Air Conditioning System

Solar V Excavator

Feb, 2009
Overseas Product Support Team
Text No. ELE0004
CONTENTS

I. AIR-CON SYSTEM

II. CHECK AND REPAIR OF AIR-CON

III. CHECK THE COOLING PERFORMANCE OF AIR-CON

IV. GUIDELINES FOR CHECK AND REPAIR OF AIR-CON AND

COMPRESSOR

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I. AIR-CON SYSTEM

1. The definition of Car Air Conditioner

• Air Conditioning : Control of temperature, humidity, air flow and a degree of air cleanness.
• Air Conditioner : The system that does air conditioning with heater and cooler.
• The composition of air conditioner.
- Ventilator : The function of air circulation.
- Air Conditioner : Heating, cooling, dehumidification
- An air filter : keep indoor air clean
• Temperature Control
Car HVAC (Heating, Ventilating, and Air Conditioning heating)
- Blower : Making wind
- Evaporator : Cooling the air by using the refrigerant
- Heater Core : Warming the air by using hot coolant from engine
Type - AIR MIX TYPE (generally used), REHEAT TYPE
• Recirculation and Fresh mode
Recirculation mode - Inlet of ventilator is blocked. The air is circulated indoor only.
- When the max. cooling is needed or bad smell (Air) is coming from out side.
Fresh mode - When inflow of fresh air is needed
- Keep windshield from fogging up

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I. AIR-CON SYSTEM

• Humidity Control
Humidity control prevents windshield from fogging up and keeps the air comfortable and at an even
temperature
2. Basic components
Solenoid Valve Air Conditioner Switch Cooling Unit

Low Pressure Hose

FICD Actuator Condenser

Low Pressure Hose Pan Motor
High Pressure Hose
Expansion Valve

Tension Pulley
Compressor
Bracket

Pressure Switch High Pressure Hose

Relay

Fusible Plug
Compressor Condenser
Receiver drier

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 I. AIR-CON SYSTEM

3. Basic Principle of Operation

EVAPORATOR
Take heat from the air
CONDENSER passing in evaporator fin,
-installed at front of while fogged gas is
the vehicle converted into liquid
-gas refrigerant is Cooling Fan
condensed into high
temp/high pressure
liquid Discharge
Filling hose refrigerator
Gas outlet
Outlet

Inlet
Inlet
High temp. and High
pressure gas
BLOWER
RECEIVER DRIER -Supply air to evaporator High temp. and High
- Removes water out
-Supply Cooled air to the pressure liquid
of liquid COMPRESSOR interior of a car
- Stores refrigerant - The motive power is provided by
Low temp. and Low
engine. pressure liquid
- low temp/pressure gas is converted
into high temp/pressure gas EXPANSION VALVE
Converted Into low Low temp. and Low
-has the magnetic Clutch which pressure gas
controls compressor temp/pressure liquid through
rapid expansion
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 I. AIR-CON SYSTEM

4. Principles and functions of cooling cycle

Compressor Condenser Expansion valve Evaporator
Engine room Front room Inside of the car Inside of the car
Heat emission
Heat transfer Expansion Cooling air
Function (condensation of
(compression of refrigerant) (throttling refrigerant) (evaporation of refrigerant)
refrigerant )
State of gas gas liquid liquid gas liquid/gas liquid/gas gas
refrigerant Adiabatic compression Isobaric change Adiabatic expansion Isobaric change

Hot wind Expansion v/v

Cooling cycle compressor evaporator

receiver
drier
condenser
Front cooling wind
(℃)
70℃
Refrigerant 55℃
Temperature temp. 50℃

5℃

(㎏/㎠G) 0℃
13㎏/㎠G (Isobaric change)
Refrigerant
Pressure pressure
2.1㎏/㎠G (isobaric change)
2.1㎏/㎠G

High pressure ·high temp. gas High pressure ·middle temp. liquid Low pressure low temp gas
High pressure ·high temp gas + liquid Low pressure ·low temp. gas + liquid Flow of refrigrant
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I. AIR-CON SYSTEM

5. Major components

1) COMPRESSOR
- Compresses refrigerant gas and circulates it in the cycle. (refrigerant is blood, compressor is heart in human)
- Low pressure gas from evaporator is compressed and sent to condenser.
- Transfers heat from evaporator to condenser (condenser emit heat to air)

▶ CRANK TYPE To condenser From evaporator

- Crank shaft makes pistons move up and down. Valve
Piston
- Simple structure and high efficiency.
- Vertical type (bad fittability to engine)
- Issues in increasing the number of cylinders.
- Fluctuation of torque.

▶ SWASH PLATE TYPE

- Pistons are parallel to the shaft.
- Complex structure and heavy weight.
- Good fittability to engine.
- Less fluctuation of torque.

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I. AIR-CON SYSTEM

5. Major components

▶ VANE ROTARY TYPE Suction Port

Displacement Port
- Good dynamic balance / less fluctuation of
torque. Displacement Suction Port
Port
- lack of power for low speed load Rotor
Swash plate
Consumed horsepower for high speed load is Vane (Changeable control)
high

Volume control valve

▶ VARIABLE TYPE
WOBBLE PLATE TYPE
Displacement changes as the angle of plate
changes

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I. AIR-CON SYSTEM

5. Major components

2) CONDENSER

• High temp. and pressure gas coming from Compressor is cooled and liquefied at radiator fin or condenser fin.
• The amount of heat emitted from condenser is determined due to;
the amount of heat which evaporator had absorbed from the inside and the amount of work
compressor did to refrigerant gas
• The lack of cooling performance in condenser results;
increasing of high pressure in cooling circuit / high load and low cooling performance
( to prevent this -> need to keep condenser clean and check the state of fan motor )

Air Flow

Fin
Pitch
FIN
FIN &
& TUBE
TUBE TYPE
TYPE SERPENTINE
SERPENTINE TYPE
TYPE PARALLEL
PARALLEL FLOW
FLOW TYPE
TYPE

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I. AIR-CON SYSTEM

5. Major components
3) RECEIVER DRIER
• Features of Receiver Drier
(1) Stores adequate amount of refrigerant. ( to control the flow of refrigerant in cooling circuit)
(2) Separates bubble from refrigerant.
(3) Separates air in drier and removes dusts in filter.
(4) Releases refrigerant to the air by using fusible plug, when temp and pressure goes up.
(overheating prevention)
(5) Halts condenser when refrigerant runs out.
(6) Checks the level of refrigerant through sight glass (only with old type of refrigerants)
Sight glass
Inlet O ring Sight glass Sight glass
Outlet
Holder
Filter
Drier

Filter Air bubble

(shortage of refrigerant) No bubble (normal)
Suction pipe

RECEIVER
RECEIVER DRIER
DRIER SIGHT
SIGHT GLASS
GLASS

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I. AIR-CON SYSTEM

5. Major components
4) EXPANSION VALVE

- Is installed at the evaporator inlet.

- Lowers the pressure of the refrigerant liquid.
- Supplies adequate amount of refrigerant to the evaporator according to the change of heat load.
- Two types of Expansion valve : Angle Type, Block Type.
- Angel Type : has less noise caused from the flow of refrigerant and.
has finer flow of air which goes through evaporator.

Cool air

Gas Outl
et

Liquid

Air blow
Inlet Expans
(refriger ion
ant) valve

ANGLE
ANGLE TYPE
TYPE BLOCK
BLOCK TYPE
TYPE LAMINATED
LAMINATED TYPE
TYPE OPERATION
OPERATION

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I. AIR-CON SYSTEM

5. Major components
5) EVAPORATOR

• While passing through expansion valve, the refrigerant liquid is atomized and has lower pressure.
• This evaporates in evaporator by the wind from fan, evaporation heat makes tube fin and the air cool.
- Therefore, Be sure to keep the tube fin clean not to disturb heat exchange
- Iced or frosted fin also disturb heat exchange, so that cooling performance goes down

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I. AIR-CON SYSTEM

6. Refrigerant
▶ Desired features of refrigerant
* Adequate evaporation pressure and condensation pressure
* Non-toxic, incombustible and stable chemically
* Non corrosive and compatible with lubricating oil
* Zero ODP (ozone depletion potentials) and low greenhouse effect coefficient

▶ Types of refrigerant
* CFC (Chloro Fluoro Carbon) : has chlorine in molecule and is stable chemically.
It could spread to stratosphere and destroy the ozone layer
* HFC (Hydro Fluro Carbon) : has no chlorine in molecule, does not destroy ozone.
But high GWP(R134a)

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CONTENTS

I. AIR-CON SYSTEM

II. CHECK AND REPAIR OF AIR-CON

III. CHECK THE COOLING PERFORMANCE OF AIR-CON

IV. GUIDELINES FOR CHECK AND REPAIR OF AIR-CON AND

COMPRESSOR

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 II. CHECK AND REPAIR OF AIR-CON
Causes of malfunction of cooling
Little or no air out
Normal fan motor
Fan motor not working
Little air out
1) Contaminated air filter
1) Short in fan motor
2) Abnormal position
2) bad connection of air duct
of connectors
3) Frozen evaporator
3) Short in resistor ☞ Defective t/con
Shortage of refrigerant
4) Short in fuse Little air comes out
Normal amount of air out
Defective compressor Normal compressor
1) Check the amount
of refrigerant 1) short circuit
2) Normal pressure 2) defective pressure switch
- high 15~17 Kgf/㎠
- low 1.3~ 2.0 Kgf/㎠ 3) Seized compressor
at outside temp. 0~35℃ clutch worn out
1,500 engine RPM
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II. CHECK AND REPAIR OF AIR-CON

1. Cases of malfunction of air-con

1) Cool air doesn’t come out at all (or not enough amount comes out.)
2) Noises occur.
3) Bad smell comes out.

2. General preparations before checking

1) Idle engine at 1500 RPM for 2-3 min.
2) Change the fan speed to Maximum
3) Change the temperature control to maximum cooling
4) Open the hood
5) Check in shade
6) Things to check
- Is compressor rotating?
- Is fan working?
- Measure outlet temperature and high/low pressure

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II. CHECK AND REPAIR OF AIR-CON

3.Check the condition of refrigerant

Air-con condition Normal A little abnormal Abnormal

A large gap A little gap

Temperature gap
(hot at high pressure & (warm at high pressure,
between high/low A rare gap
a little cool at low a little cool at low
pressure side pressure side) pressure side)

Connection pipe Normal (clean) Partially dirty Partially very dirty

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II. CHECK AND REPAIR OF AIR-CON

4. Check high/low pressure in air-con system

1) At normal state

A Pressure -Low Pressure:1.5~2.0kg/㎠, -High pressure: 15~17kg/㎠

-Refrigerant gas is normal

B Judgment -cooling performance is normal
-normal air-con system

2) At shortage of refrigerant

A Pressure - Low Pressure:0.8kg/㎠(low), -High Pressure: 8~9kg/㎠(low)

B Situation - Little cooling

-Leakage of refrigerant gas

C Cause -Blockage in expansion valve
-Blockage in receiver dryer

D Judgment -Shortage or leakage of refrigerant gas

-Repair the leakage and refill up refrigerant

E To do
-Fix up or change expansion valve or receiver dryer

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II. CHECK AND REPAIR OF AIR-CON

4. Check high/low pressure in air-con system

3) Refrigerant Overcharged
A Pressure -Low Pressure:2.5kg/㎠(high), -High Pressure: 20kg/㎠(high)

B Situation -Bad condition of refrigerant

-Overcharged refrigerant
C Cause
-Malfunction of cooling at condenser
-Refrigerant is overcharged
D Judgment
-Defective condenser pin or cooling fan

4) Air is mixed in air-con system

A Pressure -Low Pressure :2.5kg/㎠(high), -High Pressure:23kg/㎠(high)

B Situation -Low cooling performance ( low pressure pipe is not cooled)

C Cause -Air is mixed in air-con system

D Judgment -Defects at vacuuming process

-Re-do vacuuming and charging process

E To do -Check the level of oil in compressor
-Replace the receiver drier

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II. CHECK AND REPAIR OF AIR-CON

4. Check high/low pressure in air-con system

5) Water intermixes in air-con system

-Low Pressure:50cmHg~1.5kg/㎠(low or badly vibrating)

A Pressure
-High Pressure:7~15kg/㎠(low or badly vibrating)
-Cooing system works and stop periodically
B Situation
-Fluctuation of manifold gauge pressure (between normal and below)

C Cause -Water intermixes in air-con system, so that expansion valve is sometimes frozen

-Supersaturated at receiver dryer

D Judgment
-Water is frozen up at expansion valve
-Re-do vacuuming and recharging process
E To do
-Replace the receiver drier

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II. CHECK AND REPAIR OF AIR-CON

4. Check high/low pressure in air-con system

6) Refrigerant doesn’t circulate in air-con system

-Low Pressure: Lower than atmospheric pressure (very low)

A Pressure
-High Pressure:63kg/㎠ (low)
B Situation -Bad cooling performance
C Cause -Blockage in expansion valve

D Judgment -Blockage in expansion valve

-Dehydrate ; re-do vacuuming and charging process

-Clean dusts ; disassemble expansion valve, clean and replace
E To do
-Replace the receiver drier
-Replace the expansion valve

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II. CHECK AND REPAIR OF AIR-CON

5. Check each part in air-con system

1) Receiver Drier
- Turn on the air-con for 5 min, touch it with hands
-> all surfaces are at same temperature - > normal
-> partially cooler or hotter than remaining parts -> the flow of refrigerant is blocked -> replace

2) Magnetic Clutch
- Take apart the wire which goes from switch to magnetic clutch
- When connecting battery terminal(+) to magnet, energized noise occurs -> normal

3) Evaporator
- Air doesn’t come out from evaporator -> defective motor or power supply problem
- Amount of air is enough but not cool -> problem in cooling cycle
- Evaporator is frozen up -> defective thermistor, shortage of refrigerant or blockage of filter

4) Evaporator sensor
- Measure the output voltage (at connector while air-con on)
- Turn-off temperature has reached but voltage value doesn’t change -> defect
(the decline of temperature also need to be checked)
- Variations in output voltage (when input voltage is 12~14V) are like following ;

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 II. CHECK AND REPAIR OF AIR-CON

Working state Output Voltage Measuring terminal note

White On 0.8V~1.5V (+) : Out, center

Low signal
connector Off 12.0V~14.0V (-) : Gnd, first from left

Black On 10.5V~13.5V (+) : Out, center TB th'con : White

High signal
connector Off 0.0V (-) : Gnd, first from left connector

- To Measure the resistance value of duct sensor - > take the sensor apart from the vehicle, and measure
- Take the temperature of duct sensor -> use the comparison table with adjacent temp.
- when power is supplied, even though input voltage is not known if the output voltage changes, that means
the sensor is working properly.
-> when the voltage goes up, it can be said that the resistance also goes up.
vehicle Resistance at 0℃ Resistance at 25℃ note
XD 8.0㏀ 2.472㏀
S-mmo 8.0㏀ 2.472㏀
•NTC thermistor
KV-2 8.0㏀ 2.472㏀ When temp. goes up,
T-3 8.0㏀ 2.472㏀ resistance goes down.
RS 8.0㏀ 2.472㏀ When temp goes down,
Resistance goes up.
MS 12.67㏀ 4.429㏀
BL 11.36㏀ 4.027㏀

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CONTENTS

I. AIR-CON SYSTEM

II. CHECK AND REPAIR OF AIR-CON

III. CHECK THE COOLING PERFORMANCE OF AIR-CON

IV. GUIDELINES FOR CHECK AND REPAIR OF AIR-CON AND

COMPRESSOR

24
 III. CHECK THE COOLING PERFORMANCE OF AIR-CON

1. Considerations for charging/discharging refrigerant

Fill up amount of oil when ;

Charging/Discharg Changing Changing Changing Changing receiver

Changing hoses
ing refrigerant evaporator condenser compressor dryer

30 g 60 g 50 g 40 g 0g※ 40 g

※ Oil is pre-charged in new compressor

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III. CHECK THE COOLING PERFORMANCE OF AIR-CON

2. Check procedures for claims against cooling performance

1) Turn on the air-con, and turn the temperature control switch to maximum cooling
( Full automated air-con : 17℃ , Logic air-con : temperature switch to maximum cooling )
2) Turn the air inlet switch to recirculation mode ( )
3) Change the air outlet mode to operator’s front
4) Turn the fan speed control to maximum
5) If air to operator’s front is not enough, check air-con filter and change if it is contaminated
( Let customer know features of filter and the need for periodical filter replacement )
6) After releasing hot air outside and closing all windows, turn on the air-con for 15 min. at 1500 RPM of
engine; To check if the condenser fan and radiator fan are working
7) After procedure 6), lower fan speed to second degree; to check the cooling performance
by measuring the front air temperature
8) If cooling in not enough in procedure 7), use refrigerant packing tool to check parts and pressures
9) If it is judged that refrigerant is not over/under charged through procedure 1)~8), withdraw refrigerant
and check the amount and check air leakage during vacuum state.
10) If air leakage is found, fix it up and charge refrigerant and oil.
11) Follow the process 1)~7) again to check the cooling performance.a
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CONTENTS

I. AIR-CON SYSTEM

II. CHECK AND REPAIR OF AIR-CON

III. CHECK THE COOLING PERFORMANCE OF AIR-CON

IV. GUIDELINES FOR CHECK AND REPAIR OF AIR-CON AND

COMPRESSOR

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IV. GUIDELINES FOR CHECK AND REPAIR OF AIR-CON AND COMPRESSOR

1. Features of Compressor
- Working noise and vibration result from high speed/high compression movement.
- More load on engine makes more overall noise.

2. Considerations for charging/discharging refrigerants

① Make sure to check the pressure on manifold gauge while charging and withdrawing.
② Make sure to keep vacuum state while charging
③ Make sure to fill up oil when charging (20~30g of Doowon system ND8 OIL)

3. When changing compressor ;

① Do not store compressor upside down – valves could damage from fast rotation when oil
crowded in upper part
② Rotate the shaft by hands with the clutch engaged before assembling high/low pressure
hoses to compressor – it lubricates inside of compressor
③ Double-check that compressor is the cause of malfunction before changing it; other parts
might be the cause

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IV. GUIDELINES FOR CHECK AND REPAIR OF AIR-CON AND COMPRESSOR

4. Check procedures for claims against noises of air-con

① Check if noises are caused by the increase of overall load on vehicle

② Check if noises are caused by other actuating parts (eg. Water pumps, pulleys )

③ Check if noises are delivered inside by vibration of adjacent parts due to actuator’s noise.
( eg. Could be delivered through the suction hose)

④ Check if noised are caused from the expansion valve or the flow of refrigerants
(* These appear when compressor is ON, but not the issue of compressor)

⑤ Check the amount of refrigerant – under/overcharging could make noises.

⑥ Make sure to fill up oil when changing parts in air-con ( amount : 20~30 g ND8 oil)
; don’t have to fill up oil when changing compressor; oil is charged in new compressor

⑦ Keep adequate vacuum state when checking, charging, or withdrawing refrigerant

⑧ Contact the vendor when facing abnormal situation

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END OF DOCUMENT

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