DAIKIN KOGYO AIR CONDITIONER 31 STRUCTURE AND FUNCTION Piping diagram Electrical circuit diagra Compressor {Rotary * Condenser... .- Receiver dryer . : Air conditioner unit... . 02... ees e ee Operating procedure... 6s eves eee e ee Air conditioner 31-1PIPING DIAGRAM Wore Exparsion valve Heat contro! dompor { Hot water heater Air tow PRINCIPLE OF OPERATION COOLING, DEHUMIDIFYING ‘Tho air conditionor takes heat from the surrounding air the operator's compartment, and dissipates this ir outside the operstor’s com heat to the surrounding partment. To carry out this movement of heat, a frigerant (R-12) is used. Cooling cycle 1) The compressor turns the refrigerant into @ high temperature, hhigh pressure gas and sends it to the condenser. 2) In the condenser, it releases heat to the surrounding air, and the refrigerant is turned into a high pressure liquid, The fiquefied refrigerant has moisture and dirt removed from it in the receiver dryer, and is then sont to the expansion valve. 8) The high pressure liquid refrigerant suddenly expands in the expansion valve and changes into a low tem- perature, low pressure mist. It then enters the eve orator. 4) In the evaporator, the refrigerant takes the heat from the surrounding air and becomes a low pressure gas. ‘The surrounding air, which has lost it heat, becomes a 31-2 oO Receiver aryer cool air flow, It passes through the blower (indoor fan) and spreads into the operator's compartment, 15} The low pressure refrigerant gas which leaves the ‘evaporator is sent again to the compressor to repeat Step 1} 104), ‘The moisture in the air which contacts the evaporator is condensed into water to dehumidify the air. HEATING The flow for the air conditioner heating cycle is simpler than for the cooling cycle, It uses the cooling water ‘which has been used to coo! the engine Heating cycle 1) The flow of hot water from the engine water mani fold is adjusted by the water valve and enters the hot water heater to heat the surrounding ai, 2} The heated air passes through the blower and is sent {5 hot gir into the operator's compartment. 3) The hot water which heats the surrounding air in the hot water heater retums to the engine to repeat the process from Step 1), Air conditionerELECTRICAL CIRCUIT DIAGRAM mo} s| 2}0u Butssed Jo1e $06 Jo aumeradwi Udy 440 YDUIME ainssaud M07 °Z BION, ~uBiy Aljewouge 5, aunsso4d uayn 440 YOLIMS a3nSSB10 YBIH, “| BION we é g IB trosseues pune “pions soy devour 84019 tr —}-—_—_——@ vein Je soon 2 (worm <9 Air conditionerCOMPRESSOR (ROTARY TYPE) 1. Charging valve 2. Magnetic clutch 3. Front head 4. Case ‘A. Air outlet port (discharge port) B. Air inlet port (suction port) Air conditioner, 31-4 oOFUNCTION ‘The compressor circulates the refrigerant in the reftigers- ting cycle and uses the refrigerant repeatedly. It also compresses the refrigerant and makes it easier to liquefy. LUBRICATION, PROTECTION FUNCTION The lubrication oil is supplied inside the cylinder by the difference between the suction pressure and delivery pressure. It acts to lubricate the tips of the vanes, the bearings and other parts which suffer friction. The lubricating oll acts not only as a lubricant but also acts as a coolant. In addition, if the temperature inside the compressor be- comes abnormally high because of insufficient lubricat- ing oll or abnormality in the system, a thermo protector acts to close the clutch circuit. OPERATION When rotor (3} rotates in the direction of the arrow, the gas Which passes through suction port A and Is sent to the eylinder is carried to near discharge valve (8). This happens because the passage is closed by the internal wall formed by the five vanes (4) and cylinders (6), (suction stage) ‘The space in which the gas is enclosed becomes smaller as it comes closer to discharge valve (8). When front vane (4) passes port B, the compressed gas opens dis- charge valve (8) and is discharged. (compression stage) Ai conditioner 400F002 |. Clutch ass'y . Front head Rotor Vane Cylinder Case ‘Thermo protector 3. Discharge valveCONDENSER Wiring Blower fan Body Motor Condenser coil 31-6 oO Wiring connection diagram 4 / 42361628 Air conditioner1. Condenser coil (Condenser) ‘The high temperature, high pressure refrigerant gas compressed in the compressor exchanges heat with the outside air and becomes high temperature, high pressure refrigerant liquid 2. Blower fan (for condenser) This sends outside air to the condenser coil to ex ‘change heat with the refrigerant. 3, Motor (for blower fan) This rotates the blower fan Air conditioner +400°001RECEIVER DRYER en SPECIFICATIONS © Fusible plu pressurized) ‘© Pressure switch + High pressure side: OFF 27 kg/em? ON 181024 kg/cm? + Low pressure side: OFF 2.0 kg/m? ON 2.1 kgiem* Fusing temperature: 105°C (when not OUTLINE ‘The liquid refrigerant liquefied in the condenser coit is ‘temporarily stored so that it can be supplied to the evaporator coll in accordance with the cooling load. [At the sme time, a filter and desiccant (drying agent) ‘are sealed in the receiver dryar to remove any dirt or moisture from the refrigerant. In addition, there is a sight glass at the top so the flow of refi seen, {A fusible plug (on bolt) and @ combined high-low pres- sure switch are installed to the top as safety devices. 31-8 o 1. Body 2. Sight glass 3. Dryer (desiccant) 4, Filter 5, Pressure switeh 6. Fusible plug Air conditionerAIR CONDITIONER UNIT Hot water inlet port >. Hot water outlet port 3. Electrical wiring Air filter for outside air Refrigerant gas inlet port Refrigerant gas outlet port Dehumidifed water drain ports Air conditioner 31-91. Expansion valve This reduces the pressure of the high temperature, high pressure liquid refrigorant sont from the receiver dryer, and changes it to low temperature, low pres: sure mist refrigerant which is easy to evaporate. In addition, it adjusts the flow of refrigerant to the evaporator coll to the optimum amount to match the cooling load. 2. Evaporator coil (evaporator) The low temperature, low pressure mist refrigerant sent from the expansion valve pesses through the coil and exchanges heat with the air sent from inside tho operator's compartment to supply cold air to the ope- rator’s compartment. 3. Thermostat (for frost detection) This detects the temperature in the evaporator coil fins, It the temperature of the fine drops below 0°C. and the condensed water on the condenser freezes, ‘the thermostat will stop the compressor. 4, Blower (for evaporator) ‘This sends the air inside the cab to the evaporator coil {or heater coil), changes it to cold air (or hot air) and sends it back to the operator's compartment. thas a builtin air flow solector resistor, 31-10 4090008 Air conditioner5. Motor {for blower) This rotates the blower, 6. Antivibration rubber (for blower) “This reduces the vibration acting on the blower, 7. Blower switch (to change speed of blower fan) This switches the air flow of the blower to three stages: H, M, and L. If itis switched to the OFF pos! tion, the air conditioner will stop completely. 8. Heater coil ‘The radiator water passes through the coil and ‘exchanges heat with the air to make hot air. Air conditioner 400P010 31-1110, uu. conditioner This is the op ‘condenser fan, It is a push lock type, so when the switch is pressed, operation starts and the lamp lights up, When itis pressed again, the operation stops. itch ting switch for the compressor and Water valve (regulator valve to contro! flow of hot water to heater) This reguletes the flow of radiator water sont from the engine to the heater coil, In addition, it controls the temperature for heating ‘end cooling. ‘Temperature control damper This divides the flow of cold air which has undergone heat exchange at the evaporator coil. By sending some air to the heater and the rest into the operator's compartment it controls the temperature of the air sent to the operator's compartment. ‘The damper is connected by a wire cable to the tem- perature control lever. Air conditionerOPERATING PROCEDURE NAMES AND FUNCTIONS OF EACH PART |. Blower switch oso IA 1. Blower switch knob This controls the air flow for cooling and heating, © Turn the knob to L (low) — M (medium) — H {high} to adjust the air flow to the desired level. If the knob Is turned to the OFF position, the air ‘conditioner will stop. 2. Air conditioner switch Switch for cooling ‘© When the button is pushed, the switeh is turned on and the pilot lamp (blue) inside the button lights ‘up. [push lock type) ‘© If the button is pushed again, the switch is turned ‘off and the pilot lamp goes out. ‘If the blower switch is not turned ON, the pilot amp will not light up even if the air conditioner switch is turned ON. ‘* Turn the blower switch on before turning the air conditioner switch on, Air conditioner 1 2, Air conditioner switch 3. Air source setector lever 4, Temperature control lever 3, Air source selector lever This adjusts the intake of outside and heating operations, FRE (fresh air from outside) ‘This position is used for normal cooling and heat: ing operations. Air from outside Is used in addi tion to the air inside the operator's compertment. # REC (recirculation of inside air) The intake of outside air is reduced, and the air inside the cab is circulated, This position is used for rapid cooling and heating, 4% When the lever is moved to the FRE position, the pressure inside the cab rises to prevent dust from coming in, 4, Temperature control lever This controls the temperature of the air sent into the cab during cooling and heating operations, ‘© The closer the lever is to the COOL position, the lower the temperature of the air sent; the closer the lever is to the WARM position, the higher the temperature of the air sent. + If the air conditioner switch is turned on and the lever is moved to WARM, heating and dehumidity- ing will take place to remove the moisture inside the cab, 31-131. COOLING ‘Set the levers and switch knobs to the following positions. Biower witch | Airconditioner | Temperature control ever | Arsource selector lever lapid cooling CooL Rapid cooling 4 oN (moved fully to COOL side) REC Normal mae cook. - Meow MEDIUM ~ FRE Gentle cooling L ~ COOL — MEDIUM MEDIUM ~ FRE '¢ Cool air enters the operator's compartment from the vents to cool the cab. ‘+ The cool air is dehumidified by the cooler, so the air Inside the cab Is fresh, ‘+ If the window glass mists up on humid or rainy days, switch on the air conditioner at 2 reasonable tem- perature to remove the mist 2. HEATING Rec oot, FRE WARM Set the levers and switeh knobs to the following positions. 400F006 Air conditioner Blower switch con Temperature contro! lever Air source selector lever Rapid heating H OFF WARM {moved fully to WARM side) REC Normal OFF MEDIUM — WARM MEDIUM — FRE poration Gentle heating L OFF, MEDIUM — WARM MEDIUM — FRE ‘© Warm air enters the operator's compartment from the vents to heat the cab, ‘© If the vents for the window glass are used, the heating can be used for defrosting. 31-14 oO REC coo. PRESSURIZE FRE WARM 400007 Air conditioner3. DEHUMIDIFYING AND HEATING Set the levers and switch knobs to the following posi tions ever - ve | tower | Meare) Temperate conclave | Air source stor lever Berwnitvees | ye | ow MEDIUM — Want ne + This used on cold nd um or riny days. * Fresh air from the outside is dehumidified by the OFF cooker, and is then hested By the heater ‘0 sippy hot ot from the vent. mu “MH REC FRE ‘cook. WARM “o0r008 4. DEFROSTER Set the levers and switch knobs tothe following post tons, Ter 21809 | aroer site | A eansone| — Temperare convo ever | Alesource seco lever Use Fapid detoxting Wari oF demisting 4 on moved fully to WARM side) FRE Ne ! M~L ‘ON MEDIUM — WARM. FRE operation +The outside sir heated bythe heater comes out ofthe oF set Hata wed rere te fH or pre oe & misting ofthe window slass. © 4 SH (e] rressunze__ 6} ec] pre TY ARM worse 31-155, VENTILATION Set the levers and switch knobs to the following post tions. Air conditioner owiteh Blower switch ‘Temperature control lever Air source selector lever Ventilation or pressurizing HeoL OFF {moved fully to COOL side) FRE ‘+ Fresh outside air comes out of the vents to ventilate ‘the operator's compartment. 6. SELECTION OF VENTS Vent Sn | tac | voor | ee coins | oven | OPEN | cose tess | ctoseo | O° | cose cotening | c1oseo | O° | open Vertioson | ore] open | oPew “# Selecting the vents as shown above will further in crease the cooling or heating effect. * Do not turn the fan switch ON when all of the vents are closed. 31-16 oO pressunze (ob Ree | prre WARM] Fos013 Air conditionerDAIKIN KOGYO AIR CONDITIONER 32 TESTING AND ADJUSTING Service tools ...... ceeteeees B22 Service procedure 1 326 Inseason checks . 32.13 Off-season checks 3213 Using air compressor dipstick 32-15 Troubleshooting . : 32.16 Electric system func Defective cooling 92-16 32.17 Air conditioner 32-1SERVICE TOOLS 1. Gauge manifold ‘The gauge manifold is needed for evaouating and charging the refrigerant, and for performance tests It has a high pressure gauge (range. 0 — 30 kg/cm?) and a low pressure gauge (760 mmHg, 16 kg/em?). The charging hose is connected to ports (A), (B), and. {C) in the diagram, When the ports are not used, they are covered with caps. In the situation in the diagram, if the service can is ‘connected to (A), the refrigerant will flow to charging hhose (C) on the low pressure side, At the same time, ‘the pressure is displayed on the low pressure gauge S, ‘The gas does not flow to charging hose (B) on the hhigh pressure side, The refrigerant flowing into the low pressure charging hose is compressed by the com- pressor and the pressure is then shown by the high pressure gauge. 2. Compressor service valve (sorvice valve with check valve) AAs shown in the diagram, the compressor and pipes (A) and (8) are always connected. If the charging hose is connected to (C), the valve core is pushed and the whole circuit (A) ~ (B) — {C) is connected. When charging hose is removed, (C) is closed, but (A) — (8) remains open, Of course, to open and close the valve, @ special charging hose with a builtin protruding part is neces- sary to make connection and disconnection opera- tions quick and easy, 3. Charging valve The charging valve is installed to the service can to stop or take out the refrigerant from inside the 1) Turn the butterfly nut of the charging valve back fully (counterclockwise) to raise the valve fully 2) Turn the disc ring counterclockwise to raise then screw the charging valve into the service can. 3) Turn the charging valve clockwise to tighten the service can to the charging valve, ‘* Turn the valve by hand until itis tight. 4) Turn the disc ring clockwise to lock the service High pressure gouge Fe F509 Air conditioner5) Turn the butterfly nut clockwise and a hole ‘openod in the lid of the service can by the tip of the valve, 6) When taking out the refrigerant, turn the butterfly hut counterclockwise. To stop the refrigerant, ‘urn the butterfly nut fully clockwist 4, Service can The service can is filled with compressed, liquid refrigerant (R12). The pressure inside the service can changes greatly according to the ambient tempera: ture, % When storing the can, keep it in cool place out of direct sunlight, ‘* When filling the refrigerant, do not put it in hot water above 40°C. + Do not subject the service can to shock. 5. Vacuum pump The vacuum pump is used to remove the air and moisture (to create a vacuum) inside the refrigerating ‘cycle before filing with refrigerant. Follow the instructions given on the product when using it. 6. Gas leakage detector (flame-color reaction type) % When checking the location of gas leakage, the im- portant thing is to check thoroughly. Even the best detecting device may not locate the leakage unless it is used carefully and correctly, In particular, if more than 10 days pass before a slight lack of refrigerant is noticed, check sll the ‘connections, rotating parts, and joints with ‘extreme care and patience. 1) Methods for detecting gas leakage 1. First, open the PL ges control valve of the de tector slightly and ignite inside the flame. * The smaller the flame, the more sensitive the detector is for leakage, so adjust the size of the flame with the control valve, It is absolutely prohibited to make the flame large enough to reach the end of the tubs. 2. Bring the end of the suction pipe close to the, suspected cource of leakage slowly, and note any change in the color of the flame, Check the table on the right to detect the leskage, Air conditioner Temperature °C | Saturation pressure kg/em? =10 1.20 0 ~ an 10 3.29 20 475 30 656 40 | 50 11.37 ‘Temperature of refrigerant and saturation pressure (R12) (approx. g/month) Color of Flame 5-25 Pale green 25-40 Light green 40-100 Greenish purple Greenish purple 100 - 160 — medium purple _ Greenish purple 160 — 500 ~ strong purple Flame and amount of leakage of R-12cylinder 1) Structure and connection to outdoor unit 2) Method of use 1) Connect charging cylinder and freon cylinder. i) Install the connector to the freon cylinder. i) Connect the connection at the bottom of the charging cylinder to the freon cylinder 2) Align measurements on charging eylinger. Align the line on the charging cylinder with the type of freon. li) Align the indicated pressure of the charging cylinder pressure gauge with the pressure marked by the line. 32-4 Meteh marks | ‘Charging evlinder Liguid shutout valve 00°01 1 400P061 400P062| Air conditioner'3) Measuring amount charged in charging cylinder i) Open the valves of the charging cylinder and freon cylinder, and measure the specified amount. 4) Connecting service port and charging cylinder |) Connect the connection at the top of the charging cylinder and the service port of the automatic gas check valve using the gouge manifold ‘* When connecting the gauge manifoid, purge the air inside the hose. 5) Charging specified amount 1) Open the valve at the top of the charging ‘oylinder and charge the specified amount. li) The refrigerant enters moro easly if the air ‘conditioner is running, + If the refrigerant is put in through the bottom vaive, it is charged asa liquid, 6) Tighten blind cap. i) Remove the service port of the automatic 198s check valve from the gauge manifold, ii) Tighten the blind cap securely. If it is not tightened properly, the gas will leak. ‘If the inside of the cylinder has been honed and is difficult to see, turn the cylinder upside down 2 or 3 times, Air conditionerSERVICE PROCEDURE PRECAUTIONS WHEN REMOVING OR INSTALLING REFRIGERANT PIPING The following precautions must be kept strictly when removing or installing the refrigerant piping, 1. Drying * Dornot let any moisture or air insidi = Avoid removing or installing the piping on rainy days. Fit blind caps to the freon hoses when storing, # Evacuate and dry properly. + The main components are sealed, so do not open until immediately before connecting the piping. There is desiccant (drying agent) inside the receiv- er dryer, so do not remove the blind cap un assembling the piping, 2. Cleaning + Dornot lat dirt got inside, Fit blind caps when storing or piercing holes in the. freon hose or copper pipies. 3. Air tightoness 4% The refrigerant must not leak. © Check for gas leakage using soapy water or 2 gas detector, © Coat the tightening parts of the pipes with com- pressor oil, and always use 2 spanners to tighten to the specified tightening torque, © Check that there is no damage or dirt on the flared surface, ‘The tightening torques for the flared nuts Tightening torque Pipe |Thread) ‘tkgem) size | size | sorieg] Ext Location of use ecttleG jightening| torque ener i< Between outdoor unit (condenser 4 9.5)5/8-18| 370840 | 450845 | Ot enor dryer and indoor unit (alr con- ditioner unit) Between com: 612.7|3/4.16| se0t60 | 670270 | pressor and out- door unit (con- denser unit} Beween com ago | Bressor and indoor 900#90 | Oni (ei ‘condition eeunit 1915.9 |7/8-14] 700270 Fit blind 9 Fraon hore osF608 ‘Use 2 spanners F505 Tighten to specified torque _05F507 4, Removing piping ‘+ When removing the piping because of abnormali- ties in the system or gas leakage, always discharge the refrigerant gas gradually from the high pressure side. ‘This is to prevent the compressor oil from flow- ing out, 5. Checking compressor oi ‘© When removing or installing the refrigerant piping (oF when there is leakage of refrigerant gas, always check the compressor oil level. (For details of Using the dipstick, see page 32-16.) “4 If gas should leak at the specified torque, clean both faces of the flared part, cost again with oil then tighten to the extra tightening torque, Air conditionerVACUUM DRYING (repeated evacuation) 1. Purpose After completion of the installation of the alr condi- toner, carry out vacuum drying operations before charging with refrigerant. The biggest problem to be ‘concerned about with the refrigerating cycle is to make sure there is no air or moisture inside the cycle. If there is even a small amount of moisture, the system will freeze during operation, that is, clogging by water or freezing of the expansion valve wil ‘Therefore, before charging the cycle with refrigerant, it is necessary to remove completely all moisture re- ‘maining inside the cycle, The best way to do this is to use vacuum drying to boll the moisture inside the eycle and change it steam to remove it. In a vacuum of 740 mmHg, water boils at approxi- mately 226°C. However, if the air temperature is ower than that, even more complete vacuum drying is needed. In such cases, carry out vacuum drying by repeatedly evacuating. 2. Method In this method, first evacuate for at least 20 minutes (at 740 mmHg), then let in refrigerant or nitrogen as to make the pressure more than 2 to 3 kg/cm, Evacuate again for 20 minutes. It this is repeated 2 for 3 times, the moisture contained inside the cycle can be separated rapidly, so this is the most effective method of vacuum drying, Air conditioner ‘At loot 20 minutes Att 20 minutes 5 minures A last 20 minutes Let gas in Let gas in orsEVACUATING 1) Discharge the refrigerant gas inside the system til the gauge reads 0. ‘* Discharge the gas gradually from the high pressure side to prevent the compresior oil from leaking 2) Open the valve on the low pressure side Land high pressure side H of the gauge manifold. 3) Connect the vacuum pump as shown in the dia gram and run for at 20 minutes. If there is any (0) Gauge wet air or moisture inside the refrigerant system, oy pressuro (1) Gauge High pressure LU Low pressure ‘or when installing the system, evacuate the system, sa 'spen then charge with refrigerant at 2 to3 kg/em®, and $ repeat this action 220 3 times. 2 4% When the low pressure gauge Indicates 740 to ai 760 mmbig, goto Step 4). 35 vacuum pune Comoressor Refrigerant can 400F019, 4) When evacuation of the system is completed, close the valves on the low pressure side L and high pros- sure side H of the gauge manifold, Next, loosen the charging hose, and suck a litle ai with the vacuum pump. 4% This is to prevent the vacuum pump oll from flowing in the opposite direction. 55] Stop the vacuum pump and remove the charging hose. 32-8 Air conditionerPROCEDURE FOR CHARGING WITH REFRIGERANT (Charging gas) Decisis ‘After completing the vacuum drying, uso the charging cylinder to charge with gas. % Use freon gas (R12) asthe reft rant, 1) Connect charging cylinder and freon cylinder, Install the connector to the freon cylindar (service ccan), then connect the connection at the bottom of the charging cylinder to the freon eylinder, a 2) Align the measurements on the charging cylinder. ‘Align the line on the charging cylinder with the type of freon. Align the indicated pressure of the charging cylinder pressure gauge with the pressure ‘marked by the line. ‘Maten marks 3) Filling charging cylinder with specified amount. Open the valves of the charging cylinder and freon cylinder, and measure the specified amount, % When using the service can, the refrigerant can bbe charged more quickly if the sorvice can is put in warm water. In this case, the tempera ture of the water must not be over 40°C, 4) Loosen the top valve of the charging cylinder and the high pressure valve of the gauge manifold, and ‘charge the equipment with rofrigarant, ‘© Open (turn counterclockwise) only the high pressure valve of the gauge manifold when charging the cycle with refrigerant, Check that the low pressure valve is closed (turned clock- wise). % Close the high pressure valve when the high ‘and low pressure gas is balanced (When the movement of needle stoped in the gauge), Air conditioner 32-95) Start the engine, 6) Turn the air conditioner fan switch to H. 7) Run the engine at idling, open the low pressure valve of the gauge manifold, and charge the re- frigerant. ‘When using a service can, to prevent the service ccan from breaking, never open the high pressure value of the gauge manifold when the compres: sor is running. 8) Check the whole cycle for ges leakage, '* Check the readings of the high pressure gauge and low pressure gauge. ‘© Check temperature of the suction and discharge i. ‘© Check the temperature of the suction and dis- charge piping of the compressor. 32-10 Sa Seve manifols (U) Gouge tH) Gauge Charging eytinger ‘Charging howe A00F014CHECKING FOR GAS LEAKAGE Check for gas leakage after charging with refrigerant. AX Never run he age. we when checking for gas leak- 1) Connect the service can, gauge manifold, and com- pressor service port with the charging hose correct- ly as shown in the diagram. + The service port at the clutch end of the com- pressor is the low pressure side, ‘4 Do not set the service can at an angle or upside down, (When checking for gas leakage.) 2) Open the butterfly nut of the charging valve, and set the valve of the high pressure side of the gauge manifold at the intermediate position, When the refrigerant enters the cooling cycle from the high pressure side, the refrigerant pressure is shown by ‘the pressure gauge. If the gas is charged from the low pressure port ‘when stopped, the compressor will run empty and this may cause loss of oil 8) Continue to charge until the pressure gauge on the high pressure side reads 2 to 3 kg/em?. b} Tighten the valve on the high pressure side of the gauge manifold completely to close it. 6) Tighten the butterfly nut of the charging valve ‘completely, then remove the charging hose at the service can end, d) After pressurizing the refrigerant, always check for 4a leakage with soapy water or a gas detector. + Be particularly careful to check places con- nected locally. 2) After charging with the specified refrigerant, repeat Step d) to check for gas leakage. Air conditioner J { i harsing hove Service can 400F012 Coat with soapy water osrsi2 32-11TEST OPERATION 1. Charge amount For the normal length of piping (8m to Sm), 1.3 kg 10 14 kgis- guide, 2. Relationship between amount of refrigerant and cool ing capacity If the refrigerant is filled to above the specified amount, there will be a big drop in cooling capacity. Only the pressure at the high pressure side will ri ‘and this may cause the compressor to break down. For this reason, be careful not to overcharge with re- frigerant. IF the amount of refrigerant remaining in the cycle is not known, do not force more refrigerant in, Discharge all the remaining refrigerant, and eve ‘custo the system, then charge with the specified amount of refrigerant, ‘3, Methods of judging if refrigerant amount is correct The following four points can be used to judge if the amount of refrigerant Is correct, Use these together to make any judgement. 1) Charging refrigerant using the charging cylinder (volume) For details, see the procedure for charging with ra {rigerant (charging gas) 2) Charging gas using a weight scale If the weight of the cylinder is measured using a weight scale (balance) before and after charging the gas, the difference in weight will indicate the amount of refrigerant charged in the cycle. 3) Readings of high and low pressure gouges (re- ference) The exact measurements are influenced by the ambient temperature end heat load, but the following table will act as a guide. ‘Ambient | Pressure atlow | Pressure at high temperature | pressure side | pressure side °C Kglom? Kfem? 30 13-17 105-125 35 15-19 12.5-14.5 + Measuring condition ‘© Compressor speed: 2,000 rpm ‘© Temperature of air sucked into cab: 27°C © Fan switch: H 32-12 4) Bubbles in flow in sight glass (reference) Open the window of cab and run the blower motor (Sirocco fan) at maximum speed. 1a few bubbles can be seen. ‘# If the speed is increased slightly, the bubbles disappear completely. The condition of bubbles in the sight glass is af fected by the ambient temperature, When it is cool, bubbles are more likely to appear, but the bubbles become fower as the temperature rises, Coloriess Refrigerant [Insufficient transparent correct refrigerant 00°15 AS en chasing i cook weather, be eet not to berchare. Tei necessry to check apn when thovemperture i higher Air conditionerIN-SEASON CHECKS Cheek item Condition and remedy ‘© Loose, eracked, broken, ‘© Loose, broken, missing parts > replace with new parts Mounts missing parts Loose mounts > tighten ‘+ Gas leakage from cracked or | # No gas remaining inside cycle but wet dusty air inside 0080 pipes > Evacuate cycle using refrigerant (R12) ~> Clean all parts with triflon liquid and dry © Replace roceiver dryer (desiccant) © Check oit ‘© Oil level > check with dipstick Compressor ‘© Check magnetic clutch Dirty cit > change oi ‘© Abnormal noise, play in bearing-+ replace, repair ‘+ Check air conditioner unit | Using procedure for checking and repairing unit, check ‘© Check air fitter related parts Air conditioner unit | # Bending, clogging of drain | * Clogged air filter > clean, replace hose ‘© Bent, clogged drain hose + repair or replace © Check water valve '* Opening and closing of valve defective -> replace with new part Check condenser unit ‘+ Using procedure for checking and repairing unit, check related parts Condenser unit ‘ondenser ‘= Check cooling fins ‘© Mud or dirt on fins + clean ‘© Check tension of V-belt ‘© Defective + replace with new parts V-belt ‘Check for stretching, wear |. Beit loose-+ replace with new part, adjust to specified value OFF-SEASON CHECKS To prevent oss of the ol film in all parts of the com- «If it is left for along time with the refrigerant leaking pressor, run the compressor at low speed for a few ‘out, rusting will occur inside, so check for any utes once every week. feakage of refrigerant, If the ambient temperature is low, be particularly careful when running the compressor. Be sure to run the compressor at low speed. * If the ambient temperature drops below 0°C, the compressor may not run due to the action of the igh-low pressure switch, Air conditioner 32-131. Checks using gauge manifold (standard) + Standard pressure ‘© Compressor speed: 2,000 rpm 1) Connect the high and low pressure charging hoses © Ambient temperature: 30 — 36°C ‘of the gauge manifold to the comprossor service ‘© High pressure: 10.5 ~ 14.5 kg/em? ports, Low pressure: 1.3 — 1.9 kg/em* 4 Always purge the air from inside the charging © The high pressure will vary according to changes in hoses. ‘the ambient temperature, ‘For reference, see the Evaporation table blow for 2) Raise the compressor speed to 2,000 rpm and read freon ges (R-12). Using this, compare the gouge the compression gauge after 5 to 10 minutes. pressure (kg/em?} and the temperature (°C) 10 judge the condition inside the cooler eycle. EVAPORATION TABLE FOR FREON R-12 (CC; F) Saturation pressure] Specific gravity Enthalpy Entropy Gauge | Absolute | Fluid | Vapor | Fluid | Vapor Fluid | Vapor kg/em? | kgom@abs | kg | Keal/ko | Keal/kg | Kealreg | Keat/kg | Keat/ka | Kealike -i5 | og62 | 162 | 1441 | 1079 | 96272 | 135.20 ] sas7 | o9a77 | 1.13723 -10 | 1234 | 2238 | 1425 | 1220 | 97.20 | 13587 | 3007 | 0.99188 | 1.13657 -8 1308 | 2308 | 1219 | 1368 | 98.23 | 13609 | 37.86 | o.gaasr | 1.13633, -6 157 | 2571 | 1413 | 1460 | 9967 | 13692 | 37.65 | 0.99514 | 1.13609 -4 1753 | 2753 | 1407 | 1557 | 99.12 | 13058 | 37.43 | 0.99676 | 1.13506 -2 1913 | 2989 | 1400 | 1659 | 9056 | 135.77 | 37.21 | 0.99839 | 1.13566 ° 2143 | 3.146 | 1394 | 17.65 | 10000 | 196.99 | 36.99 | 1.9900 | 1.19546 2 2ase | 3353 | 1368 | 1865 | 10045 | 197.21 | 36.76 | 1.00161 | 1.19524 “4 2se0 | asa | 1981 | 1976 | 100.90 | 19743 | 36.63 | 1.00322 | 1.19506 6 2013 | 3913 | 1375 | 21.95 | 10135 | 137.65 | 36.90 | 1.00489 | 1.19408 8 aose | 4052 | 1368 | 2218 | 101.80 | 137.86 | 36.06 | 1.00643 | 1.19471 +40 | 8.770 | 9.770 | 1.265 | 5347 | 10941 | 14008 | 3183 | s.00167 | 1.13236 sas | 10023 | 11.023 | 1.228 | 60.13 | 11066 | 141.33 | 3067 | 1.03686 | 1.13107 +50 | 11386 | 12386 | 1.212 | sea | i191 | 14166 | 2075 | 103043 | 1.13181 +55 | 12868 | 13968 | 1189 | 7558 | 11325 | 14213 | sees | 103346 | 1.13148 veo | raaer | 1s4er | 1.167 | asas | 11457 | 1449 | 27.92 | 1.04736 | 1.13177 vos | re216 | 17216 | 1.119 | 9859 | 11592 | 142.82 | 26.90 | 1.04126 | 1.13082 +70 | 18096 | 19.008 | 1.114 | 10852 | 117.29 | 143.09 | 25.90 | 1.05619 | 1.19098 +76 | 20.125 | 21.125 | 1093 | 12201 | 11869 | 14331 | 2462 | 105912 | 1.12908 +60 | 22290 | 2200 | 1.064 | 138.05 | 120.13 | 14348 | 23.93 | 1.00310 | 1.12917 Example: With the low pressure gauge reading 1.8 kg/cm”, the table shows the freon gas evaporating temperature in ‘the evaporator to be about ~2°C. In addition, with the high pressure gauge reading 13 kg/em?, the table shows the condensation temperature of the freon gas in the condenser to be about 55°C. 32-14 Air conditioner oOUSING AIR COMPRESSOR DIPSTICK 1, Method of use 1) Remove charging valve (1) at the rear of the case. 2) Taking care not to hit the oil separator inside, Insert dipstick (2) until rear face (A) of the knob ‘comes into contact. * The values for the oil level shown in the diagram are for the compressor in a horizontal position. 2. Checking compressor + Anew compressor contains 220 ce of oil (Dafni 7963}, and is completely sealed with gas pressure (over 2 kg/em?), so with normal operations, it is unnecessary to check, ‘+ If any of the compressor oil should be spilt, and the level of the oil inside the compressor is not known, measure the cil lovel with the dipstick, Correct oil level: Above top red mark (220 ec) 3. Checking compressor after mounting and operating When operating the air conditioner, if eny defects such as leakage of refrigerant gas occur, ahways check the compressor oll level before adding refrigerant gas. 1) When the system is operating, the compressor oll dissolves in the refrigerant, and the compressor off level drops, so cheek the ol level 2s follows. Dipstick roading and actual oil ovel Keep air compressor horizontal © Keep the engine running at low idling. (air condi- toner switch HI) # Run at cooling for at least 5 minutes to return the il to the compressor. Discharge gas from the high pressure valve, ‘» Check that the oil level is above the top rad mark Of the dipstick. (standard 220 cc) 2) If the oil level is low, add oil. (Daffni 7963) + Keep the compressor horizontal + After checking the oil level, tighten the chorg- ing valve firmly. "5H Tightening torque: 165+ 15 kgem ‘4 If there should be gas leak, carry out extra tightening to a limit of 200 kgem, 4, Oil level when cate is at an angle ‘When measuring the oil level inside the case, the com pressor should be kept horizontal as far as possible. However, if it is necessary to measure the oil level with the compressor at an angle, use the following table to calculate the oil level from the dipstick mes- sureme.7ts and the angle of the compressor. (unit: co) Compressor Dipstion Cn” | Horizontat 18° to left 30° to left 18° toright, | 30° to right messurement Red 60-100 95 — 130 140 — 165 Max. 75 Max. 65 Green 100-140 130 — 160 165190 75-110 65-80 Brown 140-170 160 - 190 190-215 110 = 180 90 — 120 Blue 170 — 200 190 = 215 Min, 200 160 — 180 120 - 155 Red Min. 200 Min 218 = Min. 180 Min. 155, Air conditioner 32-15 oTROUBLESHOOTING ELECTRIC SYSTEM FUNCTIONAL SEQUENCE Blower switch ON ‘lower motor speed change fveltamp. fue) resistor Fan motor rotatae Heating cooling FFenp. contr! “Tamp. eontoT [Somber inWaRt| | damper in COOL, Hot mater valve Hot water valve i j-—| ve slosea ‘opaned WARI stood [Warm wind bo lour Pitot lamp Hits oct} ‘Set temp. OFF [Pressure switches (HPS & LPST ‘OFF LPS: 2.0 + 0.2 kofem?, 2.1 + 0.2 kalem? 2 le OFF ‘on HS" 27_9 kale 822 kslem* Thermo-protecter set temp, OFF ‘On im'ess'e ogre Condenser fan on Note: LPS: Low pressure switch HPS: High pressure switch ‘Cold wind blows out ‘MC: Magnetic clutch 32-16DEFECTIVE COOLING Detective cating 5 Air fier igtogped = Clusn RECIRCULATE air ee ee eee filter or PAESH air iter Blower |_| Sppotie diection” ———e Corret the wiring Tack of wind]! | Totate ‘An obstruction near» Remove the obstruction eta ‘Notion port out) } Evaporator is frosted --~ m= Turn the cooler switch OFF Todi SBalceSE OSE lov i deformed ———m- Replace the blower erdamaned uct how is iconnectad —=- Reps L{Raiaica]- Power sure vlan ops —=- satery charge 0 ow Terminal contset i oor —S Petieh the termine with snd Pee Sater a i an a § etower motors foulty —= Replace Tirostes}- Resistor is broken ————=- Replace _| fe'toss not rotate Replace the bower resistance Somer restr temp, -——— fuviebumt out eo. fe | paren | Breckor works ——————e check tor couse, ropa, noir os Sears Erte ie, Co |} The wiring ful nd — me heck the igen reload pas. {ds not ote! connastor nr diconnected The body gundiouty a= CMEC ound score Blower swith is detective —e Rapa oF repo Bower isin contst ——=- Repair or reploce ere os ers or er Blower motor fouty ——e> Replace Water vai faulty = Replace [Samora Temperature contol Inspect or rola he thermortat frome Teton ak omen] | femaly Cutie ir flows in. —7—= Cove windows andl doors Hiscrna = ajust she ouside ad inside sir ange damper Frame |_¢ tighoressuresauge reading ls 00 high fea] sSeonmal’ | {Higprasour'aafehis often actutel Lowpremare om toghish , ————» {62 rR STS IN etsy Hlohocesure gage readings 9 ay (Preshire does not excoee 10 kglom™) ym rey org ening op ow ——————»{Ea] (Breskire dropebotew 68 bale?) Both the low and high resure sou reeding are hah —e-{O5] Both the low and hgh-presaure gauge eading are low —e{ 6-6] Gutzh dos not actuate because of ————e Check the wiring ‘re foulty store system 13 —= {D7} Vbelt i broken oF sips, = Correct the bet alignment Srrapioce the bak Magnetic clutch is faulty += Repair or roplace ‘Comprottor is faulty (Locked) ——e- Replece compressor Blower resistor and tomp, fuse we Corect the portions in contact Befecive ai froin comack with ench other ow slotor ows Blower anitoh fs out of order m= Replace (ote) Compressor works even wien the temp. ofthe ougide air. ———=- Low pressure switch i faulty {ihe femp, of ei drawn into consensor fe below 2c ———-> oploce he low pressur eniteh Note: Hi: High, Me: Medium, Lo: Low Troubleshooting chart 32-17[—1 Capilary tubs of the frost thermostt is erronsously located or out of place Insert the capilary tube into the right postion at ‘2 the trost thermostat is faulty Replace [1 Air infitates into the refrigeration systam ———— Remove refrigerant avacuste cycle competeh ‘hen chorg agen with rtigerent [2 !nsutcint condenser —r (27) Fins are clogged with mud clean fins cooling (22) The cooling fon does —7-(Z27) olay ie feulty Replace relay 2) Fan isin contact —— Repair or replace the fan with the shoud 3) Detective connection— Check connection of ‘of conagctor, mi eonnector taken wiring eH | gay Fan motor is out —— Replace the fon motor of order \Cooting fan rotates —— "Tho fan ie deformed oF Replace the fon bucinsufficient mages ‘ooling [3 Too much refrigerant piacharge refrigerant until proper ety 4 Ambient tomperature is oxtramely high (Note) If te pressureon the high pressure sido is oH it {5 The condenser tube s clogged (rushed oy bent) ——-—Replace the condensar Replace the high pressure swith ‘over 27 kalem®, but the compressor does not Feplace the receiver melt bolts (fusible plug) 90 OFF and the furble plug of the recstuor {rlted, the high prose cut Huish it efecto, expansion vale The expansion valve ——Replace pete foo woe Isteuley (£2) The neat sensing tube in poor Place the tuba in close contact, using 9 sensing tube holder [2 Too much refrigerant ————_______—-pisenarge rfrigarant until proper aity 32-18 oO 15 the compressor i faulty Feplace the compressor as'y Air conditionercot Air conditioner ‘Shortage of refrigerant. charge the system up to the proper quantity ‘Chock the system for gas leakage ‘The expansion vave ‘The expansion vave — Replace ‘sfoulty is frozan or clogged. The heat eansing Repalce tuba i leking os Vebett tips Adjusting the belt tension “The magnotic catch slips —~__________— Replace or repair “Ambient temperature is extemely tow “The compressor I faulty place the compressor at'y “% Special tachniquos sre required for the overhaul and repr of the compressor, DDornot alssssemble, but replace the cormpresso ae tho as'y, ‘Shores of refrigerant Not enough retigerant —Charge the system upto the proper quantity chore ‘Gheck the system org leakage tossing in oi T) The exoanson valve ——Replace the expansion valve sures is cloged ech ot fs lncage rom the Rratsoning tbo (EZ) THe excomion ave —Replce the exverson vate eclogged wit torenn ‘nator Te resiver yer ——enlace er The expansion vale —Remove the moisture o replace the ae 0 snd (25) The piping is closoed Rei or replace wit orion moar “The evporstr i frotted ola] ‘Ambiant temperature is extremely tove Insufficient condenser cooing ————_____ rol] 2 ‘Too much retigerant Discharge refrigerant until propos a'ty ‘Components or piping in low pressure tine i clogged ——- Repair or replace the clogged portion High-pressure piping i longed Repair or replace the clogged portion ‘Shortage of refrigerent 32-19 oO1 Low prassure smite is faulty Replace 2 “The wiring i out of place, broken, in poor contact, —— Crack the wiring and related parte or wrong ‘3. Frost thermostat is faulty ———Repiaco ba —4 Blower switch is faulty Replace {6 Air conditioner switch Is faulty just or replace 16. Tharmo-protector is faulty —————Replace DEFECTIVE HEATING ‘Lack of wind | — Same as for detative cooling Detective The hot water heating erporature L, [Wind volume The het water in the hot water crcult——seBleed the sir from the crcult is pormal termpersture temormal | |—the water vave ig clogged or ——e-Replace tho mater valve tends tobe cloneed |The pining i clossed or bent ——e-Repsr or replace Ambient temperatura is extremely low |The engine coolent level = Add coolant up to lew ‘ho specified lovat {the heater core is broken ———-m-Replace the heator core 1% Be sure to chack the pump dalivery presure to ea Ifthe es normal, and chack the noatr Rosas to 808 I the ‘and “OUT” lings are connected in reverse. [The temperature J Adtust damper control damper i out of exjustment| water Drain hole is clogged ————==Ctean 32-20 Air conditioner oDAIKIN KOGYO AIR CONDITIONER 33 DISASSEMBLY AND ASSEMBLY Tools Disassembly of compress Assembly of comprestor Disascembly and testing of air conditioner unit. . 33-11 Condenser unit... ee. eee Receiver dryer... oe eeees eee neee ee Air conditioner 33-1TOOLS 1. TOOLS TABLE No. Tools name Specification ory 1 Hexagonal wrench ‘Simm 1 2 Clutch armature holding jig = i 3 Clutch armature extraction jig = 1 4 ‘Spread-type snap ring pliers small 1 5 Pincer-type snap ring pliers small 1 6 Pulley remover jig (remover jig and jaw) = 1 7 Adjustable wrench 17mm 1 8 Plastic hammer = 1 9 Shim remover jig = 1 10 Cover plate insertion jig = 1 un Cover plate pusher jig = 1 12 Socket wrench 6mm 1 13 Feeler gauge 0.4 mm 0.6 mm 1 4 Rotor shaft protection sleeve = 1 18 i 1 33-2 Air conditioner2, REFERENCE DRAWINGS 1) No. 2. clutch armature holding jig Piteh diameter 709 210 Pitch cidmeter 460 3-65hole MEX 125 11/8 = 20uNc. +9, ‘coupling groove 08 “9, Knurled finan 400018 Air conditioner 400F017 Material: SPCC (brazed pin X 3) Meterial: S45C Quantity: 1 Material: S45C Quantity: 3 (use snap ring inside diameter 5 mm X 3)me oo Material: hexagon socket bolt (08) (material not decided) ‘Quantity: 1 Center serew 400F019 3) No. 16 pulley press-itting jig 2» Material: S45 Quantity: 1 33-4 Air conditionerDISASSEMBLY OF COMPRESSOR ASSEMBLY u 1. Center bolt 2. Washer 3. Armature 4, Shim 8, Snap ring 6. Snap ring 7. Snap ring 8. Core 9, Pulley 10. Clutch ass'y 11, Rotor ass’y 12. Oil separator 13, O-ring 14, O-ring 15, Case 16. Charging valve 17. O-ring 18. O-ring 19. Oil level gauge 20. Oil (Dafni 7963) sooroes 21. Thermo protector Air conditioner @DISASSEMBLY OF CLUTCH 1. Center bolt 1) Insert 3 pins of clutch armature holding jig into three matching holes in clutch armature to hold clutch armature firmly and prevent it from turn. ing. 2) Loosen center bokt (1) with Emm hexagon wrench, and remove together with washer, 2. Clutch 1) Screw butterfly nut and 3 bolts of clutch armature extraction jig into center of rotor shaft, tighten clockwise and pull out clutch armature (2) 3. Shim 1) Remove felt and shim (3) of rotor shaft with shim remover ji, 4. Snap ring 1) Remove inner snap ring using spread-type snap Fing pliers. 2) Remove outer snap ring using pincer-type snap ring pliers. 00Po88 Clutch armature ‘Shim remove ig Air conditioner5. Pulley 1) Fit tip of jaw (A) of pulley remover jig firmly in pulley snap ring groove, 2) Cover rotor shaft with rotor shaft protector. 3) Allgn pulley remover jig with jaw, then secure jaw 2 bolts of jig, 4) Using a wrench, tighten bolt in center of pulley re- mover jig and pull pulley (4) out straight, 6. Electrical cord 1) Remove electrical cord from clamp, 7. Core 1) Using spread-type snap ring pliers, remove snap ‘ing on inside of front head, then remove core, DISASSEMBLY OF COMPRESSOR 1) Loosen 4 hexagon socket bolts (M8 x 35) at top front head, then remove two of them, + Donot remove all four hexagon bolts. + When loosening the bolts, hold the compressor firmly in position, 2) Loosen 6 hexagon socket bolts (MB x 20) connect. ing case to front head, then remove front head, 3) Hold case firmly in position, and rotate front head ‘to remove compressor rotor. Air conditionerASSEMBLY OF COMPRESSOR ASSEMBLY ASSEMBLY OF CLUTCH 1. Core 1) Align protruding stopper of core (1) with notch in front head to prevent core from rotating, then fit to front head. 2. Snap rings 1) Using spresd-type snap ring pliers, fit snap ring Into groove on inside of front head. 2) Using pincer-type snap ring pliers, fit snap ring into groove on outside of pulley. 3. Pulley 1) Fit pulley (2) horizontally on front head, then use pulley press-fitting jig and hammer to knock in pulley until snap ring groove of front head appears fully. 4, Snep rings 1) Using spread-type snap ring pliers, fit snap ring {$-40) into groove on inside of front head * Rotate the pulley and check that there is no contact or interference between the pulley and ‘front head, 5. Shim 1) Fit felt and shim to rotor shaft ‘+ The number and thickness of the shim is adjusted exactly at the factory, so use all the shims that were removed, ‘After using for a long time, if wear has caused the ‘gap between the pulley and armature to become larger, adjust the number and thickness of the shim. % There are three types of shim thickness: 1mm (after heat treatment, 0.2 mm, 0.1 mm). Feeler coum 33-8 Air conditioner6. Clutch armature 1) Install clutch armature to rotor shaft, 7. Center bolt 1) Insert hexagon socket center bolt together with washer in tap hole of rotor shaft which passes through hole in center of clutch armature. Then tighten using @ § mm hexagon wrench and clutch armature holding jig. + Sot the washer with the round edge at the top. SZ) Mounting bolt: 135 + 15 kgem 21 Using feeler gauge, check that gap between arma- ture and pulley is 0.4 t0 0.6 mm, If the gap is not within the specified range, remove ‘the armature and adjust the number and thickness of shims, 8, Electrical cord 1} Secure electrical cord with clamp. 2) Apply 24V DC electrical current to power source ‘terminals and check operation of clutch, ASSEMBLY OF COMPRESSOR 1. Orings 1} Replace O-ring with a new part and coat with oil (Oafni 7963), 2) Fit from rear end (end where cylinder is installed) ‘and insert to root of joint between front head and front side block. 3} Replace O-ring with @ new part and coat with ofl (Dafni 7963). 4} Fit in groove of rear side block. Air conditioner2, Compressor rotor 1] Push compressor rotor straight into case 4% Be careful not to install the rotor upside down. 4 Check that the case is correct way up from the label (Serial No. and caution plate) or ports (dis: charge or suction port). ‘3, Case mounting bolts 1) Insert 6 hexagon socket bolts {M0 x 20) in screw hole of case and front head, then tighten with 6 mm socket wrench, GE] Mounting bolt: 200 kgem Hexagon socket bolt OTHERS 1. Thermo protector 41) There must be continuity between the terminals at under 120°C. 2) If there is no continuity, or if there is continuity above 120°C, the thermo protector is defective, so replace it. GSE) Tightening torque: 145+ 5 kgom 2. Charging valve If the valve has been removed, replace gasket with a new part. G32 Tightening torque: 165 + 16 kgem 33-10 Air conditioner ®DISASSEMBLY AND TESTING OF AIR CONDITIONER UNIT 1. Indoor unit 1) Remove indoor unit from mount. Cabin box (1) ‘© Blower box (2) 2, Resistor 1) Remove resistor (3) installed on blower box (2). 2) Measure resistance between terminals of resistor, 1) OUT —IN: There must be continuity i) HM: 14059 ili) M—L: 321 so0rozt 3) If the resistance values are not as given ini) ~ ili), there is a short circuit or disconnection (tempera ture fuse blown), so replace the resistor. OUT IN, HOM OL sooroz2 3. RECIRCULATE air damper 4)-Remove 6 screws mounting RECIRCULATE air damper. 2) Remove wire clip (4) of RECIRCULATE sir damper, then remove wire (5). 3) Remove RECIRCULATE air damper assembiy (6). ner 400018 ‘008018 33-114, Blower assombly 1) Remove 2 screws at connection of blower and cabin box, 2) Remove 4 mounting bolts of blower assembly. 3) Lift off blower assembly (7), 5. Blower switch 1) Test. continui switch, between terminals of blower [Knob position] Continuity betwoen terminals OFF No continuity Continuity between B =e, B-L © | No continuity between other terminals " Continuity between B= C, B— No continuity between other terminals 4 Continuity between BC, B— H No continuity between other terminals + If the condition of continuity is different from the above table, the blower switch is defective, so replace it with a new part. 33-12 © a00rc09 U M s00r029 Air conditionerir conditioner switch 1) Test for continuity between the terminals of the air conditioner switch, ‘Switch Continuity between terminals OFF Continuity betwor 3 1-2 on Continuity between 2~3 1-3 4 When the switch is OFF, if there is no continuity between terminals (2) and (3), the lamp Is de- fective, so replsee it. % When the switch is ON, if there is any part which 's non-continuous, or if there is continuity between any torminals not listed above, the air conditioner switch is defective, so replace it. 7. Console cover 1) Remove coupler of blower switch and air condi tioner switch, 2) Remove 3 hexagon bolts mounting console cover and 2 screws mouting lever, then remove console cover (8). 3) Remove 2 screws mounting coupler, then remove coupler (tock plate) (9). 4) Remove frost thermo terminal (10) and harness (11), 8. Cover 1) Remove 4 screws mounting blind plate, then remove blind plate (12), 2) Remove wire (13) between temperature control ‘damper and lever assembly, 3} Remove 10 screws mounting cover, then pull up ‘cover (14) to remove, Air conditioner Ne ow Q ® ®9. Cover mounting plate 1) Remove 10 mounting bolts from cover mounting plate (15), then remove 3 mounting plates. 2) Remove 9 mounting screws of frost thermo ‘mounting plate (top cover of evaporator) (16). 3) Remove evaportator cover. 10, Frost thermo 1) Pull out capillary tube (17) from evaporator fins. 2) Remove frost thermo (18) from fin white still con- nected to tip of tubs. 3) Test for continuity between terminals of frost ‘thermo. i) Tum frost thermo temperature setting shaft fully counterclockwise, acoro2s ii) There should be continuity between the ‘ter rminals when the tip of the capillary tube is put into warm water (Approx, 20 ~ 30°C). il) There should be no continuity between the ter- rminals when the tip of the capillary tube is put into cold water (betow 0°C). |v) If the correct results are not obtained in ii) and Tif), replace the frost thermo with a new part. & When checking for continuity, leave in the hot water or cold water for atleast 5 minutes, ‘* When installing the frost thermo, check that the temperature setting shaft Is turned fully clock- wi ‘Insert the capillary tube correctly into the eva- orator fins 33-14 o Air conditioner11, Wire 1) Remove 1 mounting serew of wire clip for tem- erature control damper, then remove temperature ‘contro! wire (19). 2) Remove water valve wire (20) from vane of tem- perature control damper. 12, Temperature control damper 1) Remove 4 mounting screws of temperature controt damper cover (21). 2) Lift off temperature control damper cover. 3) Pull up evaporator cover (22) to remove, 4) Remove evaporator cover (23). 5) Remove heat prevention material (24) of intake pipe, 6) Pull up temperature control damper (25) to 13, Expansion valve 1) Remove flared nut (26) of capillary tube for pres: sure balance tube, 2) Remove heat prevention material (27) of heat sensing tube. 3) Remove mounting screws of heat ser clamp plate. 4) Remove heat sensing tube(28). 5) Remove flared aut (28) of expansion valve 6) Remove expansion valve (30), tube ‘% Always use 2 spanners when removing the parts in ‘Steps 5) and 6). * When installing the expansion vaive, coat the joint ‘with compressor oll and tighten securely. 4 Always wrap the heat sensing tube with heat pre: vention material, + If there is any clogging of the expansion valve, ges leakage from the heat sensing tube, or if the vaive opens too fer, replace with new parts, Air conditioner 33-1514, Evaporator 11) Remove flared nut of suction pipe (gas pipe). 4% Always use 2 spanners. 2} Remove flared nut of liquid tube, Always use 2 spanners, 3) Remove 2 clamps at liquid pipe end. 4) Pull evaporator (46) up and remove, 16, Heater assembly 1) Remove 1 mounting screw of hose clamp (31). 2) Remove 3 mounting screws of heater support plate (32). 3) Remove 2 mounting screws of water valve mount- ing plate (33). 4) Raise heater assembly (34) so that heater support plate comes to top of cabin case. 33-16 Air conditioner16. Heater hose clamp 1) Remove 4 mounting screws of heater hose clamp, 2) Remove heater hose elamp (36). 17, Hose clamps 1) Remove 2 hose clamps (36). 18, Heater assembly 1) Raiso heater assombly (heater core, wator valve, hheater hose) (37) and remove, 10, Water valve ‘¢ Check that the water valve works properly. 1) Start engine and warm heater. 2) Turn air conditioner switch (47) OFF. 3) Move air solector lever (48) to REC, 4) Move temperature control lever (49) to COOL. 5) If the results of checks 1) — 4) show that the ‘temperature of the air coming from the vents is same temperature as the intake air, check the fol lowing items ifthe air is hot. a) Correct adjustment of water valve wire, b) If the water valve is dafective, replace it. Air conditioner or L uw Xe sc coor, X { @ rtsume @ Fre| WAR 33-1720. Hester case 1) Remove 4 mounting screws of heater case (top: 2; bottom: 2). 2) Pull heater case (38) up and remove, 21. Liquid pipe grommet 1) Remove liquid pipe grommet (39). + Use a flat screwdriver blado, 22. Liquid pipe 1) Remove 2 clamp plates of liquid pipe, 2) Remove liquid pipe (4) 23. Evaporator case 1) Remove rubber bushing of suction pipe, 2) Romove 7 mounting screws of evaporator case. 3) Raise evaporator case (42) and remove, 33-18 ‘4008098 Air conditioner24, Suction pipe grommet 1) Remove suction pipe grommet (43). + Usea flat screwdriver blade, o0Po40 28, Suction pipe 1) Remove 3 mounting screws of suction pipe clamp. 2) Remove 3 suction tube clamps (43). 3) Raise suction pipe (45) and remove, Air conditioner 33-19CONDENSER UNIT 1. Condenser unit assembly 1) Condenser fan motor i) Remove coupler of wiring harness, then run DC current at 24V through motor (1). ‘Motor (1) should rotate at speed, If it does not rotate, replace the motor. 2. Blower fan 1) Rotate fan (2) by hand and check that it ro- tates smoothly, ii) If mounting bolts are loose, give extra tighten: ing. If fan and shroud are hitting each other, correct or replace, 8. Condensor coil i) If fan of coil (2) is clogged with mud or Is dirty, clean it. If coil is defective, replace it RECEIVER DRYER 1, Receiver dryer 1) If receiver dryer is defective, replac part 2) If fusible plug (melt bot) is open, replace it. When. doing this, replace highow pressure switch at the same time. 3) When the refrigerant gas pressure is below 2 kgiam? or above 27 ka/em?, there should be no ‘continuity between the terminals of the high-low presture switch, 4) When the refrigerant gas pressure is 2 kg/cm? to 27 kglem®, there should be continuity between ooro08 ‘the terminals of the high-low pressure switch ‘with anew 33-20 Air conditioner