A/S Training for Modine Bus A/C
June 2, 2009
Modine History
2006 Purchased balance of South America Joint Venture
2005 Spin-off Aftermarket Start Transpro
2004 Acquisition of WiniaMando ACC / Korea
2004 Windtunnel in Filderstadt
2001 European Headquarters and Tech Center
2000 Serial HT EGR-cooler worldwide
1999 New Tech Center in Racine / USA
1998 Sales exceed 1 billion US$
1993 Company makes its largest
acquisition, Lngerer & Reich
1974 Sales exceed 100 million US$
1941 Modines unique, first vehicular
windtunnel
1926 Start of high volume production with Ford Model
T
1916 Founded by Arthur B. Modine
Modine Global Network
Worldwide Headquarters &
Technical Center
Racine, Wisconsin, USA
European Headquarters &
Technical Center
Bonlanden, Germany
Korean Headquarters &
Asian Technical Center
Asan City, Korea
A/C Application : BAC, TAC & Military Item
City bus
Express bus
Subway train
Armored vehicle
Chunma
Bus A/C Products
Mini-Bus A/C System (Integrated and Roof Mounted)
New In
2007
Fully Integrated Evaporator
and Condenser
Integrated Evaporator and
Roof Mounted Condenser
Roof Mounted Condenser
and Evaporator
Midi-Bus A/C System and Large Bus A/C Systems
Conventional Roof Mounted Bus Air Conditioner
Slim Style Roof Mounted Bus Air Conditioner
New products
- Luxury Bus A/C System
Two Models
Metal Frame
Fiberglass Frame
One Piece Evaporator and
condenser are combined into one
unit.
Under Development (PFC Slim type)
Weight of 15~20% lighter than
Pin & Tube type Condenser
Roof-on with Separate Engine
(Power pack)
MBA 260 RSN
Ring
RingFans
Fans
: Lower Noise
1212Single
SingleBlower
Blower
: Air Flow(5,000/Hr),High
Driven
Drivenby
byaa
Separate
SeparateEngine
Engine
: Hyundai D4BB (40ps/2,200 rpm)
1ps = 735.5w (29.42kw)
Compressor
Compressor
: MBA-58(575cc/rev)
Alternator
Alternator
: DC 24Vx150A Battery less Type
Composition
Condenser
1. COND.MOTOR&RING FAN 2. COND.COIL 3. RECEIVER TANK 4. DRIER
1
1
2
2
4
3
MBA260RSN
MBA240RN
Part Function
DRIER
The drier absorbs the harmful water inside the cooling system and
also filters out the minute dust inside the system. The drier of MBA260RSN is installed in Evaporator unit.
* The drier of MBA 240RN is installed in Condenser Unit.
When the drier is closed by some minute dust or moisture, it
happens the similar symptom by throttle effect like function of
Expansion valve.
Part Function
RECEIVER TANK
Plug
The Receiver tank temporarily stores the liquefied refrigerant from the Cond. Unit.
The Receiver tank has an inlet, outlet unit and a fusible plug.
When the temperature & pressure inside the liquid tank become abnormally high,
The fusible plug will be melt
Melting temperature of the fusible plug : 105
Evaporator
1. EVAP.MOTOR&BLOWER 2. OPERATION PANEL 3. EXPANSION VALVE 4. TEMP. SENSOR
5. EVAP. COIL 6. LOW PRESS. SENSOR 7. SOLENOID V/V 8. DRIER
4
3
6
7
1
5
5
2
MBA260RSN
MBA240RN
Part Function
Low pressure switch
The Low pressure switch is installed
Suction line in the Evaporator Unit.
When this switch operates, open
Signal sends the unloading valve
(= solenoid valve) and then the
Solenoid valve is operated to insert
Hot gas into Evaporator coil.
On
1.4 0.2kg/
Off
2.2 0.2kg/
Part Function
Part Function
EXPANSION VALVE
Temperature Sensor
The Expansion v/v is installed at the evaporator inlet and changes the
high pressure liquid refrigerant to a low temperature low pressure liquid
by adiabatic expansion. This valve on the Evaporator outlet senses the
refrigerant temperature through temperature sensor and autimatically
adjusts the amount of refrigerant flowing to the evaporator.
Part Function
SIGHT GLASS
The sight glass is installed on between expansion valve and drier.
And, This is used to check the refrigerant charge in the system and to
check the state of the refrigerant in the liquid line.
Eng. & Comp.
Part Function
HIGH/LOW PRESSURE SWITCH
These pressure switchs are installed to the Dis. & Suc. service valve. It is a safety
device which opreates when the refrigerant system pressure rises above the
specific pressure and drops below the specific pressure.
When this switch operates, the HI/LOW PRESS alarm lamp on the control panel light on,
a buzzer sounds the engine stop device operates. And the air conditioner will be stops
automatically. The operating pressure of these high/low pressure switchs are shown
in the table below.
HIGH
Operating pressure
28.0 1.0/
Resetting pressure
15.0 0.7/
LOW PRE. S/W
HIGH PRE. S/W
LOW
Operating pressure
0.5 0.3/
Resetting pressure
2.0 0.5/
Compressor
Compressor
6-CYLINDER
PART
BOLT
M6
4-CYLINDER
SIGHT GLASS
CONNECTING ROD
UNLOADING VALVE
TORQUE
BOLT
10010 kg-
M6
15010 kg-
M8
30020 kg-
M14
10010 kg-
UNLOADING VALVE
15010 kg-
GLAND
30020 kg-
MAIN BEARING COVER
CYLINDER HEAD
SERVICE VALVE(SUC)
MAIN BEARING COVER
CONNECTING ROD
38030 kg-
OIL DRAIN PLUG
25020 kg-
SERVICE VALVE(SUC)
M10
SIGHT GLASS
BASE
BASE
GLAND
TO RQ UE
CRANK CASE COVER
CRANK CASE COVER
M8
PART
M10
OIL DRAIN PLUG
25020 kg-
CYLINDER HEAD
SERVICE VALVE(DIS)
45030 kg-
SERVICE VALVE(DIS)
OIL CHARGE PLUG
35020 kg-
M14
OIL CHARGE PLUG
45030 kg-
35020 kg-
Engine
40ps(29.42kw/2,200rpm)
Part Function
Alternator
The alternator generate electric power during the engine operating time
and supplies electric power to the Cond.motor and the Evap.motor.
Modified Solenoid rpm control
Control Panel
CONTROL PANEL
- O n th e s te p s o f
K ey"O N "
T u rn o n th e O IL & S O U R C E
la m p s .
- O n th e s te p s o f
" A fte r s ta rt"
T u rn o n th e B A T & S O U R C E
la m p s .
Basic Circuit
Maintenance cycle
Estimated
Inspection period
Adjustment
Inspection Item
replacement
Work contents
time or
standard
Daily
Weekly
Monthly
Season
number of
year
Compressor
Oil level check
Level check at
2years
sight glass
Inspection
Oil leakage
Overhaul
Piping joints
Inspection
5,000hours
Visual inspection
gas leakage
Refrigerant
charge
Refrigerant
cylinder
Condenser
for oil leakage
Inspection
Leak detector
Inspection
No bubbles in sight
glass
Inspection
Leakage, damage,
5years
aging
Cleaning
Soiling
Gas leakage
Oil smears
Inspection
Cleaning
Soiling
Evaporator
Gas leakage
Oil smears
Inspection
Expansion valve
Inspection
Operation
3years
Unloading valve
Inspection
Operation
5years
By-pass valve
Inspection
Operation
5years
Remarks
Maintenance cycle
Estimated
Inspection period
Adjustment
Inspection Item
replacement
Work contents
time or
standard
Daily
Weekly
Monthly
Season
Remarks
number of
year
High and low
pressure
switches
Inspection
Operation
5years
Relief valve
Inspection
Gas leakage
Dryer
Inspection
No difference
5years
3years
between inlet and
outlet temperature
Charge valve
Inspection
Gas leakage,
5years
operation
O-ring
Inspection
Flange gas leakage
Evaporator filter
Inspection,
Soiling
2years
clogging
cleaning
Evap. Motor
Inspection
Operation
3years
Cond. Motor
Inspection
Operation
3years
Duct joint
Inspection
Deformation, aging
2years
sponge rubber
Moun-
Unit sealing
Inspection
Deformation, aging
2years
ting
rubber
Unit suspension
Inspection
Deformation,
2years
bolts and nuts
damage, wear
Maintenance cycle
Estimated
Inspection period
replacement
Adjustment
Inspection Item
time or
Work contents
standard
Daily
Weekly
Monthly
Season
number of
year
control
Selector switch
Inspection
Operation
Lamps
Inspection
Operation
Connectors
Inspection
Looseness
Power cable
Inspection
Looseness, damage
Room
Inspection
Operation
thermostat
Harness
Inspection
Damage
Remarks
Maintenance cycle
Estimated
Inspection period
replacement
Adjustment
Inspection Item
time or
Work contents
standard
Daily
Weekly
Monthly
Season
number of
year
Visual inspection
for oil and fuel
No leakage
leakage
Strong:1,700rpm
Engine
Speed check
Medium:1,400rpm
Weak:1,100rpm
Overhaul
As stipulated by
manufacturer
P
O
Oil level gauge
Engine oil
Replacement
Visual inspection
According to engine
200Hours
W
E
instruction manual
Oil filter
Replacement
200Hours
According to engine
element
Fuel filter
Cleaning
300Hours
instruction manual
element
Replacement
600Hours
Engine coolant
Inspection
Level
Radiator hose
Inspection
Damage,aging
600Hours
1Year
Remarks
Maintenance cycle
Estimated
Inspection period
replacement
Adjustment
Inspection Item
Work contents
time or
standard
Daily
Weekly
Monthly
Season
number of
year
Visual inspection
for oil and fuel
No leakage
leakage
Strong:1,700rpm
Engine
Speed check
P
Medium:1,400rpm
Weak:1,100rpm
Overhaul
As stipulated by
-
manufacturer
Oil level gauge
E
R
Engine oil
Replacement
Visual inspection
According to engine
200Hours
instruction manual
Oil filter
Replacement
200Hours
According to engine
element
Fuel filter
Cleaning
element
Replacement
Engine coolant
Inspection
Level
Radiator hose
Inspection
Damage,aging
300Hours
instruction manual
600Hours
600Hours
1Year
Remarks
Maintenance cycle
Estimated
Inspection period
replacement
Adjustment
Inspection Item
Work contents
time or
standard
Daily
Weekly
Monthly
Season
number of
year
Visual inspection
for oil and fuel
No leakage
leakage
Strong:1,700rpm
Engine
Speed check
P
Medium:1,400rpm
Weak:1,100rpm
Overhaul
As stipulated by
-
manufacturer
Oil level gauge
E
R
Engine oil
Replacement
Visual inspection
According to engine
200Hours
instruction manual
Oil filter
Replacement
200Hours
According to engine
element
Fuel filter
Cleaning
element
Replacement
Engine coolant
Inspection
Level
Radiator hose
Inspection
Damage,aging
300Hours
instruction manual
600Hours
600Hours
1Year
Remarks
Maintenance cycle
Estimated
Inspection period
replacement
Adjustment
Inspection Item
time or
Work contents
standard
Daily
Weekly
Monthly
Season
Remarks
number of
year
P
O
Engine fan belt
Tension
According to engine
adjustment
instruction manual
Inspection
200Hours
Damage,aging
Alternator
Inspection
Operation
Muffler
Inspection
Exhaust gas leakage
Air cleaner
U
element
Cleaning
Inspection
Cloggy
500Hours
every
50Hours
Engine air
intake hose
Inspection
Cracking,aging
Oil filter joint hose
Inspection
Cracking,aging
Radiator
Inspection
Leakage
soil
3Years
2Years
2Years
Engine air
Inspection
Aging
Inspection
Soil
breather hose
Engine throttle
valve
When engine
speed drops
Trouble Shooting
Trouble
Probable cause
Corrective cause
1.High pressure too high.
1.Air or uncondensed gas inside.
2.Excessive refrigerant charge.
3.Condenser air side fins clogged, or
dirty.
4.Condensor motor faulty.
5Ambient temperature too high
(poor ventilation)
6.Condenser motor fuse is disconnected.
7.High pressure switch faulty.
1.Loosen liquid tank high pressure line
joint and condenser inlet joint and vent
uncondensed gas.
<note>
1.This operation must not be preformed
while the air conditioner is operating.
2.Discharge refrigerant
3.Blow out with air, or wash with water
4.Change the motor
5.Operate in a well ventilated place.
6.Change the fuse
7.Inspect and replace switch.
2.High pressure too low.
1.Liquid refrigerant in intake gas from
evaporator.
(Liquid back)
2.Expansion valve faulty.
(Open state)
3.Unloader valve operated.
4.Unloader valve faulty.
5.High pressure gauge faulty.
6.Compressor discharge valve leaking
7.Compressor intake strainer clogged
1.Check if temperature sensor fitted
against the suction pipe.
2.Inspect and replace valve.
3.Set selector switch to HI position.
4.Inspect and replace valve.
5.Inspect and replace gauge.
6.Inspect and replace compressor
7.Inspect and clean strainer.
Trouble Shooting
Trouble
Probable cause
Corrective cause
3.Low pressure too high.
1.Excessive liquid refrigerant being supplied
from the expansion valve.
2.Expansion valve faulty.
3.Unloader valve operated.
4.Unloader valve faulty.
5.Low pressure intake and discharge valve
leaking.
1.Check the temperature sensor is fitted
against suction pipe repair, if necessary.
2.Inspect and replace valve.
3.Set selector switch to HI position.
4.Inspect and replace valve.
5.Inspect and replace gauge.
6.Inspect and replace compressor
4.Low pressure too low.
1.Pipeing, drier, expansion valve, etc.
Partially blocked.
2.Insufficient refrigerant
3.Frost on evaporator causing a drop in oil
capacity.
4.Compartment air intake blocked.
5.Air filter closed with dust and dirty
6.Dirty and dust on evaporator.
7.Piping between temperature sensor and
expansion valve damaged, or broken.
8.Water inside system froze at expansion
valve.
9.Evaporator motor faulty.
10.Bus compartment too cold.
11Outside air temperature and compartment
temperature are low.
12.Expansion valve faulty.
13.Low pressure switch faulty.
14.Fuse is disconnected.
1.Remove and inspect parts.
2.Check for gas leakage, then charge
refrigerant until there are no more bubbles
in sight glass.
3.Inspect and replaced frosting thermostat.
4.Inspectand clean intake.
5.Clean air filter.
6.Inspect and clean evaporator.
7.Inspect and replace expansion valve
8.Replace drier discharge gas from system.
Remove water component with a vacuum
pump, then recharge system with
refrigerant.
9.Change the motor.
10.Switch the selector switch.
11.Stop cooling.
12.Inspect and replace valve.
13.Inspect and replace switch.
14.Cahnge the fuse.
Trouble Shooting
Trouble
Probable cause
Corrective cause
1. Can not starting
1. Battery power not enough.
2. Fuel pump has air or blocking.
3. Fuse burning.
4. Air cleaner/nozzle blocking.
1. Alternator/Regulator check & replace.
2. Purge or replace Fuel filter assembly.
3. Control & relay check replace.
4.
2. Cooling is not enough
1. Gas leak or not enough.
2. Motor not working. (Evap/Cond)
3. Discharge air filter not clear.
4. Drier has not working.
1. Check & repair recharging gas.
2. Replace motor.
3. Cleaning filter.
4. Replace drier.
3. Leaking problem
1. Suc. Dis hose burst.
2. Comp seal leaking.
3. Eng. Gasket leaking.
4. Coil connecting Hose parts.
1. Replace hose.
2. Seal or leak position check & replace.
3. Replace gasket.
4. Check & Repair.
Special checking point.
1. Filter (return air).
2. Fuse & relay.
3. Every Parts clearance.
Thank you
