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AIR CONDITIONING SYSTEM Return To Main Table of Contents GENERAL SERVICE ADJUSTMENT PROCEDURES 10 HEATER 30 VENTILATORS 37 COMPRESSOR 40 COOLING UNIT 58 CONDENSER 62 RECEIVER DRIER 63 CONDENSER FAN AND RELAY 64 A/CON RELAY AND RESISTOR 65 GENERAL GENERAL SPECIFICATIONS (DKK) Heater assembly Air-mix, warm water type 3,800 (15,000) Control knob Type Performance Kcal/h (B.T.U./h) Heater control assembly Air-conditioning Cooling capacity Kcal/h (B.T.U./h) Compressor Model No of cylinders and displacement cc/Rev Maximum allowable speed Magnetic clutch 3,300 (13,000) DKS - 15BH cylinders, 153 7,000 rpm Electromagnetic, single-plate dry clutch DC 12V, 45W Type Voltage, power consumption Control Idle up device Frost prevention °C (°F) 850-900 rpm Fin mounted thermostat OFF: - 1° - 1°C (30° - 34°F) ON: 3° - 5°C (38° - 41°F) Protective equipment High pressure switch OFF: 2,647 kPa (384 psi, 27 kg/cm2), ON: 2,059 kPa (299 psi, 21 kg/cm2) OFF: 206 kPa (30 psi, 2.1 kg/cm2), ON: 196 kPa (28 psi, 2kg/cm2) 103°C (217°F) R-12, 850-1,000 (30-35, 1.9-2.2) Low pressure switch Fusible plug Refrigerant and quantity gr (oz., lb) SERVICE STANDARD Air-conditioning Amount of deflection of V belt Engine idling speed Clutch clearance 8-10 mm (0.3-0.4 in.) 850-900 rpm 0.3-0.6 mm (0.01-0.02 in.) LUBRICANTS Heater assembly Heater control lever Air-conditioner Compressor oil 97-2 Recommended lubricant Quantity Multipurpose grease SAE J310a, NLGI grade #2 As required FREOL DS-83P 150 cc (5.1 US fl oz, 5.3 Imp fl oz) GENERAL SPECIFICATIONS (MANDO) Heater assembly Air-mix, warm water type 3,800 (15,000) Control knob Type Performance kcal/h (B.T.U./h) Heater control assembly Air-conditioning Cooling capacity Kcal/h (B.T.U./h) Compressor Model No of cylinders and displacement cc/Rev Maximum allowable speed Magnetic clutch 3,300 (13,000) SD-709 cylinders, 155 7,000 rpm Electromagnetic, signal-place dry clutch DC 12V, 49W Type Voltage, power consumption Control Idle up device Front prevention °C (°F) 850-900 rpm Fin mounted thermostat OFF: -1° - 1°C (30° - 34°F), ON: 3° - 5°C (38° - 41°F) Protective equipment High pressure switch Low pressure switch Fusible plug Refrigerant and quantity gr (oz., lb) OFF: 2,647 kPa (384 psi, 27 kg/cm2) ON: 2,059 kPa (299 psi, 21 kg/cm2) OFF: 206 kPa (30 psi, 2.1 kg/cm2), ON: 196 kPa (28 psi, kg/cm2) 103°C (217°F) R-12, 850-1,000 (30-35, 1.9-2.2) SERVICE STANDARDS Air-conditioning Amount of deflection of V belt Engine idling speed Clutch clearance 8-10 mm (0.3-0.4 in.) 850-900 rpm 0.4-0.78 mm (0.016-0.031 in.) LUBRICANTS Heater assembly Heater control lever Air-conditioner Compressor oil Recommended lubricant Quantity Multipurpose grease SAE J310a, NLGI grade #2 As required SUNISO 5GS 135 cc (4.6 US fl oz, 4.8 Imp fl oz.) 97-3 GENERAL SPECIAL TOOLS A: DKS-15BH 97-4 B: SD-709 GENERAL A: DKS-15BH B: SD-709 97-5 GENERAL Tool (Number and name) Illustration 09977-21811 Bearing remover and installer and pulley installer 1) Removal and installation of bearing from the pulley (use with 09216-21300) 2) Installation of pulley A: DKS-15BH 97-6 Use B: SD-709 Applicable Model A B GENERAL HEATER Symptom Remedy Probable cause Stuck water valve Repair or replace the water valve Incorrect adjust installation of warm water flow control cable Adjust the warm water flow control cable Incorrect adjustment of water valve link Adjust the mode control cable No ventilation even when the mode control lever is operated Incorrect adjustment of change over dampers Adjust the mode control cable Loose duct connection Connect the duct securely or replace the packing Abnormal sound from blower motor Foreign material inside blower Remove foreign material Incorrect balance of blower motor or fan Replace the blower motor or fan Damaged blower Replace Ventilator duct connection malfunction Connect the duct securely or replace the packing Incorrect adjustment of inside/ outside air changeover damper Adjust the inside/outside fresh air changeover cable The temperature cannot be regulated by operating the temperature control lever on the panel Duct enters passenger compartment AIR CONDITIONER Symptom No blower operation Insufficient air Remedy Probable cause Blown “BLOWER” fuse Replace Malfunction blower motor Replace Faulty resistor Replace Malfunction blower control switch Open or loose connection in electric circuit Replace Repair open-circuited point Obstruction in the inlet of the blower unit Remove obstruction Clogged evaporator Clean evaporator with compressed air Frosted evaporator Check thermostat Leaking air Check for leakage on both sides of cooling unit and air ducts Blown “COMP.” Fuse Replace 97-7 GENERAL Compressor does not run, or runs poorly Remedy Probable cause Symptom Malfunctioning A/C relay Check operation Malfunctioning dual pressure switch Check operation Malfunctioning thermostat Check operation Malfunctioning A/C switch Check operation Malfunctioning blower switch Check operation Blown “A/C” fuse and/or “BLOWER” fuse Replace Loose compressor drive belt Battery voltage too low Internal malfunction of compressor Readjust Recharge battery Repair or replace compressor Short circuit in the magnet coil Replace Oil on clutch face Clean or replace clutch Gap between drive plate and pulley too large Adjust gap Open circuit in the magnet coil Replace Open or loose connection in electric circuit Repair open-circuited point Refrigerant pressure is abnormal Normal pressure are: High pressure 1,470-1,760 kPa (213-256 psi, 15-18 kg/cm ) Low pressure 190-290 kPa (28-42 psi, 1.9-2.9 kg/cm ) When, ambient temperature 35°C (95°F) Engine speed 1,500 rpm Low pressure is too high Internal malfunction of compressor Repair or replace compressor Faulty contact at sensing bulb of the expansion valve Repair Faulty insulation at sensing bulb of the expansion valve Repair Expansion valve opening is too large Repair Insufficient refrigerant Charge refrigerant Receiver-Drier clogged Replace Expansion valve clogged Replace Faulty thermostat Check operation Frosted piping Clean or replace piping Low pressure is too low 97-8 GENERAL Probable cause Symptom High pressure is too high High pressure is too low Remedy Insufficient cooling of the condenser Check and clean condenser Too much refrigerant Discharge refrigerant Air in system Evacuate and charge system Malfunctioning condenser fan motor Check operation Insufficient refrigerant Charge refrigerant Internal malfunction of compressor Repair or replace compressor 97-9 SERVICE ADJUSTMENT PROCEDURES SERVICE ADJUSTMENT PROCEDURES CHECK AND ADJUSTMENT After installation, check the following points and confirm that everything is in order, and then charge the gas, adjust the idling, and make the adjustment, performance test and the operation test Check for any abnormal vehicle performance, etc which might have been caused by installation of the equipment Check the magnetic clutch for operation (without turning the compressor) Check for any parts left unmounted or any tool left behind in the vehicle Check the belt for improper tension Belt deflection Drive belt 7-9 mm (0.28-0.35 in.) Air conditioner compressor belt 8-10 mm (0.32-0.40 in.) 97-10 ... (217°F) R-12, 85 0-1 ,000 (3 0-3 5, 1. 9-2 .2) SERVICE STANDARDS Air-conditioning Amount of deflection of V belt Engine idling speed Clutch clearance 8-1 0 mm (0. 3-0 .4 in.) 85 0-9 00 rpm 0. 4-0 .78 mm (0.01 6-0 .031... idling speed Clutch clearance 8-1 0 mm (0. 3-0 .4 in.) 85 0-9 00 rpm 0. 3-0 .6 mm (0.0 1-0 .02 in.) LUBRICANTS Heater assembly Heater control lever Air-conditioner Compressor oil 9 7-2 Recommended lubricant... Imp fl oz.) 9 7-3 GENERAL SPECIAL TOOLS A: DKS-15BH 9 7-4 B: SD-709 GENERAL A: DKS-15BH B: SD-709 9 7-5 GENERAL Tool (Number and name) Illustration 0997 7-2 1811 Bearing remover and installer and pulley