigeration unit for the sake of safety when the service door of condensing unit is open. Switch Lead cables A B Limit switch — 26 — 00_TU42DXB.indd 26 2008/02/04 13:31:33 Abnormality judgement Check the conductivity at point A and B with a tester. If it is conductive when the switch pressed in the arrow direction and it is disconnected when the switch released, it is normal. 12.25 Tension adjustment of belt Adjust tension of the belt as explained below. Note: Be careful not to tighten the belt excessively. 12.24 Setting value and revolution speed list Factory-setting at shipment is as follows: Setting value Item Setting value CUT OUT 2.9 MPa (29.5 kgf/cm2) CUT IN 2.2 MPa (22.5 kgf/cm2) High pressure switch Defrost completion thermosensor Engine oil pressure switch OFF 7.0 ± 1.5°C ON 3.0 ± 1.5°C CUT OUT 0.05MPa (0.5kgf/cm2G) Water temperature switch CUT OUT 111°C Fusible plug Fusible at 95°C Excess current relay for motor 11A Item Unit: min-1 (50Hz) Number of revolution Item Sub-engine Compressor Motor Condenser fan Evaporator fan Point L1 Number of revolution High speed Low speed High speed Low speed L2 2400 1900 2000 (1100) 1600 L3 L4 1000 Sag in (mm) Belt size Low edge cog belt Type HM, 2 piece (1015 mm) Low edge cog belt Type A, silver (855 mm) Low edge flat cog belt Type B, silver (2025 mm) LL, Type HM (905 mm) 10 10 10 10 ~ 12 Pressing force N (kg) 69 ~ 78 (7.0 ~ 8.0) 84 ~ 93 (8.5 ~ 9.5) 54 ~ 63 (5.5 ~ 6.5) 98 (10) High speed 1900 (1000) Low speed 1500 2000 Remarks: ( ) means motor drive case. Note: The belt alignment should be within 1 mm degree of parallelization, and the axial fall of each pulley should be made within 0.5°. — 27 — 00_TU42DXB.indd 27 2008/02/04 13:31:33 — 28 — 00_TU42DXB.indd 28 2008/02/04 13:31:34 13.1 Ladder diagram 13.WIRING DIAGRAM Black White Red Green B W R G O Br L Y Orange Brown Blue Yellow Gray Violet Pink Lg Light green Gy V P Code Wire color Code Wire color Code Wire color Wire color codes wire colors are identified by the following color codes. 13.2 Refrigeration unit wiring diagram 㪘㪚㩷㫇㫆㫎㪼㫉㩷㫊㫆㪺㫂㪼㫋 㪜 㪏㪝㪈 㪜 # & # $ % # 㪜 2TKPVGF DQCTF %0% 4 㪧㪩 $ # ) # ( # # 㪧㪚 㪪㪮 . 㪛㪜㪝㪩㪦㪪㪫 㪫㪟 㪈㪈㪊 㪈㪈㪉 㩷㪜 㪪㪮 㪛㪫㪪 㪪㪮 #4 /1 㪩㪬㪥㪆㪪㪫㪦㪧 ' 㪈 $ 㪈㪈㪈 㪈㪈㪇 㩷㪜 #4 55 #4 &* 㪜 㪠㪆㪝 㪣㪠㪞㪟㪫 ' 㪏㪝㪉 $ 㪜 㪏㪝㪊 $ 㪜 㪎㪚㪊 #4 51. & ' 㪚㪸㪹㫀㫅㩷㪺㫆㫅㫋㫉㫆㫃㫃㪼㫉 㪜 ' ( 㪎㪚㪊 㪎㪚㪊 㪈㪈㪌 㪈㪈㪋 % %10 4 㪝㪤㪈 . $ 㪝㪤㪉 . 㪝㪤㪊 . 9 㪛㪟 2' 㪛㪟 ) 㪜㫍㪸㫇㫆㫉㪸㫋㫆㫉㩷㫊㪼㪺㫋㫀㫆㫅 # # ## # # # # # # #4 (2 #4 (/ 㪎㪞㪉 㪜㪏 㪎㪞㪈 㪏㪝㪊 㪏㪝㪉 㪏㪝㪈 㪈㪈㪙 㪜㪎 㪈㪈㪘 㪎㪞㪉 㪜㪏 㪎㪞㪈 㪏㪝㪊 㪏㪝㪉 㪏㪝㪈 㪈㪈㪙 㪜㪎 㪈㪈㪘 㪎㪚㪊 㪈㪉 #4 *5 # $ # % % ( # #4 58 $ # & #4 (/ $ # # ' ' 㧔9㧕 㧔)㧕' 㧔$㧕 $ %0# # # 4 $ $ # # $ # $ 4 # # 㧔9㧕 $ $ 㧔$㧕 '㧔)㧕 㧔)㧕 ' 㧔$㧕$ '㧔)㧕 㧔9㧕# ) 㧔$㧕 㧔9㧕 ) # % $ $ $ # # $ % % 4 $ 4 # 4 㩿㪜㪀 #4 )7 4 % 4; 4 % #24 . . . 㪏㪞 . . $ 㩿㪂㪀 㪜 $ ' $ # $ # ( # /% ' 㩿㪄㪀 㪜 ' 㪙㪸㫋㫋㪼㫉㫐 㪈㪉㪭 # ' ' $ $ %0$ 4 . . . * 㪙㪞 #4 (/ 4 5 6 . 1%4 㪚㪿㪸㫊㫊㫀㫊㩷㫊㪼㪺㫋㫀㫆㫅 㪝㪧 & 㪪㪜㪫 4 . . . 㪪㪮 㪈㪇㪈 㪎㪘 㪉㪚 㪉㪚 㪎㪘 㪜㪈㪈 㪈㪇㪊 㪈㪇㪉 㪜㪈㪇 /% 㪛㪦㪮㪥 C 4 5 6 C 㪪㪮 㪈㪇㪈 㪈㪇㪈 㪎㪘 㪉㪚 㪉㪚 㪎㪘 㪜㪈㪈 㪈㪇㪊 㪈㪇㪉 㪜㪈㪇 ' D 㪬㪧 D 㪤㪦㪛㪜 㪪㪮 7 8 9 㪪㪮 㪎㪚㪊 㪈㪉 㪮㪟㪠㪪㪧㪜㪩 . * * * & * * #4 2*# # #4 45 㩿㪏㪟㪈㪀 / 㪜 㩿㪏㪟㪍㪀 & % 㩿㪜㪀 㪜 㩿㪎㪚㪈㪀 㪪㪭㪉 㩿㪜㪀 㪈㪇㪘 㪈㪇㪙 㪜㪍 & (. $ (. / 㩿㪉㪀 㩿㪪㪀 㪚㫆㫅㫋㫉㫆㫃㩷㪹㫆㫏 㪪㪼㪺㫋㫀㫆㫅 2. '/ 2. * ' ' $ # $ # # 59 *. # # # ( # ( # ' ( # 2. % 2. / 59 %106 59 &' 59 / */& $ % ( $ ( 㪏㪙㪌 㪏㪚 ( 㩿㪏㪟㪉㪀 㩿㪏㪙㪋㪀 㩿㪜㪀 㩿㪏㪙㪊㪀 㩿㪏㪙㪌㪀 㪚㫆㫅㪻㪼㫅㫊㪼㫉㩷㫊㪼㪺㫋㫀㫆㫅 㪏㪙㪌 㪏㪚 㧔㧕 㧔㧕 㪦㪧㪪 ' 㪟㪪 㪪㪦㪣 # 㪩㪪 㪏㪙㪋 㪏㪞 㪉㪙 㩷㪜 㪏㪟㪍 㪏㪟㪈 㪏㪟㪉 㪏㪟㪊 㩷㪣 㪪㪦㪣 㪏㪙㪋 㪏㪞 㪉㪙 㩷㪜 㪏㪟㪍 㪏㪟㪈 㪏㪟㪉 㪏㪟㪊 㩷㪣 ' 㪧㪟 㩿㪏㪚㪀 㪎㪚㪈 㪏㪙㪊 / 㪝㪮㪪 㪎㪚㪈 㪏㪙㪊 2' 㪮㪫㪪 㩿㪏㪟㪊㪀 ' 㪈㪋㪙 㪈㪇㪘 㪈㪇㪙 㪜㪍 㪪 㪜 54 㪈㪋㪘 㪈㪋㪙 㩿㪜㪀 㪪㪤 & 㩿㪜㪀 㩷㩿㪘㪀 㪜㫅㪾㫀㫅㪼 㩿㪣㪀 & 㩿㪙㪀 㪈㪋㪘 㩿㪉㪛㪀 % % $ 㩿㪧㪜㪀 $ ( 㩿㪈㪋㪙㪀 㪞㪬 5 & 㩿㪈㪋㪘㪀 㪫㪛㪪 㪤 㪪㪭㪈 #4 2* ' & & 㩿㪎㪚㪈㪀 % ' ' #4 51.# 㩿㪉㪙㪀 $ $ ' 㩿㪏㪞㪀 㪪㪮 㪝 & ' 㩿㪜㪀 㪣㪤 㩿㪜㪀 % 㪟㪧㪪 2. & — 29 — 00_TU42DXB_P29.indd 29 2008/01/28 13:07:47 — 30 — 00_TU42DXB.indd 30 2008/02/04 13:31:35 The following description of operation covers the principal operations. Refer to the failure diagnosis of the controller described on page 70, for other operations. 13.3 Description of operation Heating will not take place if the set temperature is -7°C or less. Note this does not apply when the battery fail prevention function has activated. ● When starting from cooling operation, the count of the high speed change-over timer will start when low speed cooling has started after high speed cooling operation. If low speed cooling continues for five minutes or more, the sub-engine will change to high speed cooling operation regardless of the thermostat. The unit will stop when TS1°C is reached. 2. Refer to page 41 for the thermostat operation. Continued on next page. Remarks (1) Sub-engine driving type 1. When Automatic starting and stopping is selected (a)Automatic starting and stopping under cooling ● Continue to run the sub-engine at least 3.5 minutes to protect battery discharge. Cooling and heating operations are repeated by the signals mode (During pull-down) from the thermostat to continue to run the engine at least 3.5 minutes. AOperation switch "ON" (Preheater energized; ● When the battery fail prevention function has activated, the low speed heating will be executed even when high speed heating is selected. Th1 and Th2 "ON" signal generated) ● — 31 — 00_TU42DXB.indd 31 2008/02/04 13:31:37 B6 seconds after operation switch "ON" (Starter motor energized; Th1 and Th2 "ON" signal generated) 3. Sub-engine/motor change-over switch Stop for approximately five seconds when changing over. 4. Sub-engine setting High speed operation will take place for ten seconds after the subengine is started regardless of the low speed operation command. 5. Evaporator fan delay drive control function ● The evaporator fan motor will be started 20 seconds after the subengine starts to decrease the load applied on the engine when starting the engine. 6. Alternator delay generator control function ● The generator circuit will be formed 20 seconds after the sub-engine starts. Remarks — 32 — 00_TU42DXB.indd 32 2008/02/04 13:31:38 COn completion of starting (Starter restored; Th1 and Th2 "ON" signal generated) — 33 — 00_TU42DXB.indd 33 2008/02/04 13:31:39 D20 seconds after completion of starting (Evaporator and alternator energized; Th1 and Th2 "ON" signal generated) Remarks The drain hose heater relay (AR DH ) is not energized when the temperature of the defrost thermo-sensor (DTS) is approximately 7°C or more, and energized when it is approximately 1.5°C or less. The relay is, also, not energized during the temperature decreasing and energized during the temperature increasing, between 1.5 to 7°C. — 34 — 00_TU42DXB.indd 34 2008/02/04 13:31:40 Remarks 1) The drain hose heater relay ( AR DH) is not energized when the temperature of the defrost thermo-sensor (DTS) is approximately 7°C or more, and energized when it is approximately 1.5°C or less. The relay is, also, not energized during the temperature decreasing and energized during the temperature increasing, between 1.5 to 7°C . 2) The unit will stop if the set value -1°C (Th2 OFF) is reached 3.5 minutes or more after the engine starts. 3) If the set value -1°C (Th2 OFF) is reached within 3.5 minutes after the engine starts, the battery fail prevention function will activate. (Refer to the thermostat operation explained on page 41.) EInside container temperature reached +0.5°C setting value (High speed or low speed selected; Th1 "OFF", and Th2 "ON" signal generated) — 35 — 00_TU42DXB.indd 35 2008/02/04 13:31:42 (b) Automatic starting and stopping under cooling mode (During thermostat ON operation): Operations only, which differ from those for the pull-down action, are shown. 10 seconds after completion of starting (High speed or low speed selected; Th1 "OFF", and Th2 "ON" signal generated) — 36 — 00_TU42DXB.indd 36 2008/02/04 13:31:43 (c) Automatic starting and stopping under heating mode (During pull-up high speed heating selection) 3.5 minutes after completion of starting (Th2, ON signal) Remarks 1) Refer to pages 32 to 35 for details on the operation up to the end of starting. (The operation other than "ARSV2" are the same.) AR 2) The drain hose heater relay ( DH) is not energized when the temperature of the defrost thermo-sensor (DTS) is approximately 7°C or more, and energized when it is approximately 1.5°C or less. The relay is, also, not energized during the temperature decreasing and energized during the temperature increasing, between 1.5 to 7°C . 3) The unit will completely stop when the set value -1°C is reached. — 37 — 00_TU42DXB.indd 37 2008/02/04 13:31:44 (d) Defrosting 1. The defrost start command will start with the manual defrosting switch, defrosting timer (1 to 6 hours) and air pressure switch (option). 2. Defrosting thermosensor setting value ON : 0 to 3°C OFF : 5.5 to 8.5°C 3. Defrosting forced completion function ● If the defrosting time when the outdoor temperature is low continues for a long time, the defrosting operation will be forcibly quit after one hour. 4. Defrosting timer ● The counting will start when the defrosting thermosensor turns ON. 5. The sub-engine will run at the high speed during defrosting. 6.If the defrosting thermosensor is ON while the thermostat is OFF during automatic start/stop operation, the sub-engine will start and defrosting will start when the manual defrosting switch is pressed. Remarks — 38 — 00_TU42DXB.indd 38 2008/02/04 13:31:45 1. Heating will not take place if the set temperature is -7°C or less. 2. Stop for approximately five seconds when changing over between the sub-engine and motor. 3. The evaporator heater is conducted only during heating operation when automatic start/stop operation is selected. 4. The evaporator fan motor and alternator conductivity is the same as the motor run command. 5. Refer to page 41 for the thermostat operation. Remarks Remarks 1) The drain hose heater relay ( AR DH) is not energized when the temperature of the defrost thermo-sensor (DTS) is approximately 7°C or more, and energized when it is approximately 1.5°C or less. The relay is, also, not energized during the temperature decreasing and energized during the temperature increasing, between 1.5 to 7°C . 2) The unit will completely stop when the set value -1°C is reached. (2) Motor driving type (a) Automatic starting and stopping under cooling mode (during pull-down) Operation switch "ON" (Th2, ON signal) — 39 — 00_TU42DXB.indd 39 2008/02/04 13:31:47 Remarks 1) The drain hose heater relay ( AR DH) is not energized when the temperature of the defrost thermo-sensor (DTS) is approximately 7°C or more, and energized when it is approximately 1.5°C or less. The relay is, also, not energized during the temperature decreasing and energized during the temperature increasing, between 1.5 to 7°C . 2) The unit will completely stop when the set value -1°C is reached. (b) Automatic starting and stopping under cooling mode (during pull-down) Operation switch "ON" (Th3, ON signal) — 40 — 00_TU42DXB.indd 40 2008/02/04 13:31:48 (c) Defrosting 1. The defrost start command will start with the manual defrosting switch, defrosting timer (1 to 6 hours) and air pressure switch (option). 2. Defrosting thermosensor setting value ON : 0 to 3°C OFF : 5.5 to 8.5°C 3. Defrosting forced completion function ● If the defrosting time when the outdoor temperature is low continues for a long time, the defrosting operation will be forcibly quit after one hour. 4. Defrosting timer ● The counting will start when the defrosting thermosensor turns ON. 5. The sub-engine will run at the high speed during defrosting. 6.If the defrosting thermosensor is ON while the thermostat is OFF during automatic start/stop operation, the sub-engine will start and defrosting will start when the manual defrosting switch is pressed. Remarks 13.4 Description of the thermostat operation (1) Sub-engine driven type The engine will be forced to run at high speed for 10 seconds after completion of starting, even if it is running under the low speed operation command. (a) Automatic starting and stopping 1) In case the inside container temperature reaches -1°C setting value within 3.5 minutes or more after completion of starting. 2) In case the inside container temperature reaches -1°C setting value within 3.5 minutes or less after completion of starting. <Cooling mode> Increasing temperature High speed cooling g�2 TS +0.5 (Th1) TS -1 (Th2) TS -3.5 (Th3) olin d co pee s Low Stopping High speed cooling TS +4 g lin coo eed TS +1.5 TS +0.5 (Th1) TS -1 �1 High speed heating or (optional) Low speed heating TS -1 (Th2) TS -2 (Th4) p s Low ed spe Low ling coo Decreasing temperature ping Stop Stopping Decreasing temperature <Heating mode> Increasing temperature �3 Increasing temperature Stopping �4 TS +4 TS TS +1.5 TS TS -2 (Th4) TS -3.5 (Th3) ed spe Low ting hea TS -1 Stopping �3 Low speed heating Decreasing temperature TS: Setting value Remarks (1) ø1 : The engine to be forced to run for heating at low speed for 3.5 minutes after completion of starting during heating operation. (2) ø2: The high speed change-over timer counting is started when the low speed cooling operation starts, and when the low speed cooling operation continues for five minutes or more, the sub-engine will change to high speed cooling operation regardless of the thermostat. The unit will stop when TS-1°C (Th2) is reached. (3) ø3: If TS-2°C is reached within 3.5 minutes after starting, heating operation will start. After this, low speed heating and cooling operation will be repeated if within 3.5 minutes after starting. If TS-2°C is reached 3.5 minutes or longer after starting, the unit will stop. (4) ø4: If TS is reached within 3.5 minutes after starting, cooling operation will start. After this, low speed cooling and low speed heating will be repeated if within 3.5 minutes after starting. If TS is reached 3.5 minutes or longer after starting, the unit will stop. (5) If the set temperature is -7°C or less when automatic start/stop is selected, heating will not be carried out. (6) Th4 is used only for the sub-engine automatic start/stop. This is used to repeat cooling and heating up to the stop command issued 3.5 minutes later. (b)Continuous operation Increasing temperature High speed cooling TS +0.5 (Th1) TS -1 (Th2) Low g oolin dc spee TS +4 TS +1.5 High speed heating or (optional) Low speed heating Decreasing temperature — 41 — 00_TU42DXB.indd 41 2008/02/04 13:31:49 (2) Motor driven type (a) Automatic starting and stopping (b) Continuous operation Increasing temperature Increasing temperature Cooling Cooling TS +1.5 TS -1 (Th2) TS -3.5 (Th3) ping Stop Heating Decreasing temperature TS -1 TS +1.5 TS -1 (Th2) Heating Decreasing temperature — 42 — 00_TU42DXB.indd 42 2008/02/04 13:31:49 14.INSPECTION 14.1 Daily inspection 14.2 Periodical inspection Inspect the items described in paragraph 14.5, page 46, at the same time. In order to prevent possible failure of the refrigerator truck and use it under the optimum conditions every day, perform the following inspection: (1) Run the refrigerator unit for approximately 15 minutes every 3 to 4 days, when the unit is not used for a considerably long time. (2) Take especially care to prevent oil from spilling on the centrifugal clutch during oil filter replacement or oil filling. If oil sticks to the wiring and the like, wipe it off by using waste cloth. (3) Sub-engine RPM (Revolution Per Minute) check: Check the sub-engine RPM periodically, because the engine RPM drop will cause the centrifugal clutch to fail. Refer to page 26 for engine RPM adjustment procedures. (4) Tension adjustment of V-type belt: Refer to page 27 for tension adjustment of belt. [Note] Take care of overtension. (5) Stop the refrigerator unit, melt ice in the drain pan, and completely drain off water out of the container to remove the frozen ice from the drain pan 1 to 2 times every week, when it is run for a long time with the inside container temperature kept at 10°C or lower. (6) Observe the sight glass to verify that the refrigerant level is proper. Operate the refrigerator unit, and check the sight glass after 10 minutes. If many bubbles are observed in the sight glass, the refrigerant is insufficient (it leaks somewhere). If the check color is green, the refrigerant level is normal. If it is yellow, the refrigerant level shows some failures, any may require replacement of the dryer, change of the refrigerant, etc. Inspect the items described on page 51, at the intervals given below. It is required to perform the periodical inspection by selecting the necessary items in accordance with the following intervals and to make, also, the required entry in the check sheet, page 55. 1. On installation 2. Every 100 hours 3. Every 200 hours 4. Every 250 hours 5. Every 400 hours 6. Every 600 hours (1) Inspection on installation Inspect and verify the check items in accordance with the installation test operational check sheet, page 55. (2) 100-hours inspection a) Air cleaner cleaning If the air cleaner is clogged, the engine power will drop and an abnormality in the centrifugal clutch may occur. b) Belt check Check the belt for crack and proper tension. c) Battery cable and terminal check Clean exterior surface of the battery and, particularly, the surrounding areas of the terminals. Check the specific gravity of battery electrolyte timely. Appropriate specific gravity: 1.28 to 1.30 Add distilled battery fluid, if any battery plate is exposed. Check the cable for corrosion. (3) 200-hours inspection (including 100-hours inspection) a) Injection nozzle check Check the nozzle for fit and damage, and replace the nozzle as an assembly if defective. b) Retightening of mounting bolts Retighten the mounting bolts for the condensing unit. c) Cooling check Decrease the inside container temperature to 0°C, and check temperature indication on the display, the thermometer, and the high and low operating pressure. d) Defrosting check Decrease the inside container temperature to 0°C, turn the manual defrosting switch "ON", and verify that the defrost solenoid valve is operated and defrosting process is started. Check the drain hose for drainage. e) Centrifugal clutch noise and play check Check the refrigerator unit with engine or motor operated for abnormal noise, slippage, etc. f) Vibration insulating rubber damage check Check the vibration insulating rubbers for installation security, damage, and crack. — 43 — 00_TU42DXB.indd 43 2008/02/04 13:31:49 g) Engine solenoid and related parts check ● Check the solenoid plunger for dirtiness and function. ● Check related links for smooth movement. h) Check of transmission lever ring (4) 250-hours inspection a) Air cleaner replacement (5) 400-hours inspection a) Engine oil change (including oil leak check) (After 100 hours for the first time only) Applicable oil: API Service Division, Class CD or higher, Grade 10W-30 or Summer : SAE 30, Winter : SAE10, Extreme cold time: SAE 10W, Oil capacity : 9.0l (not including filter) b) Oil filter replacement (After 100 hours for the first time only) c) Fuel filter replacement (6) 600-hours inspection (including 100-hours and 200hours inspection) a) Cooling water change Cooling water capacity: 4.0l Standard anti-freeze liquid density: 30% or more b) Glow plug check Verify whether the end of the glow plug is heated to be red or not, by connecting the (+) terminal of the battery to the terminal of the glow plug and the (-) terminal to the body. c) Starter and alternator check Check the starter and alternator for electrical current, revolution, brush, gap, etc. d) Valve clearance check (After 50 hours for the first time only) e) Retightening of mounting bolts Retighten the mounting bolts for sub-engine, compressor, compressor head, motor, vibration isolating rubbers, fan, V-type pulley, dryer, fan motor, solenoid, and evaporator housing. f) Loose electrical wiring terminals and damaged insulators check Take sufficient care for loose wiring terminals and damaged insulators, because these defects will result in shorted circuit or starting failure. g) Relay contact point check h) Clean the fuel tank, drain port, fuel pump, and strainer. i) Clean the condenser, evaporator, radiator coil, and drain port. Wash the coil by using water and washing brush, or blow the dust off the coil by using compressed air. Note: 1. The high-pressure washer should not be used for high pressure washing, or the condenser fins will be damaged. 2. The steam washer should not be used for washing, or the pressure in the washer will abnormally rise and may possibly result in extreme danger. j) Gas leakage check in refrigerant system Examine gas leakage carefully by using the gas detector, because oil blot shows gas leakage1 k) Operational check of high-pressure switch and limit switch 1) Attach a gauge to the discharge control valve of the compressor, close the suction port of the condenser by using paper and, then, operate the unit. Verify that the refrigeration unit will stop, the failure indicator lamp will come on, and " " symbol will be indicated on the display, when the high pressure becomes 3.2 MPa (32.5 kgf/cm2) in a while. 2) Verify that the refrigerator unit will stop, the failure indicator lamp will come on, and " " symbol will be indicated on the display, when the door of the condensing unit is opened with the refrigerator unit operated. l) Operational check of motor drive type Operation and insulation resistance. m) Main body painting Treatment for paint loss or corrosion on metal portion. n) Centrifugal clutch check Remove the centrifugal clutch and check the clutch shoe for wear condition. — 44 — 00_TU42DXB.indd 44 2008/02/04 13:31:50 14.3 Additional requirements (1) 14.4 Mounting bolt tightening torque list Applicable lubricants and injection N·m (kgf·m) Material Applicable lubricants Capacity SS400 S45C SUS304 Thread Head mark distance No mark or 4 r or 4 No mark M3 0.6 ~ 1.0 (0.06 ~ 0.1) 1.0 ~ 1.5 (0.1 ~ 0.15) 0.8 ~ 1.0 (0.08 ~ 0.1) M4 1.0 ~ 1.5 (0.1 ~ 0.15) 2.0 ~ 3.0 (0.2 ~ 0.3) 2.0 ~ 2.5 (0.2 ~ 0.25) M5 2.0 ~ 2.5 (0.2 ~ 0.25) 4.0 ~ 5.0 (0.4 ~ 0.5) 3.4 ~ 4.4 (0.35 ~ 0.45) Engine fuel Diesel fuel, Extremely cold season (cold weather fuel) Engine oil (Class CD or higher) Summer: SAE30, Winter: SAE10, Extreme cold weather: SAE10W 9.0l Refrigerator oil Diamond Freeze MA32R 1.0l M6 6.9 ~ 8.3 (0.7 ~ 0.85) 6.4 ~ 7.8 (0.65 ~ 0.8) * Antifreeze Fuso diesel long life coolant Standard density: 30% 1.2l 3.5 ~ 4.4 (0.36 ~ 0.45) M8 8.4 ~ 9.8 (0.86 ~ 1) 17.7 ~ 19.6 (1.8 ~ 2) 16.7 ~ 19.6 (1.7 ~ 2) Cooling water Pure water with no impurities Total cap. (including antifreeze) 4.0l M10 17.0 ~ 19.6 (1.73 ~ 2) 35.3 ~ 40.2 (3.6 ~ 4.1) 33.3 ~ 38.2 (3.4 ~ 3.9) M12 29.4 ~ 33.3 (3 ~ 3.4) 59.8 ~ 69.6 (6.1 ~ 7.1) 56.9 ~ 65.7 (5.8 ~ 6.7) M14 47.1 ~ 53.0 (4.8 ~ 5.4) 96.1 ~ 107.9 (9.8 ~ 11) 91.2 ~ 104.9 (9.3 ~ 10.7) M16 73.5 ~ 84.3 (7.5 ~ 8.6) 156.9 ~ 176.5 (16 ~ 18) 142.2 ~ 165.7 (14.5 ~ 16.9) — * Use the antifreeze density listed below in accordance with the lowest ambient temperature. Antifreeze density (%) Amount of mixed antifreeze l Lowest ambient temperature °C 30 35 40 45 50 55 60 1.2 1.4 1.6 1.8 2.0 2.2 2.4 -10 -15 -20 -25 -30 -35 -40 (a) If the antifreeze density is not suitable, the cooling water will be possibly be frozen and result in cracks or breakage in the radiator or cylinder block. (b) If the antifreeze listed in the table has a density of 30% or more, no rust-inhibitor is required. (c) Replenish the cooling water through the radiator filler port until the radiator is filled up with cooling water, with the refrigerator unit running (by the sub-engine drive) after the cooling water change. (d) Location of water drain plug on sub-engine. — 45 — 00_TU42DXB.indd 45 2008/02/04 13:31:50 — 46 — 00_TU42DXB.indd 46 2008/02/04 13:31:50 Paint on main body Precaution for centrifugal clutch during truck washing. 3 4 To take sufficient care to prevent pressurized water from splashing on the centrifugal clutch, when washing the truck body or van. Corrective action to paint scaled off or corrosion appeared on the metallic areas, when the unit is operated for a considerable long time. To prevent the heat exchanger efficiency drop caused by coil contamination. Condenser coil and radiator coil cleaning 2 To perform check as the daily work, because it is possible by using the sight glass to check the refrigerant for the fluid level and water contamination. Gas leakage check 1 Explanation Item No. Orient the user to perform the following items: 14.5 Cautionary points for daily inspection 1. To prevent oil, water, or other foreign materials from sticking to the power transmittal surface (shoe and drum) of the centrifugal clutch. 2. To prevent washing water from entering and sticking during truck washing. To close the clearance between the clutch drum and engine, by inserting waste cloth or news paper prior to washing. 3. To prevent oily material from sticking during inspection of the unit. 1.Corrosion, due to stone hit marks, scratch, etc. on the painted surfaces, has grown up without awareness. The initial corrosion can be prevented from growing up by touch-up paint. 1.The coils should be washed with tapped water by using brush, because the fins of the coils will be possibly deformed by pressurized water poured directly. 1. Refrigerant amount. If the refrigerant level is low due to the gas leakage, many bubbles are observed. If the level is extremely low, the refrigerant seems to be white (in the flushing condition). 2. Water inclusion If the check color is green, the refrigerant is proper. If it is yellow, the refrigerant is improper containing 140 ppm (refrigerant temperature 38°C) or more moisture. Precaution for service 1. The centrifugal clutch is thermally seized or damaged due to slip or heat generation. If oil or water sticks to the contact surfaces between the clutch shoe and drum, the frictional coefficient will rapidly drop. 1. Hole or crack in the panel. 2. The panel fallen. 1.The condenser coil is dirty. HPS is operated, and the refrigerating capacity drops. 2. The radiator coil is dirty. Failure will be induced by the engine overheat. 1. Refrigerant quantity is not sufficient. Improper or impossible cooling. Rise of discharge gas temperature. 2.Moisture invasion The expansion valve is clogged. The dryer is clogged. Possible failure 1. If possible, do not pour the pressurized water to the centrifugal clutch. 2. If washing water sticks to the centrifugal clutch, dry it completely before operation. 3. If oily material sticks to the clutch shoe, replace the clutch shoe. Clean the inner wall of the drum completely with degreasing detergent. 1. If rust generation is observed, clean the subjected area with sand paper at the earliest convenience, and repair the area with touch-up paint. 2. Replace a part on which rust is grown up to holes or cracks. 1. Clean the coils off dirt frequently. 1. Isolate and repair the leakage area, and refill refrigerant. 2-1. Discharge and recover the refrigerant, and replace the dryer. Evacuate the system, and refill the refrigerant to the specified level. 2-2. Check, also, the oil level in the compressor, and refill the oil in the same procedure as above. Corrective action (Remarks) — 47 — 00_TU42DXB.indd 47 2008/02/04 13:31:51 Air cleaner element Custody of fuel Fuel filter 6 7 8 Sub-engine overheat 5 Item No. In addition to dust in the fuel, moisture is, also, accumulated in the fuel filter. To prevent previously the subengine from failure caused by usage of improper fuel. Suction air amount insufficient. To maintain proper function of the cooling water system to prevent any failure caused by overheat. Explanation 1. Check the fuel filter periodically, and replace if necessary. 2. When replacing the fuel filter, make sure to purge air. 1. To make sure to use the specified fuel. Diesel fuel Extremely cold season (cold weather season) 2. To take care to prevent rain water or dust from entering into the fuel filter port. 1. To remove and clean the air cleaner element at the specified time. 2. To check the intake and pressure with a manometer. (Usage limit 500 mmAq) [Service shop] If the air filter is clogged, oxygen in the combustion chamber becomes insufficient, and the injected fuel can not be completely burned. 1. To check for cooling water quantity. 2. To check V-type belt for looseness. 3. To check radiator fin for dirtiness and clogging. 4. To check cooling water piping system and radiator for water leakage. 5. To check for engine oil quantity. Precaution for service 1. Poor sub-engine operation due to failed combustion. 2. Poor starting ability. 1. Revolution speed drops and output drops. 2. Exhaust gas color is improper, and starting 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. 1. Revolution speed drops and output drops. 2. The centrifugal clutch is thermally damaged. 3. Refrigerating capacity is insufficient. 4. Exhaust gas color is improper. 5. Carbon is deposited on the surrounding areas of the suction/exhaust valve, piston top and combustion chamber. 1. Overheat (causing revolution speed drop and output drop). 2. Thermal seizure on the sliding areas of the crankshaft, piston, etc. 3. The unit stops due to failure. 4. Oil consumption increases. 5. Excessive blow-by gas. Possible failure 1. The fuel filter is a filter paper element cartridge type. Replace the cartridge periodically (every 400 hours). (Replace even within 400 hours, if excessively dirty.) 2. Purge air securely until any bubble disappears completely. 1. Be sure to use the specified fuel for refilling. 1.Remove and clean the air cleaner element. (Air blow) 2.Air cleaner tends to be contaminated with the under mount type because of its mounting position. Frequent check and cleaning are necessary. 1. Check cooling water quantity and refill if necessary (reservoir tank). 2. Tighten the V-type belt to proper tension. 3. Clean and wash the radiator fins. 4. Check the clamps on the cooling water hose connection for looseness, and retighten the clamp. 5. Check engine oil level, and refill if necessary. Corrective action (Remarks) — 48 — 00_TU42DXB.indd 48 2008/02/04 13:31:51 periodically. Replace the lubricant filter Lubricant filter 10 Check and control the engine oil quantity, contamination, deterioration, etc. Control of engine oil 9 Explanation Item No. 1. When removing the filter, place waste cloth to prevent oil remained in the filter from spilling on the sub-engine's main body or each unit. 2. Before installing new filter, clean the filter seat surface completely. 3. Replace the filter packing (O-ring) with new one. 4. After the filter is replaced, make sure to run the engine in order to verify that oil does not leak. 5. Since the centrifugal clutch is located under the oil filter, take sufficient care for drips of the remaining oil when removing the filter. 2. The engine oil level must be between the upper and lower marks of the oil level gauge. 3. Oil change should be done while the oil temperature does not drop after operation. 1. Be sure to use the specified lubricant. API service division, Class CD or higher. Viscosity Summer: 20°C or higher SAE30 or 10W-30 Spring and Autumn: 5 to 20°C SAE20 or 10W-30 Winter: 5°C or lower SAE10W-30 Precaution for service 1. Abnormal wear and thermal seizure on the sliding area of the sub-engine. 2. Excessive blow-by gas. 3. Excessive oil consumption. When the oil filter is clogged, the contaminated oil before filtering will flow in the main gallery from the by-pass valve. In this case, the sliding area is rapidly worn. Moreover, if any metallic chip enters the oil pressure switch, it will cause improper activation or malfunction. 4. Slip or thermal damage of the centrifugal clutch the split area. 1. Overheating. 2. Thermal seizure on the piston. 3. Thermal seizure on the connecting rod. 4. Thermal seizure on the crank-shaft. 5. High oil consumption. 6. Excessive blow-by gas. Possible failure Every 400 hours 400 hours 2. If oil should be spilt on the centrifugal clutch (particularly near the shoe), be sure to clean (degrease). Second time and subsequence First time 1. Replace the lubricant filter at the specified interval. 1. Check the lubricant quantity every day as the daily inspection. 2. Make sure to change the lubricant every 400 hours (100 hours for the first time). 3. For refilling and change, use the lubricant specified in the left. 4. It is desirable to use the same brand lubricant continuously. Corrective action (Remarks) — 49 — 00_TU42DXB.indd 49 2008/02/04 13:31:51 Item Oil leakage Abnormal subengine noise. Precaution for halt of a long time No. 11 12 13 Abnormal noise often sounds as the symptom, before a large engine trouble occurs. Early finding and remedy for oil leak on any area of the subengine. When it is not used for a long time, refrigerant must be prevented from penetrating into the compressor. Oil must be prevented from running short on the shaft seal. Prevention of dewing and rusting in the sub-engine. Explanation 1. When the unit is not used for a long time, run the unit approximately 15 minutes every 3 to 4 days. 1. Since a large failure has often been previously prevented by finding an abnormal noise, usually be accustomed to normal running noise and combusting noise with your sense. Take care for any noise during inspection. 1.The oil seals and gaskets are used on some area of the sub-engine in order to seal the lubricant. Since the sealing ability may become poor as the operating time increases, this will result in oil leakage. Check the whole of the subengine sufficiently during inspection in order to find oil leakage as early as possible. Precaution for service 1. When the compressor halts for a long time, refrigerant liquid is internally accumulated. When the unit starts, this will cause improper lubrication to thermally seize the compressor. Moreover, refrigerant gas leakage may result from shortage of oil on the 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. 1. Crankshaft or main bearing is worn. 2. Bearing of connecting rod is worn. 3. Piston or piston pin is worn. 4. Valve working system of the camshaft is worn. 5. Any bearing worn. 1. Excessive oil consumption. 2. When oil leakage is excessive, the oil quantity decreases and the oil pressure drops, and the unit will stop abnormally. (The sliding area of the sub-engine is thermally seized.) 3. The sub-engine and unit will become dirty. Possible failure 1. If any area which generates abnormal noise is isolated, take the suitable remedy. (Part replacement, adjustment, etc.) 1. If looseness is found on any drain plug or bolt of the gear case, rocker cover, etc, retighten any loose one. 2. Replace any damaged gasket. 3. If leakage is found on the oil seal area, replace the seal. Check the lip contact area on the shaft side. Replace the oil seal if worn. Corrective action (Remarks) — 50 — 00_TU42DXB.indd 50 2008/02/04 13:31:51 Explanation 1. Prevention of defrosting failure, when utilizing electrical drive unit a refrigerator as a substitute of for a long time, during storage of pre-refrigerated cargo or refrigerated extra cargo in night. 1.When loading cargo, keep sufficient clearance to circulate wind in the room. 2.When cargo is loaded or unloaded with the door opened, the unit must be stopped. Item Precaution for usage of refrigerator truck as a substitute of a refrigerator Cargo loading method in van No. 14 15 1.The distance between the products and the inside wall of the freezer is specified on page 14. 1. When the unit is utilized, as a substitute of the refrigerator, melt frozen ice by raising the inside container temperature up to plus temperature one time every week. Precaution for service 1. The temperature distribution is sometimes largely uneven between the top and bottom or between the front and rear areas. 2. When the door is opened with the circulated, the cold air will be replaced with the outdoor air to rapidly rise the temperature in the container. 1. The drain pipe will be clogged failing drainage and ice will grow up progressly due to frozen defrosting water. This may cause to crush the defrosting pipe and cooling coil. Possible failure 1. The uneven temperature distribution will be reduced as the dimensions are larger. 2. Keep a clearance of 30 mm or more on both sides of cargo. Corrective action (Remarks) — 51 — 00_TU42DXB.indd 51 2008/02/04 13:31:52 2 1 No. Centrifugal clutch Solenoid Item Check the wear degree of the power transmission surface (shoe) of the centrifugal clutch coupled on the sub-engine. 1. Remove the centrifugal clutch every 500 to 600 hours, and check the clutch shoe for wear. If it is worn to the limit, replace the shoe set. When the shoe is worn to 1 mm (the clearance between the shoe and drum is 2.1 to 2.4 mm), it is the limit line. New shoe is 4 mm thick. 1. When the sub-engine revolution speed is adjusted, the adjusting rod is always used (adjusting). Take care to prevent rusting. 1. When adjusting the sub-engine revolution speed, activate the solenoid to verify that the contact point of the pull-in coil is surely opened. Adjust the adjusting rod. Rust preventive spray for adjusting rod. 1. When inspecting the solenoid, remove the plunger. If it is dirty or rusted, clean it with waste cloth. Apply a thin coat of grease on the whole. Precaution for service Clean the solenoid plunger and apply grease on it. Explanation 14.6 Cautionary points for periodical inspection 1. Centrifugal clutch thermally damaged. 2. Refrigerating capability reduced. 3. Dynamo charge failed. 1. Since the adjusting rod is rusted, it is impossible to adjust the 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. The pull-in coil and holding coil are provided in the solenoid. Since much current flows in the pull-in coil, it will be thermally damaged if the current flows for a certain time or more. 1. Once the centrifugal clutch slips, the generated heat slips the clutch further. 2. The wear limit for the drum is 0.5 mm. 1. Clean the adjusting rod and spray rust inhibitor on the rod during inspection. 1.Check the contact point. 1. Thermal damage and defective contact point. 1. Check every inspection. Corrective action (Remarks) 1. Solenoid binding. 2. Thermally damaged. 3. Improper sub-engine revolution. 4. Centrifugal clutch thermally damaged. Possible failure — 52 — 00_TU42DXB.indd 52 2008/02/04 13:31:52 Sub-engine revolution speed adjustment V-type belt tightness 5 6 Adjust the tension of the belt among the sub-engine type engine, motor and compressor. Since each part of the unit is designed to match the specified revolution speed, various failure may result if the revolution speed goes wrong. Link and related parts of the governor lever shaft adjusting rod, etc. do not operate properly. Governor lever link and related parts 4 Check the breakage degree of rubber boot covers provided on the front and rear areas of the solenoid. Water-proof cover check for solenoid boot 3 Explanation Item No. 1. Adjust the belt tension by using the tension meter. 2. Since a new belt is initially elongated, retighten the belt after an initial operation of approximate 10 hours. 3. Hereafter, check and adjust the belt every 100 hours. 1. Using the tachometer, adjust the speed to the proper value specified in the manual (it is possible to verify the round number by using the cabin controller). 2. Adjust the speed under no-load (with the belt removed). 3. Verify that the contact point of the pullin coil of the solenoid is opened, after adjusting the revolution speed. 1. Since they are influenced by rain water and dust, take care for dirtiness and rusting. Verify that the link and related parts from the solenoid to the governor lever shaft operate smoothly. Precaution for service 1. Excessively loose. Belt slippage Capability reduced. Alternator filed to generate. 2. Excessively tight. Pulley bearing failure. Belt wear early. Sub-engine crankshaft broken. Motor shaft broken. 1. Cooling capability insufficient. 2. Centrifugal clutch worn early. 3. Crack in pipe. 4. Chattering, tearing and breakage. 5. Excessive fuel consumption. 1. Improper sub-engine stopping. 2. Revolution speed drop or too low. 3. Solenoid thermally damaged. 1. Coil thermally damaged. 2. Improper suction. 3. Operation failed due to clogging. 4. Contact point becomes rough. Possible failure 1. Refer to page 27 for proper tension. 1. Refer to page 26 for adjustment procedure. 1. Check the adjusting lever shaft of the link section periodically, and clean and lubricate the lever shaft. 1. The water-proof cover must close tightly the joining surfaces of the metallic sheet cover. 2. Replace any torn and holed cover. Corrective action (Remarks) — 53 — 00_TU42DXB.indd 53 2008/02/04 13:31:52 9 Refrigerating circuit flushing and cleaning When the compressor is replaced due to some compressor trouble, check the refrigerant and oil for contamination. * If necessary, flush and clean the circuit. (*) Item 4 in the right column. ("Possible failure") 1. Refrigerant circuit flushing (1) Fill HCFC 141b and circulate it with another pump. After washing the circuit, recover HCFC 141b and evacuate the circuit. Fill, then, refrigerant. 2. Cleaning operation (1) Replace with a new compressor, evacuate the circuit and charge gas. Run the cooling operation approx. one hour (approx. 15 minutes for heating). (2) Recover the refrigerant and replace the dryer. Change the compressor refrigeration oil, evacuate the circuit again, and charge gas. The above procedure will prevent a failure from reoccurring in the compressor. 1. The refrigerating machine oil (Diamond Freeze MA32R) has an extremely high absorbency, so work quickly when handling it. 2. Never use leftover oil. Always dispose of it. 3. Dispose of any refrigerating machine oil in the oil can be used, and store it in a dry state. Precaution when using refrigerating machine oil for charging to the compressor. Refrigerating machine oil 8 1. Clamp and sealer-coat the terminals to prevent the ground cables from inner breakage caused by the running vibration of the vehicle. Remove paint on the chassis side. Termination of ground cables of the unit and battery to chassis. Ground cable check for chassis harness holder check 7 Precaution for service Explanation Item No. 1. Improper cooling. 2. Expansion valve clogged. 3. Dryer clogged. 4. Symptoms on the compressor. Thermal seizure occurs. Remaining oil is approx. black with metallic chips included. Sliding areas on the cylinder, piston, rod, etc. are worn and much scored. 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 reoccur in a short time. 1. Clogging may occur in each section if refrigerating machine oil exposed to air for a long time is used. 1. Alternator thermally damaged. 2. Many failures caused by thermally damaged relays, etc. 3. The terminal broken due to corrosion on the terminal area. 4. Improper contact. Possible failure 1. HCFC 141b is refrigerant for washing purpose. 1. Do not use refrigerating machine oil that has been exposed to air for a long time. 1. Check every inspection. 2. Apply sealer on each terminal area of the wire (except for area in the control box). Corrective action (Remarks) — 54 — 00_TU42DXB.indd 54 2008/02/04 13:31:52 Commercially Repair for painted 11 Item 10 No. Early remedy for paint peeling and areas rusting on any metallic part of the unit. Precaution for usage of commercially available parts. Explanation 1. If generation of rust is ignored, it will grow up further to result in a secondary damage. Remove rust using wire brush, emery paper, etc. and clean the areas completely. Then touch up paint or take a suitable repair. 1. Commercially available parts must not be easily used, even if the size and capacity are verified. Precaution for service 1. Panel or similar has holes or is cracked. 2. Panel drops. 1. If any bearing of a different sealing structure (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 of different characteristics is used, protection will become ineffective or it will result in malfunction. Possible failure 1. A part on which rust has developed to hole or crack must be replaced to prevent drop of the part or other troubles during driving. 1. Replace with genuine parts. Corrective action (Remarks) 14.7 Installation and test operation check sheet Refrigeration unit Van manufacture unit installing company Signature Customer Delivery date Model Inspection date Serial No. Inspection company Model Vehicle Inspector Serial No. Inspection item Inspection result Remarks Verification for locations of condenser, evaporator, battery and fuel tank installed (installation drawing) Verification for correct route of piping and wiring (installation drawing) Check for proper seal application to root of mounting bolt. Check for proper tightening of mounting bolts. Check for security of fuel hose and drain hose connections, and proper related clamping. Check for proper seal application to "go-through" portion of piping and wiring. Check for proper clamping of electrical wiring. Check for proper fluid level of engine oil, cooling water and fuel. Check for slackness on driving belts. Check for leakage of refrigerant system gas, oil, fuel and cooling water. Check for interference of moving parts (between fan, pulley, belt, etc. and piping, wiring). Check for abnormal noise or vibration. Check for proper sub-engine noise and proper fan motor rotation. Check for color and flushing degree of sight glass for refrigerant. Verification for correct high and low pressure. Verification for correct sub-engine starting and stopping (high speed/low speed selection) action initiated by thermostat. Check for proper function of inside container thermometer and thermostat. Verification for proper operation of hour meter. Verification for proper defrosting operation. Verification for proper function of high pressure switch. Verification for proper operation of stand-by motor. Verification for proper installation of protector and guard, cleaning inside container. Time Cooling inspection Item Ambient temperature °C Note: Operate unit down to the specified temperature or colder. Inside container temperature °C High pressure MPa (kgf/cm2) Low pressure MPa (kgf/cm2) Remarks — 55 — 00_TU42DXB.indd 55 2008/02/04 13:31:52 14.8 Periodical inspection check sheet Customer's signature Customer Model Refrigerator unit Serial No. Daily inspection Every 100 hours Every 200 hours Every 600 hours Inspection interval Vehicle Delivery date Inspection date Model Inspection company Inspector Serial No. Inspection items Sub-engine oil level check Fuel quantity check Sub-engine oil, fuel leakage check Check for interference with any moving part Condenser coil and radiator coil cleaning Cooling water amount and leakage (water hose, radiator and water pump) check Sub-engine revolution speed check Refrigerant sight glass color and flushing degree check Air cleaner cleaning Belt looseness and damage check Battery check (fluid level, specific gravity, terminal, wiring) Injection nozzle check Mounting bolt retorque (condensing unit) Cooling check (temperature indication on display, high and low pressure check) Defrosting operation check Centrifugal clutch noise and play check Vibration isolating rubber damage check Solenoid and surrounding area check Regulating lever link related parts check Every 400 hours Sub-engine oil change (including oil leakage check) (100 hours for the first time) Every 400 hours Oil filter replacement (100 hours for the first time) Every 250 hours Air cleaner replacement (whenever air cleaner failure indicator lamp comes on) Every 400 hours Fuel filter replacement Cooling water change Glow plug check Starter and alternator check Valve clearance check (50 hours for the first time) Mounting bolt retorque [engine, compressor, compressor head, motor, vibration isolating rubber, fan, V-type pulley, dryer, fan motor, solenoid, defrost solenoid valve, evaporator housing] Bearing grease service Check for electrical wiring terminal looseness, broken cable sheath and damage Relay contact point check Fuel tank, drain port, fuel pump, strainer cleaning Condenser coil, evaporator coil, radiator coil, drain port cleaning Refrigerant system gas leakage check High pressure switch and door switch operational check Compressor oil contamination check Motor driving operational check and insulating resistance check Inspection results Remarks Sub-engine overhaul (every 5000 hours) Season in Main body painting Centrifugal clutch removal and shoe check — 56 — 00_TU42DXB.indd 56 2008/02/04 13:31:53 14.9 Standard working pressure graph 2.5 (25) 2.4 (24) 2.3 (23) Inside container temperature -18°C 2.2 (22) 2.1 (21) Inside container temperature 0°C 2.0 (20) High-pressure MPa (kgf/cm2) 1.9 (19) 1.8 (18) 1.7 (17) 1.6 (16) 1.5 (15) 1.4 (14) Inside container temperature -29°C 1.3 (13) 1.2 (12) 1.1 (11) 1.0 (10) 0.9 (9) Inside container temperature -29°C 0.8 (8) Low-pressure MPa (kgf/cm2) Inside container temperature 0°C Inside container temperature -18°C 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 Return air temperature by condenser (°C) (Ambient temperature) Remarks The above operating pressure is applicable for cooling operation in sub-engine drive (high speed) mode. — 57 — 00_TU42DXB.indd 57 2008/02/04 13:31:53 15.TROUBLESHOOTING 15.1 Troubleshooting of refrigerant system (1) Abnormality and its cause of refrigerant system Defrosting is impossible Refrigerating capacity is not observed. Compressor generates noise. Compressor does not maintain the suction pressure. Compressor does not suck. Pump down is impossible. Suction pipe is frosted. Bubbles are observed through the sight glass. Low pressure is higher Low pressure is lower High pressure is higher Abnormality Refrigerant is overcharged. Cause Refrigerant is insufficient. Temperature of suction air of the condenser is excessively high. Condenser is clogged. Temperature of suction 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 delivery valve of the compressor. Refrigerant leaks on the suction valve of the compressor. An excessive amount of refrigerator oil circulates. Compressor pulley is improperly tightened. Compressor bearing is defective. Valve plate of the compressor is broken. Thermosensing tube of the expansion valve is defective. (lead of gas) Thermosensing tube of the expansion valve is improperly mounted. Expansion valve is excessively opened. Expansion valve is excessively closed. Refrigerant leaks from the expansion valve. Liquid back occurs. The low pressure side is clogged. The high pressure side is clogged. Expansion valve is clogged. Evaporator fan motor stops. (during refrigerating operation) Defrost solenoid valve operates improperly. — 58 — 00_TU42DXB.indd 58 2008/02/04 13:31:54 (2) Cooling is insufficient. Trouble cause Countermeasure (1) Airflow is insufficient. (a) The evaporator coil is frosted. (b) Fan motor is defective. (a) Reset the time on the defrost timer. (b) Check for the insulation, continuity, blown fuse and brush. (In the case that one fuse is blown, abnormality indication lamp flashes and symbol " " is indicated.) (2) Since a clearance exists on the refrigeration van, air enters from outdoors through the clearance. Check for clearance, and repair to eliminate the clearance. (3) Many bubbles are observed through the sight glass. In this case, the refrigerant is reduced. Check for gas leakage, and refill refrigerant after repair. (4) Condenser coil is dirty. Wash with water. Take care of the fins which may be deformed if rubbed with hard-haired brush. Note: ● If the high-pressure washer is used, the condenser fins will be deformed. Be sure to prevent using the washer. ● Avoid to use the steam washer because the pressure in the equipment will abnormally rise and it is very dangerous. (5) Rotation speed of the compressor is reduced owing to the slippage of loosened belt. Adjust belt tension. If belt is damaged, replace it. (6) If the above items are proper: (a) The expansion valve is clogged. (a) Connect the gauge manifold, and start engine. Check that the compressor rotates at the high-speed of 2000min-1. Though a slightly lower value is indicated as the pressure on the high-pressure side, the expansion valve or dryer strainer may be clogged if the pressure indicated on the lower side is lower than the value shown in page 56. 1) The expansion valve is clogged by frozen moisture at the outlet port of expansion valve. Stop the engine once and melt ice, then start the compressor again keeping the thermosensing tube afloat. The pressure on the low-pressure side will gradually increase. After the operation is kept for a while, if any pressure lower than that of normal operation is indicated, it is estimated that moisture exists in the refrigeration cycle. If the low-pressure gauge does not rise even though the thermosensing tube is floated, the expansion valve may be thermally seized or gas may leak from the thermosensing tube. (Replace) 2) Collect the refrigerant if moisture is mixed. Then replace the dryer strainer. After completely removing the moisture with the "repeated evacuating method", replace the refrigerant. Furthermore when the driver strainer is clogged, the low-pressure gauge may also show the lower value than the normal operating condition. In the worst case, the driver and subsequent tubing will be covered by heavy frost. If it is slightly clogged, the temperature difference is observed between before and after the dryer strainer. (Replace) (b) Expansion valve is excessively opened. (b) When the pressure on the low-pressure side is high together with the 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 thermosensing tube is not afloat. The expansion valve is sometimes seized. (c) Compressor valve is defective. (c) 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. If the condenser temperature hardly rises, the compressor may be ineffective for compressing. (Repair or replace) (d) Excessive refrigerant (d) This judgment is slightly difficult. The following tendency will be observed. 1) The high-pressure gauge indicates the higher pressure: that is, the pressure during operation becomes higher than the high pressure shown in page 57. 2) Even if the compressor is rotated at the high temperature, no bubbles are observed through the sight glass. For example, no bubbles are observed even though the compressor is run with the door fully opened at the outdoor temperature of 35°C or more. If it seems to be overcharged, gradually discharge the refrigerant to the specified amount. (e) Much air is mixed in the equipment. (e) In the case that the high-pressure gauge indicates a considerably high pressure but many bubbles are observed through the sight glass and the cooling is poor, air may be mixed. Since air is lighter than refrigerant, air is collected at the top portion of the device. Therefore, air purge is impossible and evacuating is necessary. — 59 — 00_TU42DXB.indd 59 2008/02/04 13:31:54 (3) Abnormal noise is heard. Trouble cause (1) Improper mounting work Countermeasure Check, repair or retighten. (2) Compressor (a) Metallic noise is heard from the internal. (b) Oil is excessively filled. (b) Drain oil to the specified amount. (3) Belt is loose. Adjust the belt tension. (4) Sub-engine muffler is clogged. Clean the muffler. (5) Fan interference Inspect and repair if necessary. (6) Liquid compression in the compressor Check expansion valve and quantity of refrigerant. (a) Disassemble for internal check. Repair or replace, if necessary. (4) Excessively high pressure on the high pressure side Trouble cause Countermeasure (1) Mixing of air in the equipment Collect refrigerant, and evacuate the equipment. (2) Dirty condenser coil Clean the condenser coil. (3) Excessive refrigerant amount Reduce to the specified amount. (4) Defective condenser fan Inspect (5) The receiver outlet valve is approximately closed. Inspect (6) Clogged pipe on the high pressure side Inspect (7) Clogged dryer Inspect (8) Condenser coil is exposed to direct sunlight. Inspect (9) Belt slip Inspect — 60 — 00_TU42DXB.indd 60 2008/02/04 13:31:54 (5) Excessively low pressure on the high pressure side Trouble cause Countermeasure (1) Refrigerant quantity is insufficient. Repair the leakage area and recharge the refrigerant. (2) Valve breakage or leakage on the compressor Inspect and repair. (3) Low outside temperature Not abnormal (4) Frosted evaporator coil Inspect (6) Excessively low pressure on the low pressure side Trouble cause Countermeasure (1) Clogged pipe on the low pressure side Inspect and repair. (2) Refrigerant amount is insufficient. Repair the leakage area and recharge the refrigerant. (3) Dirty evaporator coil Clean the evaporator coil. (4) Clogged pipe on the low pressure side Inspect and repair. (5) Defective evaporator fan Inspect and repair. (6) Low outside temperature Not abnormal (7) Excessively high pressure on the low pressure side Trouble cause Countermeasure (1) Breakage of compressor valve Inspect and repair (2) Improperly mounted thermosensing tube of the expansion valve Inspect and repair (3) Liquid compression (liquid hammering) occurs. Inspect and repair (4) Excessive refrigerant quantity Collect the refrigerant. — 61 — 00_TU42DXB.indd 61 2008/02/04 13:31:54 15.2 Troubleshooting of sub-engine and related components (1) Sub-engine troubles and their causes Battery charging is insufficient. Sub-engine overheat occurs. Sub-engine is out of order. Sub-engine oil pressure is improper. Sub-engine stops by itself. Sub-engine does not start. Abnormality Cause Starter rotation does not increase. Viscosity of engine oil is not proper. Sub-engine temperature is excessively low. Sliding parts approximately seize. Air bleeding of fuel system is not sufficient. High-speed or low-speed solenoid fuse is blown. Rpm sensor is in open circuit or in short circuit. Fuel tank is empty. Clogging of fuel filter Air is mixed in the fuel system. Oil level is low. Oil leakage at the connecting portion. Defect of oil pressure switch Cooling water level is low. Leakage at the cooling system. Loose or oil-contaminated radiator fan drive belt. Defective radiator Breakage of radiator fan Alternator belt is loose. Trouble of wiring Battery is defective. Pulley is mounted loosely. — 62 — 00_TU42DXB.indd 62 2008/02/04 13:31:54 (2) Starting trouble (a) Check items Clogged air cleaner Hardened engine oil ● Fuel of inferior quality ● Drop of cranking speed ● ● (b) Check Is it normal the preheating device? No ➡ Is the power supplied to the glow plug wire immediately after the operation switch ON? Check of wiring, glow signal No ➡ Check of fuel pmp, wiring and its related section. No ➡ Check of fuel filter, fuel pipe and fuel tank { No ➡ Adjust the sub-engine { No ➡ Check of injection nozzle ➡ No ➡ ➡ Yes ➡ Yes Check of glow plug { When the fuel pump is equipped, Is it normal the wiring. is the pump operating when the operation switch Is turned ON. ➡ Yes Is the fuel circulated in the fuel line? No ➡ Is the fuel is fed when the injection pump air vent screw is slackened? ➡ Yes Is the engine adjusted properly?Timing of atomization, timing of valve ➡ Yes State of atomization Is it normal the injection nozzle? atomizing start pressure ➡ Yes Is it normal the compression pressure? No ➡ Check of valve, piston, piston ring and head gasket ➡ Yes Check of injection pump — 63 — 00_TU42DXB.indd 63 2008/02/04 13:31:55 (3) Knocking Diesel engine operates with the specific combustion sound depending on its combustion method. This sound of knocking is normal so far as it is not excessively large. (a) Check items ● ● Clogging of air cleaner Fuel of inferior quality (kerosene, etc. with lower cetane number) (b) Check Is it normal the atomization timing? (Atomization timing is fast.) ➡ No ➡ Adjustment of atomization timing No ➡ Investigation of injection nozzle Yes Is it normal the injection nozzle? (Blasting trouble due to drop of atomization start pressure) ➡ Yes Is it normal the compression pressure? No ➡ Check of valve, piston, piston ring and head gasket ➡ Yes Is it normal the injection pump (deviation of atomization volume)? ➡ Yes Mechanical noise (wear, damage on the major moving section) — 64 — 00_TU42DXB.indd 64 2008/02/04 13:31:55 (4) Overheat (a) Check items Volume, leakage of cooling water Loose fan belt ● Clogged radiator fin ● Antifreezing solution density Clogged muffler Volume, aging of engine oil ● Recoiling of cooling air ● Defective thermostat ● ● ● ● (b) Check Is not it operated continuously under overload? No ➡ Check of cause of load. ➡ Yes Is it normal the Blow through of head gasket, clogged water cooling system? pump, water hose or radiator, defective thermostat ➡ Rework of cooling system No ➡ Adjustment of sub-engine No ➡ Check of injection nozzle Yes Is it normal the atomization timing? (5) No ➡ No ➡ Adjustment of atomization timing Much black smoke (a) Check items Clogging of air cleaner element Fuel of inferior quality ● Overload ● ● (b) Check Is it normal the injection pump, setting volume of smoke? No ➡ Adjustment of setting of smoke ➡ Yes Is the engine adjusted properly? (excessive valve clearance, wrong atomization timing) ➡ Yes Is it normal the injection nozzle? (State of atomizing, much higher atomization start pressure) ➡ Yes Is it normal the compression pressure? No ➡ Check of valve, cylinder head gasket, piston and piston ring ➡ Yes Check of injection pump — 65 — 00_TU42DXB.indd 65 2008/02/04 13:31:55 (6) Insufficient output (a) Check items Seizure of moving section of sub-engine Too much higher viscosity of engine oil ● Fuel of inferior quality Clogged air cleaner element Clogged muffler ● Trouble on drive system ● ● ● ● (b) Check Does the fuel flow with the switch ON in the case of solenoid type? Is if sufficient the fuel in the fuel line? Check of fuel filter, fuel pipe and fuel tank No ➡ Adjustment of sub-engine No ➡ Check of injection nozzle ➡ No ➡ ➡ Fuel pump Yes ➡ Yes Is the sub-engine adjusted properly? (Valve clearance, atomization timing) ➡ Yes Is it normal the injection nozzle? (State of atomizing, atomization start pressure) ➡ Yes Is it normal the compression pressure? No ➡ Check of valve, cylinder head gasket, piston and piston ring. ➡ Yes Check of injection pump — 66 — 00_TU42DXB.indd 66 2008/02/04 13:31:55 15.3 Electric circuit troubleshooting (1) Identifying the detail of trouble with the cabin controller When the alarm symbol “ ” has turned on (the backlight blinks) or blinked at the monitor display area, check the detail of trouble on the refrigeration unit. 1 1 2 2 Displaying the active alarm display When the alarm symbol “ ” has turned on (the backlight blinks) or blinked at the monitor display area, press the [MODE] switch (twice if the refrigeration unit is stopped, or once if the unit is operating) to change the screen to the active alarm display. The alarm code displays at the bottom of the digital display area, with up to 10 codes being displayed sequentially at 2-second intervals. If there are no active alarms, “ ” displays. Alarm symbol display Active alarm display Press the [SET] switch to display the setting temperature / room temperature (when refrigeration unit is running), or the clock (when refrigeration is unit is stopped). List of alarm codes (If the alarm display Alarm Code lights up continuously) Error Contents Measures Refrigeration Unit State Evaporator fan motor fuse is blown. Two or more of the fuses for the evaporator fan motor Refrigeration unit have blown. operation stops. Inspect and replace the fuses F2 to F4 in the control box. Sub-engine solenoid fuse is blown. The solenoid fuse for the sub-engine has blown. Inspect and replace the fuses F5 in the control box. Refrigeration unit operation stops. Output relay fuse is blown. The output relay fuse has blown. Inspect and replace the fuse F7 in the control box. Refrigeration unit operation stops. Commercial power supply is faulty. The commercial power supply has failed, or the power supply is disconnected. Check the power supply. When carrying out operation with the sub-engine, close the power supply plug cover. Refrigeration unit operation stops. High-pressure switch is operating. The high-pressure switch has functioned. Check whether the condenser coils are dirty, and clean them if they are. Check the condenser fan or belt for breakage. Refrigeration unit operation stops. (Auto recovery) *1 Defrost solenoid valve is faulty. Defrost solenoid valve operation is faulty. When changing from the defrosting end command to the cooling operation command, or when changing from the heating operation command to the cooling operation command, the temperature detected by the defrosting end thermosensor is recorded. If the temperature is the detected temperature + 5 deg. or more 30 minutes later, the unit will stop. If the cooling operation command Refrigeration unit ends within 30 minutes, this will be canceled. operation stops. ADVICE If loading or unloading work is carried out while the refrigeration unit is running, the alarm “ ” will display, and the refrigeration unit may stop with a fault. In this case, the defrost solenoid valve is not faulty. Press the STOP switch, and then turn the RUN/STOP switch “ON” again to resume operation. — 67 — 00_TU42DXB.indd 67 2008/02/04 13:31:56 Alarm Code *1 *2 Measures Refrigeration Unit State Sub-engine oil pressure switch is operating. The sub-engine oil pressure switch has functioned. Check the sub-engine. Refrigeration unit operation stops Sub-engine water temperature switch is operating. The sub-engine water temperature switch has functioned. (Overheat) Check the cooling water level, and replenish if low. Check whether the radiator is dirty, and clean it if it is. Refrigeration unit operation stops Sub-engine speed is abnormally low. The sub-engine speed has dropped abnormally. After the sub-engine speed has risen to 1500 min-1 or higher, and it drops to 1400 min-1 or less for five or more seconds, the unit will stop due to the abnormal drop in sub-engine speed. Restart the unit. If the sub-engine speed is lower than the specified value, adjust it to 1700 min-1. Restart the unit. If sub-engine start-up is not sufficient, bleed air from fuel system. Sub-engine starting failed. The sub-engine starting failed. Check the fuel level, and replenish if low. Purge the air at the fuel filter section. When the engine speed does not increase to more than 700 min-1 within 20 seconds after starter has energized, starting capability is insufficient, and stop the unit. Refrigeration unit operation stops Sub-engine rising failed. The sub-engine rising failed. The unit will stop if the sub-engine speed does not rise to 1500 min-1 or more even after 20 seconds has passed after the engine has started. Refrigeration unit operation stops Condensing unit door is not closed. The codensing unit door is open. Close the codensing unit door before starting operation. Refrigeration unit operation stops Motor protective device operated. The motor’s protective device has functioned. Check the motor. Refrigeration unit operation stops Room temperature sensor is abnormal. The room temperature sensor has a broken connection or short circuit, or the connector’s connection is faulty. Check the leads and connector. The room temperature display shows “ ”when there is a broken connection, and shows “ ” or higher if there is a short circuit. Refrigeration unit operation stops Sub-engine speed sensor is abnormal. The sub-engine speed sensor has a broken wire, has short circuited, or there is a contactor contact defect. Inspect the lead wire and connector. The self-starting motor start failed. If the self-starting motor does not start when the unit is restarted, the battery is dead or the self-starting motor is faulty. Charge the battery if it is dead. (The self-starting motor starts six seconds after the RUN/STOP switch is turned “ON”.) If sub-engine speed does not increase to 100 min-1 and over within 3 seconds after the starter is energized, failure of sub-engine speed sensor is suspected and stop the unit. In addition, protection should be exercised against not only abnormal sensor but also starter motor failure and starter ring gear failure. Refrigeration unit operation stops Controller communications are abnormal. The wiring harness connection to terminal No. 7 (#103) of connector CNB inside the control box is faulty. Cabin controller communications are faulty. In this case, the room temperature display shows “ ”. Refrigeration unit operation stops Error Contents *2 *2 *1 *2 Refrigeration unit operation stops — 68 — 00_TU42DXB.indd 68 2008/02/04 13:31:56 List of alarm codes (If the alarm display Alarm Code blinks) Error Contents Evaporator fan motor fuse is blown. One of the fuses for the evaporator fan motor has blown. Refrigeration unit Inspect and replace the fuses F2 to F4 in the control box. operation continues Sub-engine high-speed solenoid fuse is blown The high-speed solenoid fuse for the sub-engine has blown. Refrigeration unit Inspect and replace the fuses F6 in the control box. operation continues Discharge refrigerant gas temperature is abnormal. The discharge refigerant gas temperature is abnormal. Inspect the sight glass. If bubbles are apparent, the refrigerant gas is low. When the delivery gas temperature reaches 150°C, the unit will be stopped by the delivery temperature sensor signal (Operation will automatically resume when the delivery gas temperature reaches 100°C.) Refrigeration unit operation continues Alternator charge is abnormal. The alternator’s charge is faulty. Check the alternator. When the alternator terminal voltage drops under 3 V, the APR relay wire harness has open circuit. Refrigeration unit operation continues Defrost sensor is faulty. The defrost sensor has a broken wire, has short circuited, or there is a contactor contact defect. Inspect the lead wire and connector. Refrigeration unit operation continues List of alarm codes (If there is no alarm display Alarm Code ) Error Contents Normal display ADVICE Refrigeration Unit State Measures Measures The refrigeration unit is normal. Refrigeration Unit State Refrigeration unit operation continues (1) Always use genuine fuses, and always replace fuses with a fuse of equal capacity. (2) Alarm codes are displayed repeatedly at 2-second intervals beginning with the most recent alarm and continuing in order of occurrence. (3) If the code in *1 is abnormal, the unit stops and the alarm display blinks, but if the unit fails to return to normal by auto recovery (restarting), the code lights up continuously and stops blinking. (4) If the code in *2 is abnormal, the unit stops and the alarm display blinks. Then after 10 seconds, an attempt is made to start the unit up to 2 times. If it does not return to normal, the code lights up continuously and stops blinking. (5) After taking the necessary measures to get the refrigeration unit running again, turn the [RUN/STOP] switch to the “ON” position. Location of fuses Fuses are located in the control box of condensing unit. Control box COOL HEAT DEFROST LO.HEAT RUN ALARM RUN CON.RUN ELEC. STOP AUTO START/STOP HI.HEAT DIESEL F1 : 10A F5 : 3A F7 : 3A F2 : 15A F3 : 15A F4 : 15A DC12V — 69 — 00_TU42DXB.indd 69 2008/02/04 13:31:57 (2) Troubleshooting of in-/output from the cabin controller Check for the same pattern which the trouble occurred. In addition, check for the pattern which usually used. When the display of OFF persists though it should change to ON or when the display of ON persists though it should change to OFF, the PCB in the control box is defective. When some devices does not work or work erratically though the checking LEDs are normal, check relays and related components. (a) Indication of the in-/output signals by the service maintenance display 1 Input signal display Hold down the MODE and the SET keys for 5 seconds to change to the service maintenance display. To return to the input signal display, press the MODE key 4 times. Item Content Display Input signal display • Inputs from “ ” to “ ” are displayed in sequence in the top row of the digital display using the up switch and down switch. • The respective ON/OFF state of each input from “ ” to “ ” is displayed in the bottom row of the digital display. • The devices (symbols) connected to the main controller for each sensor are as follows: : TME35 : THTH4 : THTH3 : RNMODE : THTH2 : THTH1 See page 71 for details of each symbol. 2 Output signal display To change to the output signal display from the input signal display, press the MODE key once. Item Content Display Output signal display • Outputs from “ ” to “ ” are displayed in sequence in the top row of the digital display using the up switch and down switch. • The respective ON/OFF state of each output from “ ” to “ ” is displayed in the bottom row of the digital display. • The devices (symbols) connected to the main controller for each relay are as follows: : ARSV1 : ARSS : ARSV2 : ARPH : ARHS : ARRS : ARGU : ARDH : ARMO : ARFM See page 71 for details of each symbol. 3 To return to the setting temperature/inside container temperature display, press the SET key 2 times. — 70 — 00_TU42DXB.indd 70 2008/02/04 13:31:58 (b) In-/output signal display and code Controller Display Code PCB Connector Pin No. Name TME35 3.5-minute timer – THTH4 Thermostat – THTH3 Thermostat – THTH2 Thermostat – THTH1 Thermostat – Operation mode (Continuous/auto start-stop selection) – RNMODE Inside container temperature sensor CNA 8 ARSV2 Solenoid valve relay CNC 16 ARSV1 Solenoid valve relay CNC 15 ARSS Starter relay CNC 8 ARPH Pre-heater relay CNC 7 ARHS Engine high-speed relay CNC 6 ARRS Engine run relay CNC 5 ARGU Alternator relay CNC 9 ARDH Drain hose heater relay CNC 19 ARMO Motor relay CNA 36 ARFM Evaporator fan relay CNC 18 TH Remarks — 71 — 00_TU42DXB.indd 71 2008/02/04 13:31:58 (3) Microcontroller board service procedure (Board in control box) (a) Handling practices of printed board 1) Caution when handling the board a) When holding the board, do not touch patterned surface and parts mounted on the board. Hold the board by lightly pressing both end of board with hands. b) Do not touch the board with dirty hand contaminated with oil and so on. c) Do not depress the parts mounted on the plate by hand. d) Never give a shock caused by dropping it on the floor. e) Avoid drop of water in a rainy day. f) Avoid to handle it at the place which is possible to produce static electricity. (Dry area, carpeted room and etc.) g) When the board is held temporarily, wrap it with aluminum foil or conductive bag. (b) Procedure to replace (Conduct the procedure after turning the operation switch to “STOP” and disconnecting the terminal of the battery.) 1) Remove screws (eight places) of control box, and open the cover. Connector CNC Connector CNB 2) Pull out the connector CNA CNB CNC. 3) Remove the board mounting screws (seven screws) and remove the board from the control box. Install the board with the above procedure in reverse. (c) Caution when replacing the board 1) When pull out the connector CNA,CNB,CNC, pull them by grasping connector body. Do not pull the lead wires. When inserting or removing the connector, if it is forcibly pried out or inserted obliquely, unanticipated force will be applied to the pin and will cause to connection failure. 2) When installing or removing the board mounting screws, care should be exercised to avoid pressing or scratching the surface by screw driver etc. 3) Be careful not to drop washers or dust into the control box. If they are accidentally dropped, be sure to remove them carefully so as not to scratch the board. Connector CNA — 72 — 00_TU42DXB.indd 72 2008/02/04 13:31:59 (4) Inspection procedure of control box board and cabin controller with tester. Troubleshooting method of the control box board and cabin controller using a commercial tester is described below. (a) Checking method 1) Control box board Open the control box cover, check the terminal voltage of connector with connector inserted, or check resistance by removing the connector. Connector number and connector pin number are shown in the illustration below. CNB (12 pins) ● CNC (20 pins) ● CNC (16 pins) ● Board assy CNA (20 pins) ● 2) Cabin controller Check the terminal voltage at the back side of cabin controller with connector inserted. Pin number is shown below. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Cabin conroller connector pin number CNA (16 pins) ● Remarks 1. When measuring terminal voltage with connector inserted, make the tip of tester pin as small as φ1.0 mm diameter or extend the clip and insert into the connector. 2. Checking is possible with body grounded for tester pin GND side (Ground side). — 73 — 00_TU42DXB.indd 73 2008/02/04 13:31:59 (b) Output table 1) Control box board output table Terminal No. Terminal name Tester condition Tester connection Check condition CNA-1 OPS(8H2) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -2 WTS(8H3) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -3 LM(8H6) V GND(box ground) Power ON 0 V when normal, 12 V during abnormality -4 HPS(8H1) V GND(box ground) Power ON 0 V when normal, 12 V during abnormality -5 LS(8H7) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -6 — — -7 TH(+)(7G1) V GND(box ground) Power ON 5 V when normal, 0 V during abnormality -8 TH(-)(7G2) V GND(box ground) Power ON Approx. 2.5 V during constant temperature, 0 V or 5 V during abnormality -9 GND(E8) R GND(box ground) Power OFF 10 Ω or less -10 — — -11 APS(12) V GND(box ground) Power ON 12 V when not operating, 0 V when operating -12 MC(7D) V GND(box ground) During motor operation 12 V when not operating, 0 V when operating -13 OCR(8H5) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -14 ACS(8H4) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -15 GU(L) V GND(box ground) During operation 12 V when normal, 0 V during abnormality -16 — — — — — -17 — — — — — -18 DTS(+)(11A) V GND(box ground) Power ON 5 V when normal, 0 V during abnormality -19 DTS(-)(11B) V GND(box ground) Power ON Approx. 2.5 V during constant temperature, 0 V or 5 V during abnormality -20 GND(E7) R GND(box ground) Power OFF 10 Ω or less -21 GND(E6) R GND(box ground) Power OFF 10 Ω or less -22 FWS(10B) R GND(box ground) -23 FWS(10A) R Disconnect connector and measure the resistivity at both ends -24 GU(R) V GND(box ground) During operation 12 V when normal, 0 V during abnormality -25 F5(8B1) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -26 F6(8B2) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -27 — — — — — -28 — — — — — -29 GND(E5) R GND(box ground) Power OFF 10 Ω or less -30 TDS(-)(14B) V GND(box ground) Power ON Approx. 2.5 V during constant temperature, 0 V or 5 V during abnormality -31 TDS(+)(14A) V GND(box ground) Power ON 5 V when normal, 0 V during abnormality -32 — — — — -33 F2(8A1) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -34 F3(8A2) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -35 F4(8A3) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -36 ARMO(7B1) V GND(box ground) During motor operation — Standard value — — — — — Approx. 2 kΩ — ON: 0 V, OFF: 12 V — 74 — 00_TU42DXB.indd 74 2008/02/04 13:32:00 Terminal No. Terminal name Tester condition Tester connection Check condition Standard value CNB-1 Signal A(102) V GND(box ground) Power ON -2 — — — — -3 GND(E10) R GND(box ground) Power OFF -4 12VC(101) V GND(box ground) Cabin controller DISP SW ON 12 V when normal, 0 V during abnormality -5 12VB(7A) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -6 12VA(2B) V GND(box ground) Power ON or OFF 12 V when normal, 0 V during abnormality -7 Signal B(103) V GND(box ground) Power ON Approx. 1.4 V -8 GND(E9) R GND(box ground) Power OFF 10 Ω or less -9 GND(E11) R GND(box ground) Power OFF 10 Ω or less -10 — — — — -11 12VB(7A) V GND(box ground) Power ON -12 — — — — Approx. 3.6 V — 10 Ω or less — 12 V when normal, 0 V during abnormality — — 75 — 00_TU42DXB.indd 75 2008/02/04 13:32:00 Terminal No. Terminal name Tester condition Tester connection Check condition Standard value CNC-1 12VA(2B) V GND(box ground) Power ON or OFF -2 GND(B1) R GND(box ground) Power OFF 10 Ω or less -3 ARSOLA (7A12) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -4 — — — — -5 ARRS ARFP(7A1) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -6 ARHS(7A2) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -7 ARPH(7A3) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -8 ARSS(7A7) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -9 ARGU(7A10) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -10 Relay common(2A) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -11 12AV(2B) V GND(box ground) Power ON or OFF 12 V when normal, 0 V during abnormality -12 GND(E2) R GND(box ground) Power OFF -13 — — — — — -14 — — — — — -15 ARSV1(7A4) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -16 ARSV2(7A5) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -17 — — — — -18 ARFM(7A6) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -19 ARDH(7A9) V GND(box ground) Power ON ON: 0 V, OFF: 12 V -20 Relay common(2A) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -21 LED common(155) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -22 F7(7) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -23 F7(7) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -24 — — — — -25 PLC(152) V GND(box ground) Power ON 10 V when normal, 0 V during abnormality -26 PLD(156) V GND(box ground) Power ON 10 V when normal, 0 V during abnormality -27 SWH-L(161) V GND(box ground) Power ON Approx. 5 V during high speed heating, 0 V during low speed heating -28 SWCONT(162) V GND(box ground) Power ON Approx. 5 V during automatic start/stop, 0 V during continuous operation. -29 PLM(150) V GND(box ground) Power ON 10 V when normal, 0 V during abnormality -30 F7(7) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -31 F7(7) V GND(box ground) Power ON 12 V when normal, 0 V during abnormality -32 — — — — -33 PLH(154) V GND(box ground) Power ON 10 V when normal, 0 V during abnormality -34 PLEM(158) V GND(box ground) Power ON 10 V when normal, 0 V during abnormality -35 SWD-E(163) V GND(box ground) Power ON Approx. 5 V for engine, 0 V for motor -36 GND(E3) R GND(box ground) Power OFF 10 Ω or less 12 V when normal, 0 V during abnormality — 10 Ω or less — — — — 76 — 00_TU42DXB.indd 76 2008/02/04 13:32:00 2) Cabin controller output table Tester condition Tester connection Check condition Standard value Terminal No. Terminal name 1 Signal B(103) — — — *1 2 Light(114) V GND(terminal 9) MODE SW ON 12 V when light SW ON, 0 V when light SW OFF 3 I/F(115) — — — *2 4 GND(E) — — — *2 5 — — — — — 6 12V B(7A) V GND(terminal 9) Power ON 9-16 V when normal, 0 V during abnormality 7 12V A(7A) V GND(terminal 9) Power ON 9-16 V when normal, 0 V during abnormality 8 12V C(101) V GND(terminal 9) MODE SW ON 9-16 V when normal, 0 V during abnormality 9 GND(E10) R Chassis ground Power OFF 10 Ω or less 10 12V A(2C) V GND(terminal 9) Power ON or OFF 9-16 V when normal, 0 V during abnormality 11 Signal A(102) — — — *1 12 Printer B(111) — — — *2 13 Printer A(110) — — — *2 14 GND(E) — — — *2 15 Data B(113) — — — *2 16 Data A(112) — — — *2 17 — — — — — 18 12V C(101) V GND(terminal 9) MODE SW ON 9-16 V when normal, 0 V during abnormality 19 GND(E11) R GND(terminal 9) Power OFF 10 Ω or less 20 12V A(2C) V GND(terminal 9) Power ON or OFF 9-16 V when normal, 0 V during abnormality *1 The cabin controller display becomes abnormal when there is trouble with the communications lines. *2 Operation of each device becomes faulty when there is trouble with the communications lines. — 77 — 00_TU42DXB.indd 77 2008/02/04 13:32:01 16.INSTALLATION PROCEDURE 16.1 Cautionary points during installation (1) Be absolutely sure to keep dust and moisture from entering the piping of the refrigeration unit. Carry out the connecting of separate type of piping under a roof, and avoid a rainy or windy day and outdoor work as much as possible. (2) When glazing, pass N2 (nitrogen) gas through the piping in order to keep it from oxidation. (3) Pressurize with nitrogen gas before evacuating. (4) It is desirable to evacuate the system under the ambient temperature of 10°C or more for more than 60 minutes. The degree of evacuation should be –0.1 MPa (750 mmHg) or more. In order to check for leakage, leave it for 5 minutes, and there is no leakage if it keeps –0.1 MPa (750 mmHg). (5) Put a cover or protector to the piping which sticks out from the lowest tip of the body or the one which is placed where it can be easily hit by stones scattered by the wheel of the vehicle. (6) Select a place of 80°C or less ambient temperature for wiring routing. (7) Clamp the cable at 500 mm or less intervals to avoid unnecessary sags. Use the clamp matching to the thickness of the harness. And be sure that it does not slide or pull out when slightly pulled. Also be sure that the tip of the clamp does not cut into or crush the harness. (8) As for wiring under the floor or exposed to splashing water, set up a trap to prevent the connector of the unit terminal harness from drop of water. (9) As for installation of the undermount, set up a dust board in such a way as to cover the unit in order to keep it from flying stones, splashing water, mud and splashing of grease by the propeller shaft of the vehicle. But be careful not to prevent the unit from blowing out air. (10) Clamping of pipe and harness (11) Insulation of low pressure pipe (12) The capacity of the undermount type will be reduced much if there is any obstacle at the place where the unit sucks or exhausts air. Install the unit at the place where there is as few obstacles as possible. And also secure a specified servicing area. (13) Prevent the unit from sucking exhausted air by the unit and heated air by the vehicle engine (especially the top and side of the unit). (14) As for installation of the thermometer, select a place strong enough to hold it. (Installation on plastic section may cause damage to the unit.) (15) Be most sure to avoid installing the undermount type directly to the cross sill of a vehicle but install the unit to Z-channel after welding the Z-channel entirely to the cross sill or tightening by bolt. (16) Installation of earth wire to chassis and its maintenance Eliminate completely the coating on the chassis side to prevent from earthing poorly. (17) Cautionary point at the time of lifting the condensing unit. Lift the unit by using four wire ropes. — 78 — 00_TU42DXB.indd 78 2008/02/04 13:32:01 — 79 — 00_TU42DXB.indd 79 2008/02/04 13:32:01 3 Clamp mounting for pipe and harness The pipe, harness clamp or pipe cover is fastened on the body with screws. Insulate from heat the piping from the evaporator outlet to sucking pipe of the compressor. (excluding hose) Low pressure piping 2 Penetration of moisture Penetration of dust Be most sure to keep moisture and dust from entering the piping in order to avoid the refrigerant cycle from being damaged by them. Explanation Refrigerant piping Item 1 No. 1. When the screw hole for the clamp is drilled to the body, be sure to coat sealer. It is recommended that seal will be swelled out when the screw is tightened. And don't clamp it together with the high pressure pipe. 1.Pass the low pressure pipe thru the heatinsulated tube. 2. Apply vinyl tape on the connected area of the tube. 3. Make the route of the piping as short as possible. 1. Work on piping connection under a roof, avoiding a rainy day. 2. Because copper dust may enter the pipe from its cut and flared area, perform airblow (N2 blow) after processing. 3. Don't place piping materials (copper pipe) on the floor, ground etc, where it is dusty. 4. When glazing, pass N2 gas into the piping. 5. Perform evacuation for more than 60 minutes, and reaching of evacuation should be over –0.1MPa (750mmHg). 6. Don't use the copper pipe which has been left alone for long and inside of which is rusted. Precaution for service 16.2 Cautionary and requested points during installation 1. Unless blocked by sealer, water infiltrates into the insulated material of the body thru the clearance to cause no-cooling. 2. The seal plays the role of preventing the screw from loosening. 1. Rising of sucked gas temperature ↓ Rising of delivered gas temperature ↓ Early deterioration of compressor oil ↓ Breaking of compressor 1. Clogging of water and dust in the expansion valve and, clogging of the dryer. Possible failure 1. No remedy for the body which has sucked water. 1. Apply insulation tube to the low pressure piping in order to keep the sucked gas temperature from rising. 1. Investigation of abnormality on no freezing reveals that many of the causes are due to sticking of copper dust. 2. Perform evacuation after applying pressure in order to check for gas leakage from glazed area, etc. To check for leakage after glazing, leave the pipe alone for 5 minutes to maintain –0.1MPa (750mmHg). 3. Plug the cut of the refrigerant piping. Corrective action (Remarks) — 80 — 00_TU42DXB.indd 80 2008/02/04 13:32:02 Setup of pipe cover Wire harness (electrical wiring) 5 Item 4 No. Wiring process connecting control box, cabin controller, condenser and evaporator. To protect the pipe and harness from ice, snow and flying stone. To install pipe cover in order to improve appearance. Explanation 4. 5. Clamp the wire harness alone. 6. 4. Interference with other equipments 5. Temperature of high pressure gas pipe becomes high, causing damage to the cover and fire. 6. Broken wire and effective contact 4. Clamp cable at 500 mm or less intervals to avoid unnecessary sags. 5. Don't clamp together with the high pressure gas pipe. 6. Use the clamp according to the thickness of the harness. And when pulled lightly, it should not be slid or pulled out. Also be sure that the tip of the clamp does not bites the wire harness or crush it. Clamp the harness to the convenient direction. Holding of body, etc. by screw 3. Avoid placing it near the engine exhaust pipe and high pressure. 3. Cable sheath may be subjected to damage or fire. 2.Replace the damaged part. 2.If the polarities (+) and (-) are reversely connected, the electrical parts will be damaged (burnt). 2.Take care of polarity of battery wiring. 3.Select a place of 80°C or less atmospheric temperature for wire routing. 1. Verify that the battery terminal is disconnected. Corrective action (Remarks) 1. If it is energized during working, it will lead to shortcircuit troubles, etc. 1. Refrigerant leakage from the cracked pipe and many abnormalities generated from the refrigerant leakage. In the worst case, the compressor will be broken. Possible failure 1. Before wiring works, disconnect the battery terminal 1. Install pipe cover when the pipe is stuck out from the lowest tip of the chassis and body or when the pipe is passed thru the place where the stones scattering from the wheels of the vehicle can easily hit it. 2. Use sealer when screws are driven. Precaution for service — 81 — 00_TU42DXB.indd 81 2008/02/04 13:32:02 Chassis mounting and supporting process of ground cable Fuel pipe 7 Item 6 No. Prevention of defect due to leakage from pipes related to fuel and sucking of air Treatment of grounding wire terminal for unit grounding wire and battery grounding wire onto the vehicle chassis. Explanation 1. When routing fuel pipe at the time of installation, keep it from contacting other parts and high temperature area. 2. Tighten securely the connection of fuel pipe (Negative side sucks air). 1.Fuel pipe is holed to leak fuel. 2. It is dangerous that fire results from the above. 3. Air is sucked into the fuel to cause reduced revolution speed or poor engine running. 1. When routing the fuel pipe, provide the clamps as necessary and use the distance rubber to prevent the pipe from interference with or vibration from any other part. 2. Use the specified hose bands and securely fasten the pipe. 10.Clamp cable securely. Select the cable connection area which is free from oil or fuel sticking. 10.Clamp cable securely. Select the cable connection area which is free from oil or fuel sticking. 10.Fire may happen on the damaged sheath of cable. 11.The connector may be removed by vibration. 10.Check the electrical wiring for interference with any vibratory object on the way. 11.Insert the connector with lock until it makes "click" sound. Here, do not tighten the connector lock with a flat. 1.Many defects resulting in burning of alternator, relay, etc. 8. 9. Observe the electric wiring standards. (Neglection is prohibited. It has been reported that fire actually happened owing to the neglection.) 8. Unit may be subjected to fire owing to heating or sheath thermal damage which is caused by insufficient wire capacity. 9. Unit may be subjected to fire owing to heating and firing caused by increase of the contact resistance. 8. Be sure to use the specified cables (thickness and sheath) for wiring. 9. Use the compression terminal or solder type terminal to connect the cable. (Solder onto caulking section of crimp terminal. Hand-twisting and taperetaining alone are prohibited.) 1. The terminal area is clamped and sealercoated to prevent the ground cable from suffering of being internally broken owing to vibration during car running. 2. Remove paint from the chassis side. 7. Corrective action (Remarks) 7. Defective contact due to generation of rust and broken wire Possible failure 7. When wiring is made under the floor or at a place where rain water splashes, set up a trap on the straight line so as to prevent water drop from entering the connectors of connecting equipments. Precaution for service — 82 — 00_TU42DXB.indd 82 2008/02/04 13:32:02 Installation of dryer Countermeasure for the passing hole on the van Tightening torques of flare nuts, general bolts and nuts 9 10 Item 8 No. When tightening the bolts and nuts, observe the following tightening torques. R a i n w a t e r i s p r ev e n t e d from entering the van, and the refrigerating capacity is prevented from dropping. Maintaining capacity of dryer Explanation Tightening torque N·m (kgf·m) 9.8 ~ 19.6 (1 ~ 2) 19.6 ~ 29.4 (2 ~ 3) 29.4 ~ 39.2 (3 ~ 4) 39.2 ~ 49.0 (4 ~ 5) 49.0 ~ 58.8 (5 ~ 6) Applicable copper pipe ø6.35 ø9.52 ø12.7 ø15.88 ø19.05 1. Standard tightening torques for flare nuts (observe the following tightening torques) 1. If any hole is produced on the van side or any clearance is produced on the passingthru hole (unit mounting bolts, refrigerant pipe, electric wiring, drain hose, etc.) in the outfitting process, close the hole or clearance by coating sealer. 1. Install the dryer after other related refrigerant piping work has been finished. 2. Since the dryer is sealed up, open it immediately before installation. Precaution for service 1. Gas leaks on the refrigerant piping system. 1. Rain water enters the van through the thru-hole or clearance, and the thermal insulator is moistened. 2. Thermal load enters through the clearance of the thermal insulator and is moistened to cause poor cooling. 1. The dryer will be clogged by water or foreign materials. (When other piping work is made after installation of the dryer, moisture in the air is sucked in the drier. Also the chip and foreign materials generated from piping work may be clogged.) Possible failure 1. Periodically retighten the bolt and nut, and check that they are tightened to the specified torques. (Take sufficient care for overtightening.) 1. Verify that the hole clearance is wholly and securely sealed. Corrective action (Remarks) — 83 — 00_TU42DXB.indd 83 2008/02/04 13:32:02 No. Item Explanation 6.9 ~ 8.3 (0.7 ~ 0.85) 17.7 ~ 19.6 (1.8 ~ 2) 35.3 ~ 40.2 (3.6 ~ 4.1) 59.8 ~ 69.6 (6.1 ~ 7.1) 96.1 ~ 107.9 (9.8 ~ 11) 3.5 ~ 4.4 (0.36 ~ 0.45) 8.4 ~ 9.8 (0.86 ~ 1) 17.0 ~ 19.6 (1.73 ~ 2) 29.4 ~ 33.3 (3 ~ 3.4) 47.1 ~ 53.0 (4.8 ~ 5.4) M5 M6 M8 M10 M12 M14 M16 156.9 ~ 176.5 (16 ~ 18) 4.0 ~ 5.0 (0.4 ~ 0.5) 2.0 ~ 2.5 (0.2 ~ 0.25) M4 73.5 ~ 84.3 (7.5 ~ 8.6) 2.0 ~ 3.0 (0.2 ~ 0.3) 1.0 ~ 1.5 (0.1 ~ 0.15) M3 142.2 ~ 165.7 (14.5 ~ 16.9) 91.2 ~ 104.9 (9.3 ~ 10.7) 56.9 ~ 65.7 (5.8 ~ 6.7) 33.3 ~ 38.2 (3.4 ~ 3.9) 16.7 ~ 19.6 (1.7 ~ 2) 6.4 ~ 7.8 (0.65 ~ 0.8) 3.4 ~ 4.4 (0.35 ~ 0.45) 2.0 ~ 2.5 (0.2 ~ 0.25) 0.8 ~ 1.0 (0.08 ~ 0.1) No mark r or 7 1.0 ~ 1.5 (0.1 ~ 0.15) Thread distance 0.6 ~ 1.0 (0.06 ~ 0.1) SUS304 S45C SS400 No mark or 4 Material He ad ma rk 2. Tightening torques of general bolts N·m N·m (kgf·m) Precaution for service If insufficiently tightened, looseness may lead to troubles. If overtightened, the bolt may break owing to the excessive elongation. 2. General bolts and nuts Possible failure Corrective action (Remarks) 16.3 Reference illustration for installation (1) Whole unit outline Condensing unit Fuel pump AC power socket In case installed at right side In case installed at left side Fuel tank Evaporator unit Condensing unit Battery (Exclusive use for refrigeration unit) 1. Voltage DC12V, capacity 120AH or more. 2. Never interchange battery connections. Otherwise it will burn or damage the refrigeration unit and its electrical parts. Cabin controller (Locate at driver’s position) Installation layout Installation notice Warning 1.Installation must be done properly according to the installation drawing. Improper installation may cause refrigerant leakage, electric shock and/or fire. 2.Installation must be done properly to carry the weight of the unit. The unit may fall down if not properly installed and causes accident and/or injury. 3.Never adjust the setting of safety devices. Improper adjustments may cause explosion and/or fire. 4.Avoid contaminating the refrigerant circuit with air. It may cause abnormal high pressure which may lead to explosion and/or injury. 5.Installation drawing must be followed. Any modification may cause electric shock, fire, explosion and/or injury. Notes: 1.This installation drawing is for model TU42DX. 2.In this installation drawing, part No. of each part are shown in the table on pages 97. 3. Mark parts are not attached as standard parts of the vehicle. 4.The van must be strong enough to support the refrigeration equipment to be installed. 5.Modification of the truck and manufacture of the van, keep the dimensions and limitations indicated in the layout so that the equipments and parts can be installed securely. 6.Balance of the vehicle must be considered when installing the refrigeration unit to maintain stable running condition at 35˚up to maximum inclination. 7.During installation, read and follow strictly the safety precautions found on page 85. 8.After installing, check carefully the total condition of the installation using check sheet. 9.Condensing unit must be installed with care on the exhaust vent port of the vehicle’s engine so that it will not intake the exhaust. — 84 — 00_TU42DXB.indd 84 2008/02/04 13:32:03 (2) Safety precautions for installation WARNING Caution for safe installation Before installing the refrigeration unit, read first this installation manual and follow strictly the instructions to prevent any trouble or accident. 1. Preparations for the vehicle (1) Modification of the truck and manufacture of the van must be strong enough to support the refrigeration equipment to be installed. Installation must be done properly according to the installation drawing. (2) Do not prepare the unit, except by an expert in refrigeration unit. It may cause injury. (3) Use stoppers for front and rear wheels to prevent the vehicle from forward and backward movement during installation. Furthermore, parking brake must be activated. If failure to do so, accident may occur causing injuries to workers or operator due to mis-operation. (4) Turn-off the unit switch and disconnect terminal from the nearest battery side. Furthermore, battery cable and terminal must be insulated by taping and so on, otherwise, accidents like electric shock, short circuit, etc,. May happen if battery terminals comes in contact with the vehicle body, tools or worker. (5) Before installation, remove the ignition key and keep into safer place. Then, display a warning sign like that of “WARNING! work in progress. Don’t start the engine”, otherwise, another worker, not knowing that the installation has already started, might switch on the ignition key, causing accident to happen. 2. Unit installation (1) State clearly and make effort among workers to understand the nature of their job. (2) When carrying and installing the unit, avoid finger or foot from getting squeezed. Furthermore, care must be considered on the weight when handling each main component to avoid back injuries. Especially when the condensing unit weighs about 300kg. Work in a safe position in such case. To be safe, multiple workers are required. (3) Care should be observed, so that the rubber stopper would not be pulled out, preventing charged nitrogen gas in the unit from leaking. (4) Be careful of dangerous parts such as high temperature parts or sharp edges of the vehicle and of the refrigeration unit to avoid from getting burn or other injuries. To be safe use helmet, gloves and protecting cover. (5) When installing, use the right tools. Apply the specified tightening torque indicated in this manual and observe proper posture. To be safe, multiple workers are required. (6) Mounting places of each component on the chassis must be properly checked for strength and rigidity. Accidents such as breakage or shearing may occur in case of faulty welding, inappropriate thickness of plate, etc,. (7) Refrigerant circuit pipes and harness must be installed without contact with high temperature parts or edges. If inevitable, provide protection or insulation. (8) Earth must be secured properly to prevent short circuit. Never work with harness when the hands are wet with oil or water to avoid electric shock. (9) When charging or discharging refrigerant gas, extinguish lit cigar or any other fire to prevent production of toxic gases which are hazardous to human body. (10)When working inside a building, make sure that the place is well ventilated to avoid suffocation due to refrigerant gas. (11)Put on protection eyeglasses and gloves when handling refrigerant. Direct contact with refrigerant could freeze the skin. — 85 — 00_TU42DXB.indd 85 2008/02/04 13:32:03 3. Test operation procedure (1) Before trial running, check carefully the total condition of the installation using the installation sheet. (2) Use stoppers for front and rear wheels to prevent the vehicle from forward and backward movement during test operation. Furthermore, the parking brake must be activated if failed to do so, accident may occur causing injuries to worker or operator due to mis-operation. (3) Before starting the unit, confirm that no tools, gauges or other parts are left inside the unit or at any part of the chassis. (4) Before starting the unit, initiate a warning sign such as alarm (sound) and make sure that there is nobody left around or under the vehicle. (5) Before trial run, confirm that each service valve is open. (6) After a few minutes of the first trial run, install each door, panel and make sure that it is tightly close. (7) During trial run, stop and check again when abnormal operation, abnormal noise and error display occur. (8) When standby motor is running, never use power source other than 380V/50Hz. (Power source depends on specification) (9) Do not sprinkle water directly to the electrical parts to avoid short circuit and electrical shock. (10)Do not operate the refrigeration unit control panel with wet hands. (11)Make sure there is no circuit failure damage by test operation. (12)When checking of terminal, etc of electric circuit, care must be considered not to short circuit to vehicle body or other parts. (13)Take caution to prevent any part of the body, hand or foot from being caught by the rotating components (pulleys, driving belts, condenser fan, radiator fan) inside the condensing unit and fans of the evaporator. (14)Keep distance from rotating parts such as fan, belts, etc. To avoid severe injury from being hit by flying debris in case those components break. (15)Avoid contact with high temperature parts of exhaust line, cooling water line, high pressure ref. piping & electric heater of evaporator. (16)Never open the radiator cap while the engine is running. Wait until the engine gets cold after stopping to avoid from getting burns due to boiling water (coolant). (17)When cleaning the unit, do not use high pressure water or steam. It can cause abnormal pressure on the unit and deformation of fins on the heat exchanger. (18)Never use refrigerant, refrigerant oil, engine oil, coolant and fuel other than specified on the unit. (19)Avoid direct contact with refrigerant, coolant, engine oil, etc. It may cause frostbite and burn. (20)When refrigerant leaks, avoid eye contact and breathing of refrigerant gas. (21)When discharging the refrigerant gas, be careful about the pressure. Keep away face, foot, hand and other parts of the body to avoid injuries. (22)Do not use the refrigeration unit in explosive atmosphere. — 86 — 00_TU42DXB.indd 86 2008/02/04 13:32:03 (3) Outline drawings 591 1477 (36) 1400 41 1287 (Diffuser) 100 4- 14 (For fixing the unit) B 70 255 6 133 39 OUT Copper pipe 19.05 HD Copper pipe 18 9.52 A 40 45 Drain pipe O.D. 18 (2 places) 180 146 1366 63 Evaporator unit 180 214 210 198 124 46.5 181 40 60 4- 7 (For fixing) Cabin controller Length of connecting wire : 11m 51 ~ 64 325 52 83 43 4- 12 96 120 200 240 45 103 25 IN 137 HD 105 270 OUT 58 C 5 20 113 165 128 (40) IN Copper pipe 9.52 Accumulator Prepared by van maker part name Battery ø Installation part Refrigerant Fuel tank ø Notes:1. mark shows the position of gravity 2.Unit: mm Model Dimension of gravity (mm) Weight (kg) A B C Condensing unit 652 329 308 288 Evaporator unit 801 65 291 32 <The cooling water and engine oil weights are included in the above weights.> Weight (kg) 40 14.8 3.4 14.3 (ø Reference) — 87 — 00_TU42DXB.indd 87 2008/02/04 13:32:04 (4) Recommended dimensions of each part inside the van Maintain refrigerating air circulation to ensure even temperatures throughout the van by observing the following 4 recommmended items: Set up the bulkhead. The floor railings' (T-rail) height must be maintained as high as possible. (50 ~ 75mm) Maintain air passages of 100 mm or more between rear door and cargo by providing air ribs or spacer. Arrange the intervals of the side wall air ribs serving as air passages, such that the cargo doesn't block them. Unit: mm 180 About (a) (b) (c) (d) (e) Clearance,not to be piled up with loads. Railings 500 Rear door spacer Bulkhead 50 ~ 75 100 or more 100 or more — 88 — 00_TU42DXB.indd 88 2008/02/04 13:32:04 (5) Condensing unit installation dwg. (In case of installing at the right side) Running direction 75 Vehicle centerline Chassis 76,16,13,9,3 Joist Vehicle's exhaust pipe (M8) 430 ± 1.0 Vehicle's muffler Refer to note 4 Keep 300 or more as service space Refer to note 6 Bracket Must have sufficient strength (Prepared by van maker) 4-ø14 ( mark) Keep 200 or more as service space 1445 60 or more (Refer to note 7) (Over-hang prevention) 100 A Spacer 4.5mm or more thick 90 (Case 1) 7 14 11 M10 washer M10 spring washer M10 nut 11 1 Bolt Washer Spacer 4.5mm or more thick 30 or more 89 M10 (or M8) 30 or more 6 or more 1 11 B Washer Spring washer Nut (Case 2) Air block rubber board Air block rubber board �50-90 View B (Refer to note 3) �50-90 or Chassis 150 Approx. Chassis 150 Approx. 94 50 14 A-A (4 places) S45C M12 bolt: tightening torque 59.8 ~ 69.6N·m (6.1 ~ 7.1kgf·m) F Unit installation must be surely done between fixed channels. ( mark, 4 places) (Over-hang prevention) The condensing unit must be installed away from the fuel tank, battery and vehicle's muffler. Should there be no space, transfer the above equipments and provide a space. (refer to note 5) Hatched ( ) space is needed for the connections of the control switch. Side bumper, stay, etc. must not interfere. M10 bolt Put an iron spacer, 6.0mm or more thick (8 places). Furthermore, both bolt and nut must use flat washers. 60 or more (Refer to note 7) 120 M10 washer F A Condenser unit (Installation failure) External shape of over hang installed unit ( mark) Reinforce rib For case 1, metal reinforcement rib must be the same 30 or more Unit installation must be surely done between fixed channels. ( mark, 4 places) (Caution) During unit installtion of case 1, in case 60mm or more clearance cannot meet, weld entirely the reinforement rib to the surface of Z channel. (refer to view F) (In case of 60mm or more, leave the rib as it is) 6t Spacer (8 places) 50 Modified exhaust pipe Vehicle's muffler exhaust pipe (original) (Refer to note 5) 2 - R62 L=1830mm An example of case1 Notes: 1. This drawing shows the condensing unit installed on the right side of the running direction. As a rule, use this "right sided" installation. 2. The van must be strong enough to support the condensing unit to be installed. (weight: 288kg) 3. Strictly follow the ø marked dimensions. (For satisfactory performance of the ref. unit) 4. Bracket must be fixed in all joist for equal loading with bolts M10, M8 (8T) or more. Tightenig torque <M8: 25.0 ~ 29.4N·m (2.55 ~ 3kgf·m), M10: 50.5 ~ 58.8 N·m (5.15 ~ 6kgf·m)> (Loose bolts may cause accidents.) 5. For vehicles which the exhaust pipe is in the front, reinstall it in the back side for the exhaust not to affect the condenser capacity. 6. For places without spacer, tighten it by M10 × 45 bolt. 7. To prevent the bolt position to over hang, chanel side position must be adjusted. 8. To avoid exhaust gas to blow out towards people and flammable objects, exhaust pipe must be installed. 9. Unit: mm — 89 — 00_TU42DXB.indd 89 2008/02/04 13:32:05 (6) Condensing unit installation dwg. (In case of installing at the left side) Running direction 76,16,13,9,3 Never use item 75. Flow of exhaust gas will reverse 74 Vehicle centerline Joist 430 ± 1.0 (M8) Bracket Must have sufficient strength (Prepared by van maker) Keep 200 or more as service space Keep 300 or more as service space 1445 60 or more (Refer to note 7) (Over-hang prevention) (Caution) During unit installtion of case 1, in case 60mm or more clearance cannot meet, weld entirely the reinforement rib to the surface of Z channel. (refer to view F) (In case of 60mm or more, leave the rib as it is) 4-ø14 ( mark) Refer to note 5 Refer to note 4 Spacer (8 places) 30 or more Unit installation must be surely done between fixed channels. ( mark, 4 places) Unit installation must be surely done between fixed channels. ( mark, 4 places) (Over-hang prevention) Reinforce rib For case 1, metal reinforcement rib must be the same G C G (Installation failure) External shape of over hang installed unit ( mark) Condenser unit D 60 or more (Refer to note 7) The condensing unit must be installed away from the fuel tank, battery and vehicle's muffler. Should there be no space, transfer the above equipments and provide a space. (refer to note 5) M10 bolt M10 washer Bolt Washer M10 (or M8) Spacer 4.5mm or more thick (Case 1) 30 or more M10 washer M10 spring washer M10 nut 11 Washer Spring washer Nut 1 (Case 2) Chassis Chassis (Refer to note 3) 94 14 C-C (4 places) S45C M12 bolt: tightening torque 59.8 ~ 69.6N·m (6.1 ~ 7.1kgf·m) �50-90 or View D 50 50 90 7 14 11 30 or more 89 Air block rubber board Air block rubber board �50-90 6 or more 1 11 Spacer 4.5mm or more thick Put an iron spacer, 6.0mm or more thick (8 places). Furthermore, both bolt and nut must use flat washers. 6t Hatched ( ) space is needed for the connections of the control switch. Side bumper, stay, etc. must not interfere. 2 - R62 L=1830mm An example of case1 Notes: 1. This drawing shows the condensing unit installed on the right side of the running direction. As a rule, use this "left sided" installation. 2. The van must be strong enough to support the condensing unit to be installed. (weight: 288kg) 3. Strictly follow the ø marked dimensions. (For satisfactory performance of the ref. unit) 4. Bracket must be fixed in all joist for equal loading with bolts M10, M8 (8T) or more. Tightenig torque <M8: 25.0 ~ 29.4N·m (2.55 ~ 3kgf·m), M10: 50.5 ~ 58.8 N·m (5.15 ~ 6kgf·m)> (Loose bolts may cause accidents.) 5. For places without spacer, tighten it by M10 × 45 bolt. 6. To prevent the bolt position to over hang, chanel side position must be adjusted. 7. To avoid exhaust gas to blow out towards people and flammable objects, exhaust pipe must be installed. 8. Unit: mm — 90 — 00_TU42DXB.indd 90 2008/02/04 13:32:06 (7) Holes for installation of evaporator unit 4-M10, Bolt hole position for unit installation. bolts must protrude 20 2 or more inside the van. Tightening torque 17.0 ~ 19.6N.m (1.73 ~ 2.0kgf.m) C 1.0 ( F 200 255 F Mark) 1400 1.0 30 ( Mark) (Perforation for piping) 700 55 130 25 135 63 30 ( Mark) (Perforation for piping) (Perforation for wiring) 688 1366 2- 30 ( Mark) (For drain hose) (Front view of van) 20 or more Head bolt must be properly fixed 8,12,15 Apply sealant. M10 (nut size) Tightening torque 17.0 ~ 19.6N·m (1.73 ~ 2.0kgf·m) F-F (Structural illustration of eva. unit installation) Notes: 1. The fabricated or renovated structure of the van must be designed for the installation of the evaporator unit (TU42DX, weight: 32kg). 2. Each penetrating hole (¢, , r, mark) can be positioned wherein clamps can properly hold the pipings. (But, installation of item 31 cover, should be possible, excluding drain hose) 3. Unit: mm — 91 — 00_TU42DXB.indd 91 2008/02/04 13:32:06 (8) Piping installation 53 Pipe insulation (LP) About 200 102 72 G 104 103 Detail R R ( mark) (4 places) 30 55,57,79 Protects pipes & wires seal it by item 79. Evaporator unit Unit model TU42DX-EV In channel intallation, bolt & nut must be fit with the holes (over hang prevention) unit 100 Condensing attachment Fabricate and install "Z" chanel 32 50 21 23 P Check that the dryer is installed with its arrow mark in the downward direction. (360) Cover installation pitch 5,67,68 Copper pipe 19.05) (LP) 33,54 ( 102 ( mark) (4 places) Copper pipe ( 9.52) (HOT GAS) 69 32 Copper pipe ( 9.52) (HP) 6,31 Install by adhesive G Receiver Condensing unit P 65 101 6 ø4.2 +0.05 (in case of T1.2) 0 (Install to fit) Clamp installation Notes: 1. Charging mass of refrigerant: R404A--3.4kg (In this charge amount by standard charging, add 100g after the flash in sight glass disappear) 2. Connection of pipings must be gauged. 3. It must be free from any foreign matters to prevent clogging of expansion valve, leak in solenoid valves and damage of compressor. It must be free from moisture that can cause clogging due to ice formation and must not be scratched to prevent leakage of refrigerant. 4. Apply refrigerant oil between fittings and use double spanner when tightening. Pipe size Tightening torque N·m (kgf·m) ø9.52 19.6 ~ 29.4 (2.0 ~ 3.0) ø19.05 49.0 ~ 58.8 (5.0 ~ 6.0) 5. In case of clamp fixing in front wall apply sealant to screw etc. to make this portion water-proof. 6. Unit: mm — 92 — 00_TU42DXB.indd 92 2008/02/04 13:32:07 (9) Fuel tank, pump & battery cable installation dwg. 51 (Use ID ø6 pipe) From fuel pump 51 (Use ID ø6 pipe) From fuel tank connecting port for fuel return pipe H (Running direction) Condensing unit Ground bolt on chassis provided by installer (Ground to chassis, M8) H 24 Clamp at every 500mm. Remove the paint on the chassis before connecting the ground terminal for secure grounding. 40,79 Ground to body frame, using the existing bolt 36 40,43,79 80 Fuel pump 29 4,10,17 131 + Concern with fuel pump 24 Clamp at every 500mm. 28 Battery Connect to battery, (-) terminal. (8G) 2-ø8 (Drill holes on chassis) 61 Connect to battery, (+) terminal. (Reserve) 29 - 24 62 Use appropriately cut length. Never interchange the polarity. ø55.2 64 40,79 Ground bolt on chassis provided by installer (Ground to chassis, M8) 28 81, 79 Ground bolt on chassis provided by installer (Ground to chassis, M5) Connecting port for fuel tank return pipe (Use ID ø6 pipe) Connecting port for fuel outlet pipe (Use ID ø8 pipe) Fuel hose Install the fuel hose with clamp, so as not to get damaged from vibration, shock & the like. With in 10 0 2 pla ces Cover the wires with corrugated tube. (ø14, provided by installer) Remove the paint on the chassis before connecting the ground terminal for secure grounding. 8-M10 or more This dwg. shows the outline dimension of the mounting pitch. For the actual pitch, consider the width of the chassis before drilling holes on the bracket of the tank. Tightening torque --- 32.9 ~ 38.2N·m (3.35 ~ 3.9kgf·m) Type of bolt & nut to be used shall be decided by installer. Fuel tank Install the fuel tank & pipe firmly, so as not to get damaged from vibration, shock & the like. Notes: 1. Battery, fuel tank & fuel pump may be installed at either side of the chassis. However, fuel intake port and vent port of fuel tank must be kept 300mm or more away from the exhaust and its direction. 2. Use a battery with a voltage of DC12V, exclusively for the refrigeration unit. 3. Never interchange battery connections, otherwise it will burn or damage the refrigeration unit. 4. Fuel intake port and vent port of fuel tank must be kept 200mm or more away from exposed electrical terminals or contactors. 5. Remove the painting on the chassis before connecting the ground terminal. 6. Fuel pump must be installed vertically. 7. Disconnect the negative (-) terminal of the battery before working to prevent short circuit. 8. Never extend the length of the battery cable, or use any extension. (Extension leads to huge voltage drop when starting, thereby causing failure.) 9. Unit: mm — 93 — 00_TU42DXB.indd 93 2008/02/04 13:32:07 (10) Wiring method DTS L FM1 FM1 FM1 Frame ground (E) Return air temp. sensor (RH) (E) (PE) Battery 94 FL 1 FL 2 (B) (2) <MC1> 78 10 5 91 Fix item 94 properly. Never mistaken "DTS" wire with "TH" wire mark both end of the wire with "DTS" (2D) Battery Ground For ground Drain hose heater ground Fan motor ground unction Condensing unit ground (3 pcs.) M Return air tenp. sensor connector <OCR> DTS Apply sealant item 79 (M) J 3P (F) (M) (M) Wire "E" After connecting the wires, apply item 79 sealant, to the end part (F) 3P (F) 2P (M) HTS-overheat thermostat (with dummy connector) J 2P (F) (E) 20P (F) Cabin controller install in the position where it can be seen and operated from the driver's seat. 3P (F) Grommet Wire 30mm2 Control box 60 (F) Chassis ground 10P (M) (-) (+) Condensing unit Battery Gap between lead ware protection tube & plate (item 92) 92 1 or Evaporator ground junction change the bolt attaching the shroud. (M6x16 M6x25) 96 To control box 93 re mo 97 83 71 L 84 Fasten both storage temperture sensor & evaporator fan guard. M Notes: 1. Harness must be aligned with the main harness of the vehicle. 2. Cover the wires using the appropriate corrugated tube. 3. Harness must be tied-up by item 35 & 36 band, and fixed with clamp. 4. Harness must be protected with a grommet when passing through the toe board. 5. Connectors shown ( (F) (M) ) must be fastened until the "click" sound is heard. 6. Unit: mm — 94 — 00_TU42DXB.indd 94 2008/02/04 13:32:08 (11) AC power socket installation drawing B L = 3m AC power socket Condensing unit Install AC power socket with enough strenght of this material. 4-M6 [Maker's mounting preparation] 15 17 (Weld bolt to strengten the structure) 150 17, 18, 19 (230) (4 pcs.) (4 pcs.) (4 pcs.) View B Sample of AC power socket installation structure Install AC power socket in a way that the structure can support its weight 116 H L2 (S) 95 150 ø73 64 L1 (R) L3 (T) N E H-H H Terminal position Lead wire diameter ··· ø2.1mm ~ ø3mm (Section area ··· 3.5mm2 ~ 7.1mm2) Cable diameter ··· ø7mm ~ ø24mm Plug installation drawing — 95 — 00_TU42DXB.indd 95 2008/02/04 13:32:08 (12) Guidelines on electrical wiring installation for fire prevention G Never cut the battery cable if addition or shortening of length is required, rather replace with the required length. Retain wire clamping method, position and wire sagging condition especially between starter and the parts attached to the frame. H When connecting an extension wire, use the same nominal size and color. Use solder or connector to connect the wires securely. Never connect the wires by splicing. Do not use hcl as a medium of reactance for soldering method. Insulate the connection along the chassis properly to prevent water penetration. I For long wires, loop the wires and band together along with the existing wiring using vinyl tape without cutting. (c) Clamp A The clamp must be insulated with coating or rubber. For different types of clamp see the figure below. The following are procedures on repair and addition of wiring for fire prevention (a) General guidelines on addition and repair of wiring: See JIS C3406* (for low voltage wiring for automobile) , JASO D608* (heat resistance low voltage wiring for automobile) , JIS C2336* (insulation tape for wiring) vinyl tape or equivalent. (b) General procedure for wiring installation: A Clamp the wires on the frame, chassis and other parts of the van to prevent hanging of wires. Use clamps to avoid contact with chassis, sharp edges, vibrating and rotating parts or use grommet for holes with sharp edges to prevent wire damage and short circuit. For details refer to the figure on the right. Wire Straight clamp Grommet Metal sheet B In case of inevitable contact with sharp edges, fix the wire with clamp to be stable and cover with protector to prevent wire damage caused by vibration. refer to the left figure below. If the preceding method is not applicable, cover the wire with sleeve or tube. Refer to the right figure below. Harness dia. 5 or less 5 ~ 10 5 ~ 20 Clamp distance 300mm or less 400mm approx. 500mm approx. (d) Caution on welding works Battery terminals must be detached before welding. Do not position the ground terminal near the electronic parts or the electronic parts lie between it and the area to be weld to prevent damage. Even the parts have switches, but still must follow the guidelines below. A Detached the battery terminal B Position the ground terminal near the object to be weld. (e) Wire selection For heat resistance wire, refer to the table below. (JASO D 609*: applicable current for low voltage wire for automobile). Sleeve or tube C Band the wires along with the existing harness using vinyl tape. Never attach along with brake system and fuel pipe (metal, vinyl chloride, vinyl hose, etc.) and provide a minimum distance as shown in the table below. Path Distance Parallel 10mm or above Crossing 20mm or above D For wires within the engine compartment, clamp the harness along with the existing wiring and must be far from heat source. Use heat resistance vinyl tape or metal clamp (rubber or vinyl coated) . Do not use ordinary tape which can loose its function due to high temperature. E Clamp the wires along with the existing wiring and provide an allowance for sagging for wires that are attached to vibrating parts to absorbed its relative movements. F Female type giboshi connector must be for live line to avoid short circuit when disconnecting. Round clamp B For distance between clamps, refer to the table below. Protector Add more clamps To be stable. Vinyl tube or vinyl coating Type of wire AV wire (Low voltage wire for automobile) AVX wire (Heat resistance low voltage wire for automobile) AEX wire (High temp. Heat resistance low voltage wire for automobile) * Ambient temp. Remarks Applicable 60˚C or below at ordinary condition Applicable near 70˚C or below the engine or at any heat source Applicable near 90˚C or below the engine or at any heat source Avoid installing the wire at temperature above 70˚C. If necessary use AEX type of wire. JIS C3406, JIS C2336, JASO D0608 and JASO D609 are standards of Japan. — 96 — 00_TU42DXB.indd 96 2008/02/04 13:32:09 (13) Parts list Code Parts No. Name Q’ty Remarks 1 B002B12 × 050 Bolt 4 M12 × 50 2 B001G10 × 030 Bolt 4 M10 × 30 3 B001G08 × 060 Bolt 1 M8 × 60 4 SSA911D206D Bolt & washer 2 M6 × 40 5 SSA911D206A Bolt & washer 9 M6 × 20 6 W010D05 × 016 Tapping screw 40 M5 × 16 7 N002B12 Nut 4 M12 8 N001G10 Nut 8 M10 9 SSA914B007AD Nut 1 M8 10 SSA914B007AC Nut 8 M6 11 TSJ915A002 Washer 8 M12 12 W200G10 Washer 8 M10 13 W200G08 Washer 2 M8 14 W220G12 Spring washer 4 M12 15 W220G10 Spring washer 4 M10 16 W220G08 Spring washer 1 M8 17 W220H06 Spring washer 4 M6 18 W200G06 Washer 4 M6 19 N001G06 Nut 4 M6 20 TSJ937A013S Plug 1 ø35 21 TSJ937A013N Plug 10 ø25 22 TSJ937A013M Plug 15 ø22 23 TSJ937A013L Plug 10 ø20 24 TSJ937A013H Plug 10 ø15 25 TSJ937A013F Plug 10 ø12 26 TSJ937A013C Plug 20 ø9.52 27 TSJ937A012B Plug 5 ø6 28 SSA937C133G Hose clamp 2 ø13.1 ~ ø15.5 29 SSA937C133F Hose clamp 4 ø11.6 ~ ø13.6 30 SSA937C287N Clip 2 For drain hose 31 TLA032A001A Cover 1 32 TSJ321A002G Tube 1 ø9.52 × 8m 33 TSJ321A005D Pipe 1 ø19.05 × 6m 35 SSA937D045A Band 30 36 SSA937D045B Band 40 37 SSA937D045C Band 20 40 E010 × 22 × 008 Terminal 4 41 SSA562G001B Terminal (connector) 1 42 E010 × 22 × 006 Terminal 1 M6 43 E010 × 22 × 010 Terminal 1 M10 34 38 39 M8 44 45 Note: When procuring the part, be sure to refer to Parts List separately issued. — 97 — 00_TU42DXB.indd 97 2008/02/04 13:32:09 Code Parts No. Name Q’ty Remarks 46 47 48 49 50 TSJ423A001 Drain hose 2 51 SSA623A001NA Fuel hose 1 ø6.35 52 P050Y08B000 Fuel hose 1 ø8 53 SSA151A034K Insulation rubber 2 54 SSA151B462ZZ Insulation rubber 3 ø19 L = 2000mm 55 SSA151B462BG Insulation rubber 1 ø19 L = 150mm 56 SSA151B101AY Insulation rubber 3 ø10 L = 1000mm 57 SSA151B101F Insulation rubber 2 ø10 L = 150mm 60 TLA504A097 Harness assembly 1 Control box to cabin controller 61 TLA504A026A Harness assembly 1 Fuel pump 62 TSJ504A004 Cable (battery) 64 SSA566B054 Plug 1 65 TSJ423J008 Drain hose 2 67 SSA356B302 Dryer 1 68 SSA937A993 Plug 1 For dryer 69 TLA321A203 Pipe 1 Receiver dryer 71 TJC116A013C Sensor bracket 1 Return air temperature sensor 72 SSA358B100 Sight glass 1 73 SSA323A002C Elbow 1 74 TLA624A001 Pipe (exhaust) 1 75 TLA624A023 Pipe (exhaust) 1 Right installation 76 SSA937A908F Plug 1 Exhaust pipe 78 TSJ502A084D Cabin controller 1 79 SSA971G015F Sealer 1 80 TSJ621A004 Fuel pump 1 81 SSA937A105P Clamp 1 For fuel hose 83 SSA551A105D Sensor 1 Defrost termination 84 SSA551A105A Sensor 1 Return air temperature sensor 88 SSA971G056 Putty 2 89 TLA119A580A Plate 4 50 × 35 × t6 90 TLA119A579A Plate 4 50 × 40 × t6 58 59 1 Battery Control box Frame ground 63 66 70 For ø19.05, 90° 77 82 85 86 87 Note: When procuring the part, be sure to refer to Parts List separately issued. — 98 — 00_TU42DXB.indd 98 2008/02/04 13:32:09 Code Parts No. Name Q’ty Remarks 91 TLA504A083 Harness assy 1 92 TSJ116A012A Plate 1 93 TSJ937A007A Clamp 1 94 SSA937A002H Clamp 5 96 SSA911D215 Bolt & Washer 1 97 W010G04X008 Tap-screw 2 100 TSJ116A001B Bracket 1 101 TJF351A007F Accumulator assy 1 102 B070B10 × 030 Bolt & washer 8 M10 × 30 103 W200G10 Washer 8 M10 104 N001G10 Nut 4 M10 95 98 99 “Z” plate, T4.5 105 Note: When procuring the part, be sure to refer to Parts List separately issued. — 99 — 00_TU42DXB.indd 99 2008/02/04 13:32:09 17.Saturated temperature pressure table (R404A) Tempera- Saturated Tempera- Saturated Tempera- Saturated Tempera- Saturated Tempera- Saturated pressure pressure pressure pressure pressure ture ture ture ture ture °C °C °C °C °C MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) MPa (kgf/cm2) -50 -0.019 (144.0 mmHg) -26 0.137 (1.4) -2 0.461 (4.7) 22 1.049 (10.7) 46 1.991 (20.3) -48 -0.011 (79.5 mmHg) -24 0.157 (1.6) 0 0.500 (5.1) 24 1.108 (11.3) 48 2.089 (21.3) -46 -0.001 (9.8 mmHg) -22 0.177 (1.8) 2 0.539 (5.5) 26 1.177 (12.0) 50 2.197 (22.4) -44 0.010 (0.1) -20 0.196 (2.0) 4 0.579 (5.9) 28 1.245 (12.7) 52 2.295 (23.4) -42 0.020 (0.2) -18 0.226 (2.3) 6 0.628 (6.4) 30 1.314 (13.4) 54 2.412 (24.6) -40 0.029 (0.3) -16 0.245 (2.5) 8 0.667 (6.8) 32 1.393 (14.2) 56 2.520 (25.7) -38 0.039 (0.4) -14 0.275 (2.8) 10 0.716 (7.3) 34 1.461 (14.9) 58 2.638 (26.9) -36 0.059 (0.6) -12 0.304 (3.1) 12 0.765 (7.8) 36 1.550 (15.8) 60 2.766 (28.2) -34 0.069 (0.7) -10 0.333 (3.4) 14 0.814 (8.3) 38 1.628 (16.6) 62 2.883 (29.4) -32 0.088 (0.9) -8 0.363 (3.7) 16 0.872 (8.9) 40 1.716 (17.5) 64 3.020 (30.8) -30 0.098 (1.0) -6 0.392 (4.0) 18 0.923 (9.4) 42 1.804 (18.4) -28 1.118 (1.2) -4 0.432 (4.4) 20 0.981 (10.0) 44 1.893 (19.3) — 100 — 00_TU42DXB.indd 100 2008/02/04 13:32:09 ">
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