2011 Automobile Maintenance

Advanced Course for the

Industrial Technical
Instructors

Class No.: p..,tYt

~~-------

Instructor : _ _~C...;;....;..he..;;;....;;.n..;;....J...'_C_hi.ng~-~ts..;;.....an
... __
 < ,

2011 Automobile Maintenance Advanced

Course for the Industrial Technical
Instructors

Vehicle Air Conditioning

System

Chen, Ching-Tsan
June 11 th , 2010

Hours : Theory 8 hours ' Practice 22 hours 0

Syllabus:
1. Theory :
a. The principle of air-conditioning system 0

b. The main parts introduction and structure

of air-conditioning system0

2. Practice:
a. The parts assembly/disassembly of air- conditioning
system 0

b. The parts inspection of air-conditioning system0

c. The refrigerant filling of air-conditioning system 0

, d.The
 General Siat6ment of Air Cdndition~r
Air conditioner :
To regulate interior temperature " humidity " air
cleaning and air mode control in air outlet.

Inlet

. f)~
Blower fan
. Heater core t:!J ~outlet
 { ~~\~ff 1 t. %" "; ~.;:~}W;'~" .,. ,

~ 'Temperature Control
2. Air-con 3. Dehumidification

Compressor

~>
~>

Blower fan 6
Evaporator

4. Temperature Control

Air mixture throttle valve

n:l:d"I-=-[f_-\_ _ _ __
D~,----'\. ~".. ~ "' ~
l----/ ~m L±¥
c:::> :
'"
, Blower fan Heater core
Evaporator

Water valve '

Temperature switch
 , -,: .;p.~. . '< "" ':':' .~ .~>"<1~A~< 1

.Temperature Control

Air mixture throttle valve

D llbJ !--=---\-----

c)

. Blower fan Heater core

Evaporator

00[1 [jjJ 1 1]00 Water valve

I~i(=~l~J
Temperature switch

' tr :Air mixture throttle valve

r:.,1'4

'"
~ : ~:t

J Blower fan Heater core

Evaporator

; Water valve

. Temperature switch
 Air Outlet

CD o Cool air outlet

® Demister outlet ® Heater outlet

® Bottom air outlet

The cool feeling of applying alcohol to skin

before injection

The cool feeling of applying alcohol to skin

 The principle 0 Air-cond.ltiorting operation

2. The principle of Air-conditioning operation

a. the refrigerator in early time 0

3. The basic circulation principle of cool air 0

. ~ ! Coolant water inlet

~",!""!",~~~~=f=:==:;4~,,,,=.=.'F
, ....'"'l>. The heat of gaseous style alcohol is
.: absorbed by coolant water and

,
Coolant water outlet
.
;.
"
"::
~
a
becomes liquid alcohol

~
Ii
Ii

.
It

~/t=?;;;:zz;::~=~:zz:z:::~t7 " Case (heat insulation)

!
The heat in the case is absorbed by liquid alcohol and inside temperature decreased
 The principle of Air-conditIoning operation

The parts function of cool air circulation

, , Expansion valve
// '"
-- --
-~

i Evaporator ., 11
. ~ ~
J&

, ~ :/ ~
, -'
.z >-./ Driver's
- cab !'
! /"

D!
~ r
~~.
l"~J
---'
1] .p 1 \\'!

Engine room
~~
"'

JI [

~ ~ ~ ~ ,1
/
Compressor ( "

, , , ,) "

..
~ C ." • IlL . 0 ~ -- ~

Condenser Reservoir tank! drier

Cool air circulation operation

Sub-Cool type

Drier [

Regulator

condenser

Filter
Overcool area

Cap
 eharacteristicsofvellicle air~coriditioner "
1. High load
1) The sun shines over a long time and the interior temperature
reaches 60°C 0

2) The vehicle window area is big and gets more heat.

3) The vehicle needs a strong air-conditioner to make passenger
feel comfortable in a limit space.

2. Quality vibration-resisting.

3. Compressor RPM varied dramatically.

4. The interior temperature needs to be down quickly, especially

in the summer.

5. The open circulated loop design is more likely to leak air than
household air-conditioner whose is close circulated loop."

1. The circulation power of air-conditioning system

2.The heat is absorbed by refrigerant in evaporator, then the compressor
compresses to the condenser and eliminate it.
Location : by the side or in the across of engine
Quality : compress efficiency of refrigerant, reliability, durability and safety

Compressor locati
 'c

COmpf'eSSOr
Compressor type :
reciprocating type" rotating type" variable displacement type

1. Reciprocating type
1) Swash type compressor
Advantages: small change of torque '
small vibration' smooth operation,
is suitable for high-speed operation.

2) Wabble type compressor

Named "single slide side
compressor"

2. Rotating type
1) Vane rotary compressor
Advantages: simple parts, light, low vibration,
good displacement efficiency and high
assembly flexibility.
 2. Rotating type
2) Scroll type compressor
Advantages: good displacement efficiency, simply parts, light,
small friction.
Outlet
Inlet
Fix scroll

I---'--'L-'--r--'-"
- Rotation scroll

Outlet Fix scroll

Rotation scroll
Axle
High pressure
Oil seal valve

3. Variable displacement compressor

Advantages :
·Small change in outlet
temperature. The temperature r~(H

keeps stable by changing the slide ~.~.~ ~ jjfi :~~~

of inside slide plate. l?Jttt

·Decrease horse power loss of

drive compressor. Fuel
consumption is low.

·The improvement of driving

quality and riding comfortable.

'Expanding the lifelong of electric

magnetic clutch.
 .Compressor
Control principle of displacement change .
1. The change range: 3cc"""" 146cc
2. The bigger angle between slide plate and axle, the longer the piston

Long stroke
Short stroke Slide angle change Plate slide angle
Piston stroke
(fixed)

TDC •••••
(fixed) I
"" .
lIiIJ!)tpm

The principle of slide plate type Conventional slide plate compressor

variable displacement compressor

Construction and location of control valve

outlet cylinder piston Crankshaft case

Air pressure around folding box

Elastic force
~~

Folding box
Control valve
'"'=L.....-L!;;::~=i'~.
.~
Spring

folding box type control location Squeezebox structure

 Compressor
Operation of squeezebox type control valve:
1. Big heat load: ball valve close, triangle valve open.
2. Small heat load: ball valve open, triangle valve close.

Big heat load Small heat load

(Absorb pressure is high) (Absorb pressure is low)

Outlet Outlet . cylinder

cylinder

High pressure valve (open)

Low pressure valve (open) I

The operation in big load

. piston Crankshaft case

Outlet cylmder
Outlet cylinder

___ Crankshaft case

c-;:==
inlet .
a::>
, Low pressure
Squeezebox
valve (open) Control valve

Operation in maximum refrigerator

 ompressor
Electric-magnetic clutch
1. Function: control engine power to send to compressor
2. Type :
1) Rotary coil type
2) Fix coil type

Rotary coil type

m~Ji~lTom

1~~~.r,zm

Operation of electric magnetic clutch

Separation:
Electric magnetic clutch
Relay off
Electric magnetic clutch
Driving belt
Front housing
Belt bully

stator

--··
•
----- Pressure plate
Operation of electric magnetic clutch
Electric magnetic clutch
Connecting:
Relay off
Electric magnetic clutch
Driving belt

Absorb power
stator

Pressure plate

Function : emission the heat of gaseous refrigerant to the

atmosphere and liquidize it.
Location : In front of the vehicle, good place for heat evaporation
Type: One way flow: for R-12 system
 ·ondenser
Multi-flow (parallel flow) type: for R-134a system

Sub cool type : for R 134a constant temperature system

. .J .

-· · ·~ae.4&9Q

Drier package
.
- Evaporator
Function: absorb interior heat and make it cool 0

1. Type
1) Exposure type: only for cool air machine, easy to be assembled and
inspected, but the cool air is not spread evenly. The cool
performance is not good.
2) Concealed type: used for air regulation machine' the meter looks
good and has different levels of fan outlet. The temperature spreads
evenly and has a better cool performance. But not easy to be
assembled and inspected.

2. Location
I) In front of the vehicle.
2) In rear of the vehicle.
3) Compound type.
In front of the vehicle

Compound type
 Evaporator
Type:
One way flow: for R-12 system
Laminar flow: for R-134a system

One way flow

evaporator

Function: to decrease the pressure and regulate refrigerant flow

Type : Superheat controlled expansion valve
1. Interior even pressure type

The expansion valve is _.. _ _ Capillary

interior even pressure
Filter net

Even temperature passage --fi---4-----to-i ~--=::::::===I..uw . Inlet

Valve spring

Temperature sense expansion valve with interior even pressure

 Even temperature pipe

Exterior even pressure .

The temperature sensed by
temperature sense tube is
similar to the balanced
temperature, that can improve
Diaphragm Capillary
expansion valve sensitivity.

Needle valve • - .. "}.

- . ..- ~ Temperature sense tube

(c.~~;. ~UI
Evaporator

BlockTXV Needle valve

Diaphragm

Temperature sense pole

Evaporator

Pressure spring

Come from the liquid reservoir :

(high pressure) '-------\--~

Needle valve
 . ExpanSlon'valve
Expansion valve operation

Capillary

Diaphragm

Ball valve

Refrigerant inlet .....

,
I
Temperature sense tube
_. . . ~

Spring I
••
I
I
Saturated steam part· overheat stearn part

Interior even temperature

•Save refrigerant and give regulation when system hot load varies.
•Liquid and gaseous type separated, the expansion valve can control the
refrigerant flow to be stable.
• Filter the impurities of refrigerant and absorb water.
• Installed with fusible plug and pressure switch to protect the system
safety.
Type: For R-12 system: filter is more rough, usually with a window,
drier is If' Silica Gel Jl
From condenser To expansion valve
1IE*&llli* • ~~rtij:J;ij';;:fti " iqYi~rm J

- I
': -~-'\J! '"
-,.,_ .. . .
..--'"

~ ,...--.. ,
, .. ~- -
I "

1-_
. _-"

4 I.High/low pressure 2
switch
ll'--_ ~1fiH-- :; 2. Window
3. Fusible plug
4. Filter
5. Drier
 ,...--_.
For R-134a system:
The filter is more fine,
without window, drier Drier Filter

is IF Zeolite J]
Gaseous refrigerant
__ Liquid refrigerant

}. ,

~ window Insufficient
J, f'", I " , , .. "! . " "~ '" (""! I ·,

~ j u J )(I w-~- J /\v') tJ P

Few bubbles
©
Exceeding
No bubbles
o
Temperature control 'applianc'e

Control compressor electric magnetic clutch is ON or OFF

Type :
1. Temperature regulation switch : set interior temperature
2. Outside switch: detect interior temperature
3. Low pressure switch : detect if the refrigerant pressure is too
low in the high pressure pipe
4. High pressure switch : detect if the refrigerant pressure is too
high in the high pressure pipe
 Temperature control appliance
Squeezebox temperature regulator

To compressor clutch ---------~

From the battery - - - M - - - - - H I

squeezebox

Temperature regulator
Capillary

Temperature sense tube

Thermoresistor type regulate switch

Electric magnetic clutch

Control circuit

thermoresistor
I
 Temperature control appliance
Outside switch: outside temperature sensor

Mn.

Low pressure switch : could be used as an outside switch

Outside temperature 25°c

Terminals -----II-
~
:::t-
~
rl!'
t1- Outside temperature OOc
Connection point 3
;.~ .
,...,..------tr-
I
"L.......--.-------1
760mmHg 0 HlO 200 3M ~(l{l
~-..
~ Remained refrigerant amount (g)
 Temperature control appliance
Dual pressure switch: combine with high and low pressure switch
Diaphragm Pressure Contact point

~
n;
ii 8
1
rF. ON OfF

Lower than 2.1 kg/cm2 Lower than 27kg/cm2

Tri-switch : detect high/medium/low pressure to control the operation of

compressor and radiator fan

'".~ .. ..
---41
....... 14+UI
ba,
MAX"V25 bar

Radiator fan

i .
 Control circuit
Blower speed control
Resister type
Heater relay

Blower
motor
HI Transistor type

3
Blower
resistance > 2
~

··

1
0 LO
OFF HI
Selection button ®
LO
OFF LO 2 3 HI

Air-conditioner basic circuit

Resister Blower motor Fuse

Temperature regulate switch AlC switch

Fan switch , Low pressure ":" IG relay

switch

Br
Compressor electrical
Magnetic clutch
IG

R
Idle speed increase Fuse I
Condenser motor
Solenoid valve
lOA

.- Fuse
Condenser motor
 Air-conditioner inspection equipments
1. Refrigerant recycle :
Has the function of refrigerant recycle/ reproduce, some equipments has the
function of filling/cleaning and inspection.

,.ep:~~:,l!Ot:'l ,
' ':' ,:." 'f",. 11':< " , ,,\ ~
'J '}"f,:-{{

o 8 (":;:)]

2. Cool air pipe cleaner

Has the function of cleaning parts
and interior pipe 0
 . AIr-conditIoner Inspectfon equipmerits
3. Pipe side emission connectors :
Provide the connection to side emission and cleaner.

4. Refrigerant filling machine :

Has the function of pumping vacuum and refrigerant fix-quantity filling.

Refrigerant
fix -q uantity
Manifold pressure gauge
filling barrel

Vacuum pump
 Air-conoitionet inspection equipments
5. Manifold pressure gauge set:
Provide the function of inspecting system working pressure 0

, ,
;' .. 1..''r
.. -
,

,',
\

I() f ",A" '-"-~ :}I" : C'., .. ~

()
"{ , .-

r
~f\i)c/',·· · ~

6. Electrical leaking detector :

Provide the function of leaking inspection for the pipe and parts 0

Sensor
Cap protector

N If
~~!II!!!II!I!~i
OFFC!DO Power switch
\0 Power indicator
,,---\
ITlFSSSOA I
 ~ ,~'*'", """it '#' ""

Refrigerant recycle machine operation

For R-12 system

Perform the operation Recycle valve

of refrigerant recycle,
Power indicator
reproduce and pipe
cleaning. ~1I;~[=-R~eCYcle operation light
~~- Recycle finish light
:::::=~~ Machine stop in high temperature

Machine stop in high pressure

Machine stop in full quantity

~_ Fuse
___ Recycle switch
Manual exhaust switch

Refrigerant recycle inlet

iS3---'-

+=:----:----....fi!i-- Refrigerant filter (clean type)

Refrigerant drier (consumables)

.~~~-~~~----

·fi ....-r-t---- Purify refrigerant valve

~~r-tr'+----~ Refrigerant recycle barrel

n"'il~~--- Power supply

f-o-----'- Waste oil emission valve

Waste oil emission collector

Operation switch location on the back

 Refrigerant recycle operation

Procedures :
1. Use manifold pressure gauge
to connect air-con system and
refrigerant recycle machine, as
shown in the picture.

2. Open three valves, "liquid

refrigerant valve" of refrigerant
recycle barrel, "purify refrigerant
valve" of recycle machine and
"high/low pressure manual valve"
{'? t.<t!!l{'r
of manifold pressure gauge. ~ 1 ~;%lI1l.§l
..,;,'V-:.,
~~~ .. ;~:;:::~§~~: ::::~~~:~:~:~:::§:::~
Ii!

Procedure:
3. Open the "recycle valve" in
recycle machine face plate, then
tum on the "recycle switch" (the
"recycle operation" light will be
on). The recycle operation begins.
4. When system pressure down to
8inHg below, recycle machine
will stop automatically ("recycle
finish light" will be on ). That F4.
means the recycle operation ~. .~~-~ liI.SiP';l!!'1'.1

finished.
 <' &'

'Waste oil emissioir

Procedures :
1. Open the "waste oil emission
valve" slowly after finishing the
recycle operation, make the waste
oil and dirty flow to "waste oil
collector".
2. Record the waste oil quantity
of the collector, and clean it. The
waste oil emission is finished.
Caution : Before the refrigerant
operation, the same quantity of
clean freezing oil needs to be
filled inside of the air-con

Compressor ·
Disassembly:
I.Disassemble engine under
cover 0

2.Disassemble driving belt 0

3.Disassemble high/low
pressure refrigerant pipe 0

4.Disassemble
electromagnetic clutch wire
connector 0

5. Disassemble compressor
fixed screw and remove .:f
~9f.cm. fHbO. 1 ; jj'l"iiftHJ)
'iJ lHl ftJU~ ft-
thec0l1?-pressor 0
 • ...• . >'_ .c.:r...
" ' ; '. . : , " . '.,

Air-con parts disassembly

Compressor :
Installati on :
I.Replace each part
according to the reverse
assembly procedure 0

2.Adjust driving belt

according to car company
regulation 0

. I N-mlkgf-cm. ft "lbfl.l : m,iii:iB))

+'f urmmff:fH:'!ft

Disassembly:
I.Disassemble water tank top fixation 0

2.Disassemble high-pressure refrigerant

pipe and cover the pipe connector
Disassemble high-pressure
immediately to prevent from the refrigerant pipe

moisture and dust entering the pipe.

3.Disassemble condenser fixed screw.
4.Push the water tank to the back side
of engine, then push condenser inside
to the water tank and pull out.