Ac system GREAT WALL SAILOR 2006 Service Manual

AC-1
Page
Introduction ................................................................. AC-2
Electric circuit diagram of air-conditioning system ...... AC-4
System constitutes ...................................................... AC-8
General introduction .................................................... AC-9
Troubleshooting .......................................................... AC-10
Inspection for refrigerant quantity ................................ AC-11
Compressor ................................................................. AC-12
Liquid container ........................................................... AC-14
Condenser ................................................................... AC-15
Cooling device ............................................................. AC-16
Refrigerant pipeline ..................................................... AC-20
AC
Air-conditioning System

AC-2Air Conditioning System
Introduction
In case the liquid refrigerant enters into the eye or touches the
skin, the following measures shall be taken:

Wash the part where is touched by the refrigerant with a
great deal of water.

Coat the skin with the clean Vaseline.

See the doctor or go to the hospital for treatment; and

Do not try to cure it yourself.
General Introduction
1. Take notice when handling refrigerant General Introduction
(a) Do not handling with refrigerant in the closed room or
near to open fire.
(b) Safety goggles shall be worn when handling
(c) Be careful to avoid the liquid refrigerant from entering
into your eye or touching you skin.
waterair
dust
ÅçåÇÉåëÉêplug
2. Take notice when changing the parts of refrigerant pipes:
(a) The refrigerant shall be exhausted gradually before
changing.
(b) The dismantled parts shall be covered with plug right
away so as to prevent the water or dust from entering into
the system.
(c) Do not store the condenser or liquid tank under the
condition that the plug has been uncovered. and
(d) Refrigerant shall be exhausted before installing the new
condenser, because the refrigerant, if not exhausted, will
eject out in gaseous form with the lubricant oil when the
plug is moved away.
3. Take notice when fastening the connection parts:
(a) Spread a little lubricant oil at the matching position of the
O-type ring to fasten the connection and avoid of gaseous
refrigerant leakage.
(b) Fasten the nut with two spanners so as to avoid of the pipe
deformation.

AC-3Air Conditioning System
Introduction
(c) Tighten the O-ring matching position or the threaded position
to the specified moment.
4. Take notice when connecting measuring meter at branch pipes:
(a) Connect the end of filling hose with high speed joint to the
filling valve of compressor.
(b) Letter
D
marked on the compressor near the auxiliary valve
represents the side of high voltage while
S
means the side of
low voltage, which shall be looked out when connecting the hose.
(c) Fasten the bolts by hand, and
(d) In order to prevent the hose from loosing, lubricant oil shall not
be spread at the connection position.
Remarks: after connecting the measuring meter on branch pipes to
the refrigerant container (repairing tank), the air in the hose shall be
exhausted up.
5. Take notice when vacuumizing:
After vacuumizing for 20 min, maintain the container at certain
pressure to ensure that all air in it is exhausted up, and another
inspection shall be made to see whether there is leakage.
6. Take notice when handling with the refrigerant container
(repairing tank):
(a) Do not heat it.
(b) Store the container at the place where temperature is under 40

(c) In case of heating the repairing tank with hot water, care shall
be paid to the valves at the top of tank, do not dip them into the
water, or the water will penetrate into the cooling system.
(d) The empty repairing tank is forbidden to reuse.
8. Take notice when using the high-pressure air cylinder type
inspecting device:
(a) In case the open fire is used, it is the first to ensure before using
there is no flammable material around.
(b) Be careful because toxic gas will be produced when the
gaseous refrigerant meets with the open fire. 7. Take notice in the A/C operation or when adding the liquid
refrigerant:
(a) In case the gaseous refrigerant in the cooling system is
insufficient, which can lead to the compressor burns out, and
such accidents shall be avoided.
(b) If the valve on the side of high pressure is uncovered, the
refrigerant will flow in the reverse direction, which may lead
to the break of the repairing tank, therefore, only valves on the
side of low pressure are allowed to open or closed.
(c) If the repair tank is laid in reverse direction, and the refrigerant
is added in liquid status, the liquid refrigerant will be
compressed, which may lead to failure of the compressor,
therefore, refrigerant shall be inflated in the gaseous status.
(d) Be careful not over-inflate the gaseous refrigerant, otherwise,
such failures as insufficient cooling, increase of oil consuming
or over heat of engine will be followed.
under 40

incorrect
correct
measuring meter of branch pipe
loose over-fastened
A/C operation

AC-4Electric Circuit Diagram of Air
Conditioning System
Electric circuit diagram of air-conditioning system (continued)
Dr
fuseA/C switch pressure switch
engine wire
harness
air blower
speed-adjusting
module
wind speed switch M2 2
2
2 2
2
2
O 24 4 4 4
4
Q 4
44 3 3
3
3 3 3 3
3
P 5 5
5
5 5 5
5
R 1
1
N 1
1
1
1
N6
6 6
6
6
S 7
7
TU 8
8 9
9 10
10 11 12 13
ignition switch pressure switchA/C switchspeed adjusting
module of air blower
socket connectors of engine wire harnesswind speed switch
lk ^`` p q
fuse ignition switchair-conditioning relayfuse
battery

AC-5Electric Circuit Diagram of Air
Conditioning System
SF
ST
fusethree-state pressure switch
cold-hot
servomotor circular
servomotor mode
servomotor main air-conditioning
control panel
speed
adjusting
module
air blower
b`r
power resistor
water
valve
Mjjj
M
ACCON
+12V 5
R R 5
5 5 5 5
5
5 PP
P P 3
3
3 3 3 3
3
3
3 1
111
1
1
1 N
N N
1
2 2 2 2
2
22 O O OO
4
44 4
4 4 4Q
Q
Q Q
4
6 6
6 6 6
6S S 6
S6
7
7
7 8
88 9
9
9 10
1010
1111
12
13 14 15 16 17 18 1920
20 21 22 23 2423
ignition switch modular air-door motor cold-hot air-door motor air-in motor
three-stage
pressure switch speed adjusting
modul air conditioning
ignition switchsmall light relay
fusefuse electronic fan
water temperature relay
fuse
compressor relayelectromagnetic
fan relay
compressor clutch
24
Electric circuit diagram of air-conditioning system (continued)
battery
18
5
17
16
3
15
19
14
22
1
13

AC-6Air-Conditioning System
(Electric Circuit Diagram)
S
SL SK SJ
fuse
air-conditioning
request relay
connect with ECUfuseECU
^``lkpq
4
5
1
2
45 6
32
36 54
21
1
2 1
32
ignition switch speed adjusting module
air blower A/C SWITCH pressure switch
1 2 3 4
5 6 7 81 2 3
4 5 61 2 3
4 5 6
1
2 1
2 3 1
2
compressor
electromagnetic fan relay compressor relay
pressure switch fuse
fuse
electromagnetic fan
air-conditioning
request relay
A/Cswitch
blower
air-volume switch
speed-adjusting resistance
heat-sensitive resistance blower relay
charging indicating lamp
ignition switch
air-volume switch Electric circuit diagram of air-conditioning system (continued)
battery
ECU

AC-7Air-Conditioning System
(Electric Circuit Diagram)
compressor
compressor relay
fuse
rearignition switch
electromagnetic
cutoff valve
rear speed-adjusting
resistance temperature controller
rear wind-velocity switch
rear air-conditioning relay
air blower
electromagnetic fan relay
electromagnetic fan
air-conditioning request relay A/C switch
R ECU
pressure switch
speed-adjusting resistance
air
blower
blower relay
(electricity-connecting and
charging indicating lampair-conditioning
request relay
connect with ECU 2
1
312
3
3
3 22
1
1
44
44 1
1 2
23
35
5
56
6 6
4fuse1
1
1
1
1
1
1
1 22 2 22 22 23
3
3
3
3
3
3
3 4444 4 4
5
5
5
5 6
6
6
6 7
7 88
SY
STACC ON
rearignition
switchtemperature
controllerrear wind-
velocity switchrear speed-
adjusting resistancespeed-adjusting
resistanceair-volume
switchA/C switchignition switch
ignition switch
fuse heat-sensitive resistance
(air-volume
switch)
fuse
Electric circuit diagram of air-conditioning system (continued)
battery
ECU

AC-8Air-Conditioning System
System Component
system component
liquid tankcompressor
condenserHP hoseLP hose
Tightening moment for air-conditioning pipeline

Open-wrench spanner (mm)Tightening moment(N
m)
Threaded
joint of
com-
pressor Threaded
joint
Pressing
plate bolt14
17
Threaded head (mm)
Open-wrench spanner (mm)Tightening moment(N
m) Tightening moment(N
m)
Air-conditioning pipe-lineTightening moment(N
m)
LP hose interface
HP hose interface25
2 35
3
18
1.5
Dr SF SL SK SY SJ
17
19
19
19
22
24
24
27
27
2715
3
15
3
15
3
25~30
30~35
30~35
10
148~12
21~25
24
1425~30
30~35HP hose interfaceevaporator

AC-9Air-conditioning System - General introduction
General introduction
Refrigeration cycle
1. The refrigerant at the lower pressure side is condensed by the
compressor into the HT and HP gaseous refrigerant.
2. These gaseous refrigerant flows into the condenser, where it is
turned into liquid refrigerant.
3. Those liquid refrigerant flows into the liquid tank, where the
liquid refrigerant is stored and filtered so as to satisfy the
requirement of evaporator.
diaschage vent indraft vent
compressor
curent direction
evaporator heat
heat expansionvalve
liquid tank
4. The liquid refrigerant is throttled by the expansion valve to reduce the pressure, so that the liquid refrigerant is turned
into the LT and LP mixture of liquid and gaseous refrigerant.
5. The cold and fog-like refrigerant flows into the evaporator, where it is vaporized with the given heat, which is
absorbed from the hot air flow by the evaporator core. All liquid refrigerants are turned into the gaseous refrigerant
in the evaporator, and only the heated gaseous refrigerant is absorbed into the compressor. Then repeat the above-
mentioned cycling approach.
The refrigerant released from
the evaporator expands and
inflows through the evapora-
tor pipe. During this process,
the refrigerant absorbs the
heat in the air around the ra-
diating rib and pipe and
vaporizes, so that the tem-
perature inside the vehicle
reduces gradually.
The condenser allows the heated gas-
eous refrigerant to release heat to the
cooling air of engine, therefore, the gas-
eous refrigerant is cooled and turned
into liquid state again.
The expansion valve is used
to measure the gaseous re-
frigerant entered into evapo-
rator core, which reduces the
pressure and temperature of
refrigerant gradually.
The liquid tank is used to exhaust
the water in system and to filter
the dust and dunghill. It serves as
the store to store the redundant
refrigerant.
The compressor absorbs the
gaseous refrigerant emitted
from the evaporator and com-
presses it. In doing so, the tem-
perature and pressure of gas-
eous refrigerant increases
rapidly.

AC-10Air-conditioning System - Troubleshooting
Troubleshooting
TroubleReparation approachesPage
Lack of cold airNon-pull-in performance of electromagnetic clutch:
(a) Break of ignition switch and fuse;
(b) Trouble of electromagnetic clutch;
(c) Trouble of A/C switch;
(d) Wiring or grounding trouble;
(e) Lack of refrigerant; and
(f) Trouble of pressure switch.
Abnormal operation of compressor:
(a) Looseness or break of driving belt;
(b) Compressor trouble;
Expansion valve trouble;
Systematic leakage;
Liquid tank fusible plug melting or filtering
screen blocking;
Non-work of air blower:
(a) Failure of A/C switch;
(b) Failure of air blower motor, and
(c) Wiring failure.Change the fuse and check to see whether
there is short circuit;
Check the electromagnetic clutch;
Check the A/C switch;
Repair it as requirement;
Check the refrigerant pressure;
Check the pressure switch;
Adjust or change the driving belt;
Check the compressor;
Check the expansion valve;
Conduct lubricating test for the system
Check the liquid tank;
Check the A/C switch;
Check the air blower motor;
Conduct reparation as requirement.
Inconsecutive
cold airElectromagnetic valve slip
Failure of expansion valve;
Wiring or connecting failure;
Over water content in systemCheck the electromagnetic clutch;
Check the expansion valve;
Make reparation as requirement.
Reclaim the water first, then exhaust the
system to vacuum and inflate in the refrigerant.
Cold air occurs in
high-speed conditionBlocking of radiating face of condenser;
Driving belt slip;
Compressor failure;
Insufficient or redundant refrigerant;
Air existing in systemCheck and wash the condenser
Check and change the driving belt;
Check the compressor;
Check the refrigerant quantity;
Vacuumize the system and inflate
the refrigerant;
Insufficient
cold airCondenser blocking;
Driving belt slip;
Electromagnetic clutch failure;
Compressor failure;
Expansion valve failure;
Insufficient or redundant refrigerant;
Air existing in system;
Redundant compressor lubricant;
Liquid tank blockCheck the condenser;
Check and change the driving belt;
Check the electromagnetic clutch;
Check the compressor;
Check the expansion valve;
Check the refrigerant quantity;
Reclaim the air, then vacuumize the sys-
tem and inflate the refrigerant;
Check the compressor lubricant quantity;
Check the liquid tank
Evaporator blocking or frosting
Air leakage in cooling device or air
pipeline;
Air inlet blocking;
Air blower motor failure;Clean the evaporator radiating rib
or filter;
Make reparation as requirement
Make reparation as requirement
Change the air blower motor.
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Page AC-12
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Page AC-11
Page AC-13
Page AC-12
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Page AC-14
Page AC-4 to 7
Page AC-12
Page AC-16
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Page AC-15
Page AC-12
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Page AC-12
Page AC-16
Page AC-11
Page AC-14
Page AC-18
Page AC-20
Possible causes
Page AC-15
Page AC-13
Page AC-12
Page AC-11
Under-speed cold air