16.

HEATER AND AIRCONDITIONER

SECTION 16

HEATER AND AIRCONDITIONER

1. SPECIFICATIONS .............................................................................................................. 3

2. HEATER .............................................................................................................................. 4

3. AIR CONDITIONING SYSTEM

3-1. A/C COOLING CYCLE ...................................................................................................... 6
3-2. HOW TO ADJUST ............................................................................................................ 7

4. INSPECTION ........................................................................................................................... 8

5. REFRIGERANT CHARGING METHOD

5-1. HOW TO CONNECT THE CHARGING TOOL .............................................................. 13
5-2. VACUUM OPERATION AND REFRIGERANT CHARGING .......................................... 14
5-3. HOW TO HANDLE THE COMPRESSOR REFRIGERATION OIL ............................... 15

6. TROUBLESHOOTING
6-1. DIAGNOSIS DIAGRAM .................................................................................................. 18
6-2. COMPLAINTS AND CORRECTIONS ............................................................................. 19
6-3. TIGHTENING TORQUE ................................................................................................. 22

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16. HEATER AND AIRCONDITIONER

2
 16. HEATER AND AIRCONDITIONER

1. SPECIFICATIONS
Item Specifications

Type Inside/outside air mixing hot water

Heater unit Heater performance 5040-5%(Kcal/h)

Blower Multiblade type

Evaporator Laminated type

Cooling unit
Cooling performance 4800-3% or more(Kcal/h)

Model V-5(variable delivery type)

Compression Turnaround type

Compressor
Infuse oil PAG type oil

Clutch Dryer single plate magnetic type

Type Parallel flow type

Condenser
Heat-resisting performance 9500-5% or more(Kcal/h)
Receiver dryer Type Cylinder type

Service refrigerant HFC 134a

Refrigerant
Fill volume Front condenser: DE engine 800+_30g, DV engine 850+_30g

Side condenser: DE/ DDC/Cummins engine 550_+20g, DV engine 580+_20g

Type B-type A-type

V-belt
Length(mm) 1,610(DE12 E/N), 1,260(DV15 E/N) 826(DDC E/N)

Type PK-type
Poly-belt
Length(mm) 882 (Cummins engine)

HI/LO pressure switch(receiver dryer), fusible plug(receiver dryer)

Safety system
High pressure safety valve(compressor), fuse

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16. HEATER AND AIRCONDITIONER

2. HEATER

Heater control panel

DAEWOO

Blower

Fan motor

Heater unit
Combination switch Left-hand drive type

Heater control panel

OOWE
AD

Blower

Fan motor

Heater unit

Combination switch
Right-hand drive type

EL0011

The heater unit is actuated to produce heat by the cooling system of the engine. It operates in a blend
of OUTSIDE and INSIDE AIR types. Temperature of both outside and inside air can be easily adjusted.
The amount of air is adjusted by the air select damper which is adjusted by outside air intake or inside
air circulation selecting lever.

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 16. HEATER AND AIRCONDITIONER

3. AIR CONDITIONING SYSTEM

Air control panel

DAEWOO

Blower

Fan motor

Cooling unit

Left-hand drive type

Air control panel

OOWE
AD

Blower

Fan motor

Cooling unit

Right-hand drive type

EL0021

The air conditioning system is composed of condenser, evaporator, compressor, receiver dryer, expansion
valve and control switch. The evaporator is connected to the heater and ventilating device.

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16. HEATER AND AIRCONDITIONER

3-1. A/C COOLING CYCLE

Condenser

Compressor

Expansion valve
High pressure vapor
High pressure liquid
Low pressure liquid Dryer
Low pressure vapor Evaporator

EL0030

The cooling cycle is composed of:

evaporator which evaporates the refrigerant, condenser which condenses the evaporated refrigerant
into liquid again, compressor which compresses and circulates the refrigerant, and expansion valve
which adjusts the flow amount and pressure of refrigerant.

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 16. HEATER AND AIRCONDITIONER

3-2. HOW TO ADJUST

Check the control switch for function, and adjust the cable as follows when a defect is found:

Temperature control switch

1) Remove the cable from the heater unit, then

place the temperature control switch in “A/C”
position as shown.
2) Turn the heater door link to the full right-hand
position with the heater unit mounted, then
assemble the cable of the temperature con-
A/C
position trol switch.
Heater door link
Heater
Cable

A/C
Bracket

Cable fixing clip

EL0040

Mode control switch

1) Remove the cable from the heater unit, then

place the mode control switch in “BAND
MODE” position as shown.
2) Turn the main link cable assembly most close
Band
to the cable fixing clip with the heater unit
mode position mounted, then assemble the cable of the mode
Main link control switch.

Cable
assembly

Cable fixing clip

Cable

EL0050

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16. HEATER AND AIRCONDITIONER

4. INSPECTION Inspect the portions between each terminal(ML,

MH, and Mi) and (E) for the passing of electricity.
Fan switch If the passing of electricity is not identified as
shown, replace the heater control assembly.

Switch position
OFF 1 2 3 4
Terminal
E O O O O O

Fan control switch Lo O

ML O

EL0060 MH O
Hi O
Fan motor
Apply voltage(DC10v-DC32v) to the fan motor
terminal to check for proper rotations of the fan.

EL0070

A/C switch
Check the terminals 1, 2 and 3 of the A/C switch
for the passing of electricity and replace the switch
if required.

2 3
EL0080

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 16. HEATER AND AIRCONDITIONER

V-belt(DE08 engine series)

Air compressor pulley 1) Set a v-belt at a crank pully, Alternator pully,
and fan pully.
Water pump pulley
15mm 2) Adjust a V-bolt tension by the tension control
support.
Alternator
Idle pulley pulley

Crank pulley EL0091

V-belt(DE12 engine series)

1) When having replaced with a new belt, be sure
Alternator pulley to adjust its tension within 2~3 days as a new
Compressor belt is likely to be lengthened at the initial time
pulley
of use.
Idle pulley (When a force of 10kg·m is applied to the belt,
it should be deflected about 8~10mm nor-
12~15mm mally.)
(when a force of 2) Temporarily unscrew the compressor mount-
10kgf.m is applied)
Crank shaft pulley ing bolts, then adjusting the belt tension with
EL0090 the nut while pushing the compressor.

V-belt(DV15 engine series)

Unscrew the idle pulley mounting nut, then adjust
Water pump pulley the belt tension by turning the adjust nut.
Crank pulley
Idle pulley

5~7mm

Compressor pulley
Alternator pulley
EL0100

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16. HEATER AND AIRCONDITIONER

V-belt (DDC engine)

(1) New standard V-belts will stretch, if used, after
Alternator pulley
the first few hours of operation. Be sure to
Compressor pulley
check the belts after 8 hours or 400km of
operation and adjust the tension. Thereafter,
Fan pulley check the tension of the drive belts every 100
hours operation or 10,000km of operation and
Accessory pulley adjust, if necessary.
Idle pulley (2) Adjust the belt tension so that a firm push with
the thumb, at a point midway between the two
Crankshaft pulley EL0101 pulleys, will depress the belt 12.70~19.05mm.

V-belt (Cummins engine)

Compressor pulley
Idle pulley Alternator

Fan pulley

Accessory pulley
Alternator pulley
Crankshaft pulley EL0103

Condenser
Thoroughly remove dirt or dust from around the
pin and make straight any distorted pins.

Caution
Don't brush the pin with a wire brush, strongly.

Condenser
Pin

EL0110

Hose and fuse

To discharge the refrigerant, loosen the hose
connection and relieve the residual pressure from
the cooling cycle, then disassemble the connector.
Torque wrench Be careful of the following while replacing or
cleaning the components of the cooling cycle:
• Take care not to lay down or stand the com-
pressor up side down for 10 minutes or
more, or the compressor oil can flow into
the chamber of low pressure portion.
EL0120 • When connecting tubes, tighten to speci-
fied torque with torque wrench.

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 16. HEATER AND AIRCONDITIONER

• Just after disassembling the tubes, stop up

all the openings with suitable caps or plugs
to prevent contamination by dust or foreign
substances.

Plug(cap)

EL0130

• Never reuse O-rings.

Don’t apply
O-ring compressor oil. • When assembling tubes, refer to the left-
hand figure to correctly apply compressor
Apply com-
pressor oil. oil.
• The O-ring should be in full contact with
Bad the inflated portion of the tubes.

Bad
Inflated
Good
EL0140

Receiver dryer
Low pressure switch(integrated with the receiver
dryer)
When the low pressure switch is provided in the
Low pressure switch condition as shown, check each terminal for the
passing of electricity.
Receiver
dryer

Tester terminal

EL0150

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16. HEATER AND AIRCONDITIONER

5. REFRIGERANT CHARGING METHOD

A newly-developed refrigerant “R-134a” is used for your vehicle.

Charging tools

CFC12 HFC 134a

Dimensioned in inch Dimensioned in millimeter

EL0160

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 16. HEATER AND AIRCONDITIONER

5-1. HOW TO CONNECT THE CHARGING TOOL

Charge gauge

Charge hose(yellow)

Charge hose
Charge hose Charge gauge
Connector

Yellow
Gas tank

Connector

Vacuum pump
Connector
Connector(low pressure)
(High pressure) Red hose
Blue hose

EL0170

1. Lock all the valves of gauge manifold.

2. Securely connect the three (3) charge hoses of the gauge manifold.
Red hose: for high pressure portion, blue hose: for low pressure portion, yellow hose: for vacuum
pump/refrigerant bomb.
3. After properly connecting the three hoses to the gauge manifold, connect them to the air conditioning
system in turn.
The yellow hose should be connected to the vacuum pump, refrigerant recovering system, or refrig-
erant charger.
Note: If the internal pressure of charge hose of the high pressure portion is 980KPa(10kg/cm2) or
more, it may be difficult to connect it to the A/C cycle. In this case, first connect the charge
hose of the low pressure portion to the A/C cycle, unlock the high/low pressure valve of the
gauge manifold to force the pressure of the high pressure portion to flow in the low pressure
portion, then connect.
Caution
Maintain proper discharge speed so that refrigeration oil may not be discharged. Add refrigeration oil if drained out.

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16. HEATER AND AIRCONDITIONER

5-2. VACUUM OPERATION AND REFRIGERANT CHARGING

Preparation for operation

Primary vacuum operation

(for more than 5 minutes)
-98.6~-101.3KPa
(-740~760mmHg)

Leaving it for 5~10 minutes

Gauge pressure check Trouble identified Repair

Normal gauge pressure

Secondary vacuum operation

(for 20~30 minutes)
-101.3KPa(-760mmHg)

Primary refrigerant charging

(zero setting on weighing machine)
Low pressure gauge 200KPa(2kg/cm2)

Refrigerant leakage check Trouble identified

Normal

Refrigerant charging to specification

(About 0.8~0.85kg based on weight)

Refrigerant leakage check Trouble identified

Operation test

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 16. HEATER AND AIRCONDITIONER

5-3. HOW TO HANDLE THE COMPRESSOR REFRIGERATION OIL

5-3-a. IMPORTANT OPERATIONS-REFRIGERANT
1. Always keep the refrigerant free from moisture, dust, or metal chips.
2. Never mix with different brand refrigerant.
3. Moisture content should not exceed 30ppm.
The refrigeration oil used as the new refrigerant is so susceptible to moisture that extreme care
must be used. (150ppm)
4. If the refrigeration oil is exposed to the air for prolonged time, moisture in the air can penetrated
it, resulting in increase in moisture content. Therefore, it is necessary to cut off from contact with
outside air.
The refrigeration oil used as the new refrigerant should not be exposed to the air.

5-3-b. INSPECTION AND REPLACEMENT OF REFRIGERANT

When the refrigeration oil won’t circulate well, make inspection as follows:
1. Have the refrigeration oil circulate according to “How to circulate refrigeration oil”.
2. Remove the compressor from the vehicle.
3. Take off the refrigeration oil and measure the amount of refrigeration oil with measuring cylinder.
4. Measure the contamination degree according to “How to determine contamination of refrigeration
oil”.
5. If the refrigeration oil taken off from the compressor is measured at 70cc or more, add the same
volume of oil.

Complaints Correction
Opacity of refrigeration oil Clean the inside of the system with R-113 or equivalent.
The color has changed into red. Replace the receiver dryer.
Foreign substances or metal chips found in the refrigeration oil Add 265cc of new refrigeration oil into the compressor.

V-5 COMPRESSOR AND OIL DRAIN PLUG

If the volume of discharged refrigeration oil is 70cc
or less, check again the compressor in the
following sequence:
1. First, add 50cc of refrigeration oil into the com-
pressor and mount it onto the vehicle.
2. Have the refrigeration oil circulate according
to “How to circulate refrigeration oil”.
3. Remove the compressor from the vehicle and
take the volume of refrigeration oil.
4. How to inject the compressor with new refrig-
Oil drain plug
(15~25N.m) eration oil.

Drained volume Injected volume

EL0180 70cc or more 70cc

70cc or less 90cc

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16. HEATER AND AIRCONDITIONER

V5 COMPRESSOR SECTIONAL VIEW

1 2 3 4 5 6 7 8

9
B
10

11
12

13 14 15

EL0190

1. Piston 9. Ball
2. Piston rod 10. Pin
3. Ball socket 11. Control valve
4. Needle bearing 12. Bellows
5. Drive plate 13. Lift spring
6. Lug guide pin 14. Wobble plate
7. Drive lug 15. Wobble plate guide pin
8. Compressor shaft

Compared with other type vehicles, the vehicle equipped with V-5 compressor has a large difference in
installation method for mounting bracket, drive system, pulleys, and connections(as well as in the system
capacity). But the fundamental repair procedure for a single component is almost similar to the repair
procedure for the compressor used in other type vehicles.
When servicing the compressor, use care to prevent the entry of dust or foreign substances into the
compressor and system. It is essential to clean the tools and to keep the workshop clean for correct
maintenance operation. The compressor connecting portion and its exterior should be thoroughly cleaned
before the repair operation for the vehicle or removal of the compressor. When cleaning the components,
always use rinsing cloth.
When removing the compressor from the vehicle to carry out maintenance operation, drain out the oil
remaining in the compressor and add refrigeration oil with viscosity of 525.

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 16. HEATER AND AIRCONDITIONER

5-3-c. REFRIGERATION OIL INSPECTION INTERVALS

Unlikely engine oil, refrigeration oil does not need periodic inspection and replacement. But in the
following cases, inspect the refrigeration oil and add or replace as necessary.
1. when replacing compressor, cooling unit, condenser or liquid tank,
2. when refrigerant is leaked from the hoses or pipes in the cooling cycle,
3. when refrigerant or refrigeration oil is leaked from the compressor,
4. when refrigerant comes suddenly off the cooling cycle, or
5. when any refrigerant-related trouble occurs at the cooling cycle

5-3-d. COMPONENTS REPLACEMENT

When replacing components of the system, inject the refrigeration oil as follows:

Components Fill volume

Condenser About 50cc
Evaporator About 30cc
Receiver dryer About 30cc
Pipings(when replacing the whole freon hose) About 20cc

5-3-e. CIRCULATION OF REFRIGERATION OIL AND INSPECTION

While operating normally, part of refrigeration oil circulates together with refrigerant within the system.
1. When the volume of refrigerant in the system is decreased, fill it up to the specified level.
2. Place the blower switch in the “HIGH” position.
3. To operate the system, operate the compressor for at least 20 minutes at 800~1,200 rpm.

5-3-f. MAINTENANCE OF THE SYSTEM WHILE NOT IN USE

Run the engine at idle to operate the compressor for about 10 minutes 1~2 times a month even in the
season where the air conditioning system is not in use. Also check the compressor belt for tension from
time to time.

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16. HEATER AND AIRCONDITIONER

6. TROUBLESHOOTING
6-1. DIAGNOSIS DIAGRAM

Insufficient cooling

Check for air flow

• Insufficient air flow Air flow is OK.

• No air flow

Check fan motor operation

Problem with fan Fan motor is normal, but air

motor flow is insufficient.

Refer to item 1. Refer to item 2.

Check for compressor function.

Compressor rotates nomally. Fan motor is normal, but air flow

rate is insufficient.

Check high and low pressure. Refer to item 3.

Low pressure is high. Low pressure is low. High pressure is high. High pressure is low.

Refer to item 4. Refer to item 5. Refer to item 6. Refer to item 7.

* When the low pressure is identified as high, the high pressure also is identified as high.

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 16. HEATER AND AIRCONDITIONER

6-2. COMPLAINTS AND CORRECTIONS

ITEM DESCRIPTION CAUSE REPAIR

1 No rotation of fan motor • Bad Acc relay • Check

(Front air-con) • Fuse burnt • Remedy
• Short circuit • Replace
• Bad connection of electrical
connectors
• Bad grounding

• Bad resistor • Check

• Bad fan motor • Replace
• Bad fan switch

2 Fan motor is normal, but • Obstructive materials in cooling • Take away obstructive
air flow rate is insufficient unit or duct materials
(Front air-con) • Air is leaking • Repair air duct

• Evaporator frozen • Replace thermo switch

(Thermo switch malfunction)

3 No or abnormal rotation • Short circuit • Check

of compressor • Bad grounding • Remedy
Electrical • Bad air-con switch • Check, Replace
• Bad air-con relay • Check, Replace
• Bad pressure switch • Replace, Check
• Bad thermo switch • Replace
• Too much distance • Adjust the clearance
between the plate
and wheel of com-
Others pressor clutch
• Oil penetration on • Clean the facing
clutch facing

• Internal trouble of • Replace

compressor

Measurement of high
pressure and low pressure
* Check the pressure of high and low pressure sides.
– Normal pressure
(Determine in accordance • High pressure side: 14~15kg/cm2
• Low pressure side: 1.5~2.0kg/cm2
with high and low pressure)
(Under environmental temperature 30~35°C and
compressor speed 2,000rpm)

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16. HEATER AND AIRCONDITIONER

ITEM DESCRIPTION CAUSE REPAIR

4 Low • Dewing of low • Over opening of expansion • Replace

pressure pressure hose valve
is high and cool from
• Bad contact of thermo • Relocate the thermo
the outer of
sensor of expansion valve sensor on the right
cooling unit
position of low pressure
tube and attach securely
by pressing

5 Low • Too many • Lack of refrigerant • Discharge refrigerant,

pressure bubbles on sight evacuate the system and
is low glass refill specified amount

• Tubing is de- • Tubing of low pressure side • Remedy

formed and is clogged or deformed • Clean
clogged, even • Replace
negative pres-
sure occurs at
low pressure
side

• Evaporator frozen • Bad thermo switch • Replace

• Dewing of inner • Expansion valve clogged • Clean

to expansion • Replace

• The outer of • Leak at thermo sensor of • Replace

expansion valve expansion valve
and cool but
negative pressure
occurs in low
pressure side

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 16. HEATER AND AIRCONDITIONER

ITEM DESCRIPTION CAUSE REPAIR

6 High • Abnormal noise • Air is penetrated in cycle • Discharged the refriger-

pressure in cycle ant and refill specified
is high amount

• Even though • Overcharged refrigerant • Discharged the refriger-

cooling con- ant and refill specified
denser by water, amount
the bubbles
didn't appear on
the sight glass
immediately

• Bad cooling of • Contaminated, damaged • Clean condenser

condenser or clogged condenser
• Cooling air for condenser • Check, Remecly
is leak

• Abnormal opera- • Bad fan motor • Check, Remedy

tion of condenser
cooling fan • Short circuit • Check
• Bad connection of electri- • Remedy
cal harness

• Bad condenser relay • Check

• Replace

7 High • Too many • Lack of refrigerant • Discharge refrigerant

pressure bubbles on sight and refill specified
is low glass and the amount
temperature
distance of high
and low pressure
side of con-
denser is very
tiny.

• If the tubing is • Low pressure side tubing • Remedy

clogged, nega- is clogged or deformed • Clean
tive pressure • Replace
could occur

• Internal trouble • Bad gasket or valve • Replace

of compressor

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16. HEATER AND AIRCONDITIONER

6-3. TIGHTENING TORQUE

Fixing position Pipe(outer diameter in mm) Tightening torque (kgf.m)

ø9 1.5 ~ 2.0

Pipe fittings (union, nut, etc.) ø12.7 2.0 ~ 2.5

ø15.88 3.0 ~ 3.5

• Tightening torque for general bolts and nuts

Tightening torque (kgf.m)

Kind of bolt Pitch
Bolt mark 4 Bolt mark 7 Bolt mark 8

M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6 0.5 ~ 0.7

M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1 0.8 ~1.2

M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5 2.0 ~ 3.0

M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0 4.5 ~ 6.0

M10 1.5 1.8 ~ 2.7 3.3 ~ 5.0 4.3 ~ 6.0

M12 1.25 3.5 ~ 4.5 6.0 ~ 8.0 8.5 ~11.0

M14 1.5 7.5 ~ 8.5 12.0 ~ 4.0 13.0 ~18.0

(Note: The above bolt marks indicate the symbols of the bolt head.)

22