Great Wall Florid. Manual — part 51

GWFLORID Maintenance Manual

202

Air Conditioning System

Areas of Importance . . . . . . . . . . . . . . ... 203
Technical Parameters . . . . . . . . . . . . . . . 203
Troubleshooting . . . . . . . . . . . . . . . . .. 204
Air Conditioning System's Structure Diagram and
Fundamentals . . . . . . . . . . . . . . . . . . 207
Air Conditioning System Overview . . . . . . . . . . 207
Air Conditioning System Terminal Definition . . . . . ... 208
Compressor . . . . . . . . . . . . . . . . . . 208
Electromagnetic Clutch. . . . . . . . . . . . . ... 210
Vacuuming and Charging Refrigerant . . . . . . . . 211
Filling Quantity and Method for Refrigerant Oil . . . . .. 212
Daily Maintenance of the Air Conditioning System . . . 212

203

Air Conditioning System

Areas of Importance

1. When putting in a new compressor, adjust the new compressor's inner lubricant to make it the same

level as of the old compressor's.

2. When the air conditioner malfunctions, if the pipeline, condenser or evaporator is the source of the

damage leading to its replacement, just add model number RS20 professional lubricant 5

-

10 ml.

3. The compressor is a high speed operating component, the smallest impurity in the air conditioning

system can lead to the compressor's damage, therefore the entire air conditioning system must be

cleaned.

4. In order to avoid liquid damage to the compressor, pay careful attention when filling the refrigerant.

When the vehicle stopped, fill the liquid refrigerant from the high pressure side. When in operation, fill

the liquid refrigerant from the low pressure side.

5. When undergoing maintenance, pay attention that the amount of refrigerant being added is 510±10 g.

Observe through the check glass to determine if there is sufficient new refrigerant charge.

Item

Parameter

Compressor

Model

Rotary vane compressor (JSS-96TV4-4)

Discharge capacity

96 ml/r

Number of vanes

5

Normal rotational speed range

800-7800 r/min

Max. speed

8400 r/min

Weight

4.744 kg (without clutch)

Pressure resistance

Low pressure side 50 kg/cm

2

, High pressure

side 75 kg/cm

2

Leakage

≤14 g/year

Direction of rotation

Clockwise (looking from the clutch)

Refrigerant

R134a

Lubricant number

RS20

Lubricant capacity

200±10 ml

Clutch

Min. pull-in voltage

7.5 V (12 V)

Pulley style

4PK810

Weight

2.1 kg

Rated voltage

12 V (DC)

Power consumption

≤45W (20

o

C DC 12 V)

Static friction torque

≥40 N·m

Pulley diameter

φ110 mm

Coil resistance

(3.5±5%) Ω

Thermal protector

Operating temperature

On / Off (130±5)

o

C/(150±5)

o

C

Rated voltage, current

16 V, 5 A

Technical Parameters

GWFLORID Maintenance Manual

204

Failure

Symptoms

Cause analysis

Air con-

ditioning

system fails

to produce

cold air

Compressor

does not work

Blown fuse, compressor relay damaged

Pressure switch contact broken, short circuited, or open circuit

Compressor electromagnetic clutch open circuit

Switch burnt out

Main relay burnt out

Clutch slips

Compressor belt broken or loose

Compressor failure

Insufficient coolant, system pressure below 0.196 MPa

System pressure exceeds 3.14 MPa

Engine water temperature is too high

Clutch voltage is below 7 V

Compressor

pulling in

Compressor relay often open contact bond, system coolant leaks severely,

system has no coolant

Blower does not work

Blower has no wind Blown fuse

Blower motor brush damaged

Blower switch damaged

Wiring connector detached or open circuit

Speed regulation module damaged

Blower has no wind at high speeds, high speed relay damaged

Note: Blower's non operational process has a resistance value of 0, with a

open circuit resistance value of

The cool-

ing system

sometimes

works, some-

times not

Compressor operates

normally

Cooling system has ice blockage

Thermistor or thermometer bulb malfunction

Abnormal A/C switch contact

Condenser blower damaged

Compressor operates

abnormally

Clutch slides, clutch coil loose, clutch coil bad connection

Insufficient

cooling

Low wind volume

Blower fan normal: air pipe damaged

Cooling fan operates abnormally:

(1) Blower switch abnormal

(2) Supply voltage low

(3) Speed regulation module damaged

Wind vol-

ume normal

Compressor operates normally

(1) High and low pressure side's pressure is low

(a) Expansion valve is blocked

(b) Expansion valve opening is too small

(2) High and low pressure pipe's pressure is high

(a) High pressure pipeline malfunction, uneven flow

(b) Thermistor failure

(c) Expansion valve opening is too big

(d) Too much refrigerant oil

(e) Too much refrigerant

(f) Poor condenser heat dissipation

Note: When the speed is at 2000 r/min, cooling fan at max gear, and air tem-

perature at 30-35

o

C, the system's low pressure side pressure should be 147-

192 KPa, and high pressure side pressure 1373-1668 KPa

Troubleshooting

205

Air Conditioning System

Failure

Symptoms

Cause analysis

Insufficient

cooling

Wind vol-

ume normal

Compressor operates normally

(3) High pressure side pressure is too low

(a) Low pressure pipeline damaged

(b) Low pressure pipeline blocked

(4) Low pressure side pressure is too low

(a) Evaporator frost

(b) Expansion valve is blocked

(c) Low pressure pipeline not clear

(d) Thermal speed adjustive resistance failure

(5) Low pressure side's pressure sometimes normal, sometimes negative,

moisture in the cooling system, and ice blockage

(6) Low pressure side's negative pressure, high pressure side's pressure too

low, blockage in the cooling system

(7) Low pressure side pressure too low, high pressure side pressure too high

(a) Inner portion of the condenser is blocked

(b) High pressure pipeline blocked

(8) Low pressure side pressure too high, high pressure side pressure too low

(a) Compressor leaks

(b) Compressor valve damaged

(9) Low wind volume of the condenser blower can lead to poor heat dissipation

Compressor operates abnormally

(1) Compressor internal malfunction

(2) Compressor belt loose, slides

(3) Electromagnetic clutch malfunction

(a) Supply voltage low

(b) Interference between the stator and the rotor

(c) Idling stabilizing amplifier malfunction

(d) Circuit broken, connector detached

(e) Bad switch and relay operation

(f) Short, open circuit

(g) Bad ground

Other causes

Dysfunctional Carriage seal

Cooling

system is

too noisy

Noise too loud

Belt loose or overly worn

Compressor's mounting bracket set screw loose

Compressor's mounting bracket damaged

Compressor's internal components are damaged

Refrigerant too little or empty

Clutch slip noise

Clutch bearing lacks oil or is damaged

Blower motor bearing damaged

Blower bracket broken or loose

Blower vane broken or loose

Blower vane rubs against other components

Troubleshooting (Continued)