AC System On Bus Roof

Air Conditioning System – Roof ON
 Describe the functions and mechanisms of

Learning
convenience/safety systems.
Objective
 Describe the locations and roles of system components.
 Test system components for normal functioning.
 Perform post-component replacement service proce-
dures.
Air Conditioning System – Roof ON 2
Introduction (Cooling Cycle)
Low-temperature/pressure gas Low-temperature/

①
pressure fluid
Suction/com- Blower
Compressor
pression ④ Heat suction
Expansion
valve
Expansion
②
High-tempera- ⑤
ture/pressure Low-tempera-
gas ture/pressure
gas
Receiver Evaporator Evaporation
drier
Moisture/dust
③ removal
Condenser
Mid-temperature/high-
Condensation
pressure fluid
System layout – Components Location

System Components (Compressor)

Low-temperature/pres-
sure refrigerant
Intake Compressed
Pumping High-temperature/
pressure refrigerant
[Swash plate compressor ] [ Reciprocating piston Compressor ]

Truck and County Bus Bus Roof on A/C
System Components (Compressor)
〈 Sight glass 〉
- When current is supplied to magnetic coil (ON)

→ Pulley assembly (Armature & Rotor Frame) and clutch pad are connected each other.
- When current isn’t supplied to magnetic coil (OFF)

→ Pulley assembly (Armature & Rotor Frame) and clutch pad are disconnected each other.
→ Clutch pad isn’t connected rotor in the pulley assembly. So, V-belt runs idle.
Auto stop for safety function circuit
High pressure switch
ON
From
Temp. Setting A/C Relay
Power S/W
OFF
17±1.0 22±1.0
Compressor
Thermostat Relay (Unit : kg/cm2)
Low pressure switch

Hi pressure
switch
ON
Compressor
Temp. Sensor Low pressure
switch
OFF
0.5±0.4 1.5±0.5
(Unit : kg/cm2)
Low & High Pressure Switch
Low pressure switch is installed on the

compressor suction pipe.
And high pressure switch is installed on
the discharge pipe of compressor.
Low and high pressure switches sense

the malfunction of air conditioning sys-
tem by the pressure, and stop com-
pressor operation by turning off the
magnetic clutch to protect the air condi-
tioning system.
At this time, the warning lamp on the

control panel comes on.
System Components (Condenser & Receiver Dryer)
Hot gas from compressor
Cooling fan
Cooling fan
Condenser
Receiver Dryer
Condenser : High-temperature/pressure gas → Mid-temperature high-pressure fluid (condensa-

tion)
Cooling Fan : Sucks in cool air for the condenser to lower refrigerant temperature quickly
Receiver Dryer : Removes impurities in refrigerant, separates bubbles, removes moisture and
saves refrigerant
System Components (Receiver tank)
Receiver tank stores and stably supplies the only liquid re-
frigerant to the expansion valve.
The fusible plug is installed on the receiver tank. When the refrigerant temperature
In case of abnormal increasing of high pressure line’s pres- reaches at 105℃,
sure, if a high pressure switch have malfunction, compres- Fusible metal is melted and
sor does not stop. Refrigerant comes out.
At this time, weak points of air conditioning system can be
exploded.
In order to prevent it, fusible metal in fusible plug is melted
and refrigerant comes out when temperature reaches at
105 ℃ (about 35.6 kg/cm2).
System Components (Service valve)
Aservice valveis located at the outlet of

receiver tank.
This valve is very useful when replacing

drier or doing pump down.
System Components (Dryer)
The drier contains a drying agent (desiccant) made of Zeolite.

- As the liquid refrigerant passes through it, any moisture is ab-
sorbed by the desiccant.
- Also It removes foreign materials in refrigerant to prevent ex-
pansion valve from clogging.
System Components (Expansion Valve)
Upper chamber
Lower chamber Sensing bulb
Outlet
Control
Ball
Expansion valve
The purpose of the expansion valve is to allow high pressure liquid to expand as it enters
the evaporator.It also controls, or meters the system to prevent the evaporator from flood-
ing and freezing up.
System Components (Evaporator)
〈 Normal opera- 〈 Evaporator freez-

tion 〉 ing 〉
Sight Glass
Sight glass is installed inside evaporator unit.
It can show flow of refrigerant in evaporator.
It can be checked the inside of bus.
It is very useful to check the amount of refrigerant.
System Components (Thermistor)
〈 Core-inserted 〉〈 Air detection 〉

 Purpose: Prevents the evaporator from freezing
 NTC Type
 Compressor off if 1°C or below (on again if 4°C or over)
Fin-Thermo Sensor
〈 County Bus 〉
〈 Truck 〉
16
Control panel
Control panel installed at the left side of the driver seat in driving room.
Control panel is for the controlling air conditioner and informs the operation status.
Therefore, various switches and lamps are installed for this purpose.
17
Error code indicate

If switch 2 & 4 are pressed concurrently, error code is displayed in display(9).
If there is no error, “Good” is displayed.
To remove error code in display, press switch 2 & 4 concurrently again.
High or low Cut/short of indoor

Communication
EO E1 pressure of A/C E2 temp control sys-
error
system tem
Cut/short of out-
Communication Poor electric power
E3 door temp control E4 E5
error supply
system
▶ Refrigerant charge function

The buttons(2 & 8) are used for “Charge” operation when it is nec-
essary to operation A/C while refrigerant is charged under condition
that it is impossible to operate A/C while inside temp. is below
17℃. “CHg” is shown on the display(9) while the refrigerant is
charged. Selecting buttons again is changed to previous operation
status.
▶ Emergency operation function (10)

• If communication error happens, A/C system is disabled. But, if
this switch(10) is pressed, A/C is operation with fan speed 4 th
step and switch is turned on with red LED. Repressing the switch
Electrical system
Input Output
Battery switch
Compressor
Power switch magnetic clutch
Mode switch Condenser fan

(Cool / Vent)
Blower speed Blower motor
Operation Mode Actuator

Engine starting Panel
(Relays &
Temperature Thermistor) Vent lamp
setting
Inside air tem-

perature Cool lamp
High pressure
switch Warn lamp
Low pressure
switch
Electrical system – Compressor magnetic clutch

Input Output
Battery switch ON
Engine starting
Power switch ON
Battery Relay
Mode switch ON
(Cool)
A/C Relay
Blower speed ON Compressor
ON
magnetic clutch
Temp.
setting < Inside air
temp. Thermostat
ON
ON
Compressor
High pressure Relay ON
switch ON
Low pressure
switch ON
Electrical system – Condenser fan

Input Output
Battery switch ON
Battery Relay
Engine starting ON
Power switch ON A/C Relay

ON
Mode switch Condenser fan
(Cool) Relay ON
Thermostat
Blower speed ON ON
Temp.
temp. Compressor
Relay ON
Electrical system – Compressor magnetic clutch

Input Output
Battery switch ON
Battery Relay
ON
Engine starting
Blower motor
A/C Relay working
Power switch ON ON
Blower speed ON Evaporator relay

ON
Electrical system – Warning lamp

Input Output
Battery switch ON
Battery Relay
Engine starting ON
Power switch ON A/C Relay Warning lamp

ON ON
Mode switch
(Cool) Cool lamp
Off
Blower speed ON
Temp.
temp.
Thermostat
ON Compressor
magnetic clutch
Off
High pressure Condenser fan
switch Off or Relay ON
Low pressure
switch Off Compressor
Relay Off
Service Points – Performance checking procedure

How to check
1. Check tension and damage of V-belt.

2. Check the crank pulley, idle pulley, and compressor clutch pulley are arranged
Check properly.
before 3. If the compressor is contaminated (by dust or oil, etc), clean it with air.
operating 4. Check equipped bolt and nut and if they are lose, tighten them up firmly.
5. Check the gas leakage in the fastened part, like pipe laying and each components
by using gas leakage detector and if necessary, fasten them.
After starting engine, follow the operating order.

1. After turning on the air conditioner power switch, check the ventilation.
2. After turning on the cooling switch, check the cooling performance according to
Operation the position of temperature setting switch.
3. Check the volume of cooling wind and temperature from indoor duct are appropri-
ate or not.
4. Check the high and the low pressure switch works normally.
1. Check cooling system stops by turning off the cooling switch.

Stop
2. Turn off the air conditioner power switch.
Refrigerant Amount
Time to inspection? : Weekly
Refrigerant Amount
8.5 ± 0.5 Kg
Check Conditions ;
- Ambient temperature : 25 ± 5℃
- Engine rpm : 1,100 rpm
- Cooling switch : ON
Sight glass
- Blowing : High
If an ambient temperature is low, bubble can be

seen sometimes despite the normal refrigerant
quantity.
Therefore, check the refrigerant level when am-
bient temperature is above 20 ℃.
When engine rpm changes rapidly, bubble also
can be seen despite the normal refrigerant quan-
tity. So keep the 1,100 rpm when checking.
Insufficiency
Insufficiency Sufficiency
Sufficiency
Service Points – Compressor lubricant oil amount and color check

For the proper quantity, check whether the lubricant
oil level positions at the 2/3 position of the sight
glass.
Black
If the lubricant oil color is black, compressor should be

checked for any problem because the color could be
changed by the carbonization.
Sliver
If it colors silver, journal parts of the compressor connect-

ing rod could be worn out.In this case, check the com-
pressor.
Milky
If the lubricant oil colors milk, water might be mixed to

the refrigerant.These cases usually happen in case of
mistake in service operation or insufficient vacuum oper-
ation.
Service Points – Pump down

Pump down means to move all refrigerant in the low-pressure side to the high-pressure side.
Using this operation, we can repair or replace the compressor, evaporator, expansion valve,
drier, low-pressure side’s pipe and hoses without removing the refrigerant
Pump down
Operation
Service Points – Pump down procedure
1.Install the manifold gauge.
2.Remove the low pressure switch connec-

tor and directly connect the
low pressure switch’s harness side
terminals.
3.Close service valve at the receiver outlet com-

pletely.
4.Loosen the low and high pressure service valve

by turning the valve stem 2.5 turns clockwise.
5.Start engine and operate air conditioner.

And then, push the accelerator pedal until␢ low
pressure gauge reaches at 0.1 kg/cm2.
6.As soon as it reaches at 0.1 kg/cm2, you ␢

should stop the engine.
7.In this condition, no refrigerant in the low pressure

line.Repair or replace the components of low pres-
sure side.
8.After the work, vacuum the low pressure line.

At last, remove the manifold gauge and then open
the receiver tank service valve andclose low/high
pressure service valve.
And reconnect Low pressure switch.
Troubleshooting - Procedure
1. Install the manifold gauge to the High / Low pressure line service port.
2. Start the engine and turn on A/C, Blow speed at high, Temp. at lowest.
3. Run the A/C for more than 5 minutes at 1,500~2,000rpm.
4. Read the scale of the gauge

Troubleshooting – Normal Pressure
High Pressure
AmbientTemperature (℃) Low Pressure(kg/cm2)
(kg/cm2)
19 ~ 21 11.3 ~ 12.7 1.4 ~ 1.5
24 ~ 26 12.0 ~ 13.4 1.5 ~ 1.7
29 ~ 31 13.4 ~ 15.5 1.8 ~ 2.0
34 ~ 36 16.9 ~ 17.6 2.3 ~ 2.5

Troubleshooting – Diagnosis
Gauge Pressure Probable Cause
Condenser motor malfunction or reverse rotation.

Condenser pollution
High pressure is too high Over-charging refrigerant
External air flows into the evaporator unit
Excessive refrigerant oil.
Insufficient refrigerant
Drier clogging
Low pressure is too low
Expansion valve get clogged
Evaporator air filter contamination or freezing
Evaporator blower motor malfunction
The low pressure is high & the

Insufficient compression of compressor
high pressure is low

AC System On Bus Roof

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Air Conditioning System – Roof ON

 Describe the functions and mechanisms of

Introduction (Cooling Cycle)

Low-temperature/pressure gas Low-temperature/

System layout – Components Location

System Components (Compressor)

[Swash plate compressor ] [ Reciprocating piston Compressor ]

System Components (Compressor)

- When current is supplied to magnetic coil (ON)

- When current isn’t supplied to magnetic coil (OFF)

Auto stop for safety function circuit

High pressure switch

Low pressure switch

Low & High Pressure Switch

Low pressure switch is installed on the

Low and high pressure switches sense

At this time, the warning lamp on the

System Components (Condenser & Receiver Dryer)

Hot gas from compressor

Condenser : High-temperature/pressure gas → Mid-temperature high-pressure fluid (condensa-

System Components (Receiver tank)

System Components (Service valve)

Aservice valveis located at the outlet of

This valve is very useful when replacing

System Components (Dryer)

The drier contains a drying agent (desiccant) made of Zeolite.

System Components (Expansion Valve)

Lower chamber Sensing bulb

System Components (Evaporator)

〈 Normal opera- 〈 Evaporator freez-

System Components (Thermistor)

〈 Core-inserted 〉 〈 Air detection 〉

Error code indicate

High or low Cut/short of indoor

▶ Refrigerant charge function

▶ Emergency operation function (10)

Mode switch Condenser fan

Operation Mode Actuator

Inside air tem-

Electrical system – Compressor magnetic clutch

Electrical system – Condenser fan

Power switch ON A/C Relay

Electrical system – Compressor magnetic clutch

Blower speed ON Evaporator relay

Electrical system – Warning lamp

Power switch ON A/C Relay Warning lamp

Service Points – Performance checking procedure

1. Check tension and damage of V-belt.

After starting engine, follow the operating order.

1. Check cooling system stops by turning off the cooling switch.

If an ambient temperature is low, bubble can be

Service Points – Compressor lubricant oil amount and color check

If the lubricant oil color is black, compressor should be

If it colors silver, journal parts of the compressor connect-

If the lubricant oil colors milk, water might be mixed to

Service Points – Pump down

Service Points – Pump down procedure

1.Install the manifold gauge.

2.Remove the low pressure switch connec-

〈 Core-inserted 〉〈 Air detection 〉