MANUAL CONTROL / SEMIAUTO TEMPERATURE CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

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1 SECTION 7C MANUAL CONTROL / SEMIAUTO TEMPERATURE CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless other-wise noted. TABLE OF CONTENTS Specifications... 7C-2 Refrigerant... 7C-2 Evaporator Unit... 7C-2 Blower Unit... 7C-2 Compressor... 7C-2 Condenser... 7C-2 Receiver Drier... 7C-2 Pressure Switch... 7C-3 Air Filter... 7C-3 Heater Unit... 7C-3 Fastener Tightening Specifications... 7C-3 Diagnosis... 7C-4 Defectives in Fan Motor Circuit... 7C-5 Defectives in Compressor Circuit... 7C-6 Diagnosis Using the Manifold Gauge... 7C-7 Component Locator... 7C-9 Ventilation... 7C-9 Heater System... 7C-11 Air Conditioner System... 7C-12 Diesel Engine... 7C-12 Gasoline Engine... 7C-13 Maintenance and Repair... 7C-14 Refrigerant Charging... 7C-14 Compressor Oil Replacement... 7C-18 Repair Instructions... 7C-19 On-Vehicle Service... 7C-19 Condener... 7C-19 Receiver Drier... 7C-21 Air - Conditioner Compressor... 7C-23 Heater and Air Conditioner Control Box... 7C-24 Air Filter... 7C-25

2 7C-2 MANUAL & SEMIAUTO-HVAC SPECIFICATIONS REFRIGERANT Capacity Type Application Description g R134a EVAPORATOR UNIT Application Core Size (LxWxT) Core Type Expansion Valve Type Thermostat Resister Type Cooling Capacity Description x x 92.0 Aluminum plate Angle ON:4.5 ± 0.6 C, OFF:1.5 ± 0.6 C Aluminum plate 4,300 Kcal/h (AT 420 CMH) BLOWER UNIT Motor Type Motor Size Application Description Magnetic φ 70 x 145 COMPRESSOR Application Model Type Displacement (cc/rev.) PCD (Pulley Center Diameter) Oil Magnetic clutch output Description FK-II (DKV 14C) Vane rotary type (cc/rev) φ 143 ZXL 200 PG (PAG Oil) 45 W CONDENSER Size (WxHxT) Capacity Type Application Description 650 x x ,000 Kcal/h Parallel Flow RECEIVER DRIER Material Capacity Desiccant Application Description Aluminum 250 cc XH-9 (35 g)

3 Type High (OFF) Low (ON) Replacement Application Application MANUAL & SEMIAUTO-HVAC 7C-3 PRESSURE SWITCH Description Direct OFF : 32 ± 2 Kgf/cm 2, DIFF : 6 ± 2 Kgf/cm 2 OFF : 2.0 ± 0.2 Kgf/cm 2, ON : 2.1 ± 0.2 Kgf/cm 2 AIR FILTER Description Every 12,000 km (replace earlier if air pollution is heavy) HEATER UNIT Application Heater Core Type Heating Capacity Heater Core Size (L x W x T) Description 2-ROW 4,600 Kcal/h (AT 300 CMH) x x 52 FASTENER TIGHTENING SPECIFICATIONS Application N m Lb-Ft Lb-In Condenser Bolt Condenser Fan Nut Condenser Bolt Receiver Drier Pipe Bolt Receiver Drier Pipe Bolt (Condenser) Pressure Pipe Bolt Pressure Mounting Bolt

4 7C-4 MANUAL & SEMIAUTO-HVAC DIAGNOSIS Insufficient cooling Check blowing outlet Normal outlet Check outlet temperature Poor outlet or no outlet Check fan motor operation Fan motor does not operate Blown fuse Check for motor control circuit Normal temperature High temperature Frosted evaporator Check the case Check heater Faulty compressor Check belt Check compressor operation Normal compressor Warmeaporator (A/C S/W off, Fan 4 ) Check with sight glass Check thermo amp Tension is normal Loosened tension Check Adjust tension Bubble is not found magnetic Bubble is not found Bubble is found Check pressure clutch Check Check refrigerant Check clutch pressure volume and air in connection system Check wire Motor operates with poor outlet Intake grille is clogged Remove cloggings Bubble is found Check refrigerant Faulty magnetic electric Faulty clutch Faulty compressor operation Check battery voltage Check control switch Normal high/low pressure High high/low pressure High pressure : low Check ground Faulty A/C system Faulty A/C mix door Faulty vent, intake door Excessive refrigerant Dirty cond., fan Excessive oil in system Low pressure : high Check intake and outlet temperature Noise Identify the place Low intake temperature Faulty evaporator - No diffence in temperature - Fast pressure balance Compressor Belt Others Faulty comp. outlet Excessive oil Faulty bearing Faulty clutch Faulty belt Belt line is correct Check belt tension

5 DEFECTIVES IN FAN MOTOR CIRCUIT Fan Motor Does Not Run MANUAL & SEMIAUTO-HVAC 7C-5 Blown fuse Battery voltage is low Faulty wiring Faulty ground Checks Action Check for short and replace fuse. Check battery voltage. Check connectors connection. Do not apply grease. This can cause voltage down. Remove body painting and completely ground, Tighten ground bolts and make sure body ground connection. Fan Motor Runs in 4 position Only ( 3, 2, 1 : Does Not Run) Checks Blown resister temperature fuse Air leakage in parts connection Action Replace resistor. Check heater, cooling unit and blower for proper connection. Motor Runs With Poor Blowing Checks Clogged or blocked intake grille Action Clogged or blocked intake grille reduces blowing capacity. Faulty thermo amp Checks Frosted Evaporator Action Frosted evaporator reduces cooling capacity. Off compressor and maximize blowing capacity

6 7C-6 MANUAL & SEMIAUTO-HVAC DEFECTIVES IN COMPRESSOR CIRCUIT Compressor Does Not Run Faulty high/low pressure Faulty A/C relay Checks Action Check compressor magnet voltage supply. A/C relay. Magnetic Clutch Slips / Idles Checks Oily clutch plate Low voltage Faulty electric connection or operation Action Clean oily plate using cleaning agent. Charge battery or check for cause. Check wire continuity Check A/C switch and fan switch for continuity and ground. Magnetic Clutch Plays By Hand Only Excessive clearance between Clutch plate and clutch coil Checks Action Adjust clutch clearance ( mm).

7 DIAGNOSIS USING THE MANIFOLD GAUGE On normal operation during the cooling cycle, the manifold gauge must indicate approximately kg/cm 2 at low pressure side and kg/cm 2 at high pressure side, on condition that the temperature at the cooler inlet, 30 ºC - 35 ºC, 2,000 rpm of the engine rpm, full cold and maximum blower speed. MANUAL & SEMIAUTO-HVAC 7C-7 YAD7B070 Symptom 1. High and low pressure are abnormally low. 2. Air at cooler outlet is not cold. Cause There is a gas leak in the cooling system. Action Check the oil leak, repair Add the refrigerant YAD7B High and low pressure are abnormally high. Insufficient cooling and faulty condenser cooling by excessive refrigerant. Keep the specified amount of the refrigerant, Clean the condenser Repair the belt 1. High and low pressure are abnormally high. 2. Connection at the low pressure is not cold. YAD7B090 Belt is slipped There is an air in the cooling system Clean and repair the receiver-drier Check the oil contamination etc. YAD7B100

8 7C-8 MANUAL & SEMIAUTO-HVAC Symptom 1. The low-pressure side indicates excessive high and high-pressure indicates excessive low. 2. There is a moisture in the connection of the receiver-drier and the front/back of the expansion valve. Cause The dust and moisture etc. are frozen at the expansion valve A gas leak in the heat reducer Action Repair the receiver-drier Replace the expansion valve for the faulty heat reducer YAD7B The low-side pressure is high or normal intermittently. The mixed moisture is frozen at the expansion valve Repair the receiver-drier and perform the bleeding YAD7B The low-pressure and high-pressure are excessive high. 2. There are a lot of moistures in the connection of the low-side pressure The faulty expansion valve, the improper installation of the heat reducer Fail to control the flow rate Repair the receiver-drier Check the oil contamination etc. YAD7B The low-pressure is excessive high and highpressure is excessive low. There is an oil leak in the compressor Replace the compressor YAD7B140

9 COMPONENT LOCATOR VENTILATION MANUAL & SEMIAUTO-HVAC 7C-9 KAA7C010 1 Foot / Face 2 Foot / Defroster 3 Foot 4 Defroster 5 Face

10 7C-10 MANUAL & SEMIAUTO-HVAC Air Flow Switch Mode Switch Recirculation Switch Temperature VENT B/L FOOT D/F DEF REC FRE Control Lever Door INDI. On INDI. Off VENT Door A B C C C FOOT Door C B A B C DEF Door D D D B A INTAKE Door AIR MIX Door - A - A B C B - KAA7C020

11 HEATER SYSTEM MANUAL & SEMIAUTO-HVAC 7C-11 KAA7B450 1 Heater-to Defrost Duct 2 Heater Unit 3 Mode Actuator Assembly 4 Heater Controller 5 Side Air Vent 6 Coolant Outlet Hose 7 Coolant Inlet Hose 8 Heater-to-Blower Duct 9 Blower Unit

12 7C-12 MANUAL & SEMIAUTO-HVAC AIR CONDITIONER SYSTEM DIESEL ENGINE KAA7C030 1 Compressor 2 High Pressure Hose 3 Condenser 4 Condenser Fan 5 Liquid Pipe (A) 6 Reveiver Drier 7 Liquid (B) 8 Evaporator Assembly 9 Blower Unit 10 Heater Unit 11 Low Pressure Hose

13 GASOLINE ENGINE MANUAL & SEMIAUTO-HVAC 7C-13 KAA7C040 1 Evaporator Assembly 2 Condenser Asembly 3 Screw-Hex SEMS (M8 x 1.5 x 35) 4 Fan & Shroud Assembly-Main 5 Fan & Shroud Assembly-Add 6 Supplement Assembly- c/ fan Mounting 7 Receiver & Bracket Assembly 8 Hose-Discharge 9 Bolt-Hex Sems (M8 x 1.25 x 30) 10 Hose Assembly-Suction 11 Pipe Assembly-Suction 12 Pipe-Liquid-A 13 Pipe-Liquid-B 14 Resister-Condenser Fan 15 Clip-Closed-CT (M8) 16 Bolt-Hex FLG (M8 x 1.25 x 25) 17 Nut-Hex (M6 x 1.0) 18 Screw-Hex SEMS (M6 x 1.0 x 25) 19 Screw-Hex SEMS (M6 x 1.0 x 16)

14 7C-14 MANUAL & SEMIAUTO-HVAC MAINTENANCE AND REPAIR YAD7B150 REFRIGERANT CHARGING Installation of Manifold Gauge 1. Close both high/low pressure hand valves of manifold gauge before installation of gauge to the charging valve. 2. Both high/low pressure hand valves of manifold gauge connect the appropriate charging valve. Tighten the hose nuts by hand. high pressure hand valve high pressure charging valve low pressure hand valve low pressure charging valve Discharging Refrigerant 1. Connect the manifold gauge to the charging valve. 2. Place the free end of the center hose in a shop towel. 3. Slowly open the high pressure hand valve and discharge refrigerant. Notice: If refrigerant is allowed to escape too fast, compressor oil will be drawn out of the system. YAD7B Check whether the shop towel gets wet in oil and if wet, close the hand valve. 5. After the high pressure gauge reading drops below 3.5 kg/cm 2, slowly open the low pressure valve. 6. When both high and low pressure gauges reading drops to 0 kg/cm 2, discharging is completed. Evacuating Refrigeration System Notice: The unit tank must contain a sufficient amount of R-134a refrigerant for charging. Check the amount of refrigerant in the tank. If there is less than 3.6 kg (8 pounds) of refrigerant, add new refrigerant to the tank. YAD7B Verify that the high-side and the low-side hoses are connected to the A/C system. Open both the high-side and the low-side valves on the unit s control panel. 2. Open both the gas and the liquid valves on the tank.

15 MANUAL & SEMIAUTO-HVAC 7C-15 Important: Refer to the manufacturer s instructions for the charging station in use. It is necessary to evacuate the system before recharging it with new or recycled refrigerant. YAD7B Start the vacuum pump and begin the evacuation process. Non-condensable gases (mostly air) are vented from the tank automatically during the recycling process. The pressure being released may be heard. 4. Check for leaks in the system. Refer to the manufacturer s instructions for the charging station in use. Important: Change the vacuum pump oil frequently. Refer to the manufacturer s instructions for the charging station in use. Check for Refrigerant Leaks 1. Connect the center hose of the gauge to the refrigerant tank. 2. Open the high pressure valve of the gauge to charge with refrigerant gas. 3. Charge until the low pressure gauge reads 1.0 kg/cm 2 and close the valve. 4. Using a gas leak detector, check the system for leaks. 5. If any leak is found, replace O-ring or repair the faulty connection. YAD7B190 How to Use the Tap Valve 1. Rotate the handle counterclockwise fully before connecting the valve to the refrigerant tank. 2. Rotate the disk counterclockwise fully. 3. Connect the center hose to the valve fitting and then rotate the disk clockwise fully by hand. 4. Rotate the handle clockwise to drill the sealed hole. 5. Remove the hose nut securing the center fitting of the manifold gauge and then tighten the nut again in a few seconds. YAD7B200

16 7C-16 MANUAL & SEMIAUTO-HVAC Charging Refrigerant Charging for Gas 1. Connect the tap valve to the refrigerant tank. 2. Open the low pressure and adjust the low-side reading below 4.2 kg/cm Place the refrigerant tank in the warm water (40 C) and keep the gas pressure in the refrigerant tank higher than the gas pressure in the charging valve. 4. Run the engine at high speed and operate A/C system. YAD7B210 Notice: Place the refrigerant tank on the flat floor to protect the liquid refrigerant from coming through the suction inlet resulting in the compressor s damage. 5. Charge the specified amount to the charging valve and close the low pressure valve. Specified amount Single: 850 ± 50 g Dual: 1200 ± 50 g YAD7B220 Notice: If the charging speed is low, it s more efficient to place the refrigerant tank in the warm water (40 C). But the temperature should keep below (52 C) at any situation. Be careful not to contact the heating device or material. Charging for Liquid YAD7B230 Notice: Do not operate when charging the system through the high-side rpessure. Do not open the low pressure valve when charging the system by the liquid refrigerant. 1. Tighten both high pressure and low pressure completely before evacuating the charging valve. 2. Connect the tap valve of the refrigerant tank. 3. Open the high pressure valve and turn the refrigerant tank upside down.

17 MANUAL & SEMIAUTO-HVAC 7C The discharging pressure increases when the charging valve charges excessively, so charge the charging valve to the specified amount with measuring the weight of the refrigerant before closing the high pressure valve. 5. Charge the specified amount of the refrigerant and then close the valve of the manifold gauge. Check the system for any leak. Operation Check ;;; ;;;; YAD7B240 Notice: Operation Check is recommended before removing the manifold gauge. 1. Install the manifold gauge set. 2. Run the engine at 2,000 rpm and set the blower switch at HI and A/C switch ON. Set the temperature control lever at COOL. 3. Keep opening all of the window and door. 4. Place a dry bulb thermometer to the front duct. 5. Place a psychrometer close to the inlet of the cooling unit. 6. Check the high pressure gauge reading within kg/cm 2 If the reading indicates high excessively, spray the water to the condenser. If the reading indicates low excessively, cover the condenser with the towel. 7. Check the temperature of air inlet within C. 8. Calculate the relative humidity from the psychrometic graph comparing the wet/dry temperature at the air inlet. 9. Measure the wet/dry temperature at the cold air outlet and calculate the temperature difference of the dry bulb between the inlet and the outlet. 10. Check the cross point of the relative humidity and check the temperature difference between the black line. If the cross point is located between the black line, the cooling performance is normal.

18 7C-18 MANUAL & SEMIAUTO-HVAC COMPRESSOR OIL REPLACEMENT Before Oil Replacement When any part is replaced or there are a lot of gas leaks in the A/C system, you should add the specified amount of the oil to keep the approval oil capacity because the oil for lubricating the compressor circulates through the A/C system during operating the compressor. Total Oil Capacity 265 cc Handling Oil Be careful that moistures, dusts etc. must not flow into the oil. Do not mix with any other material. If the oil leaves outside for long time, it s possible to mix it with the moistures and so keep the oil sealed with a container. Circulating Oil For checking or adjusting the oil level, set the control unit to full cold and max blower speed with keeping the engine run at idle for minutes in order to circulate the oil through the compressor.

19 MANUAL & SEMIAUTO-HVAC 7C-19 Preceding Work : Removal of the radiator REPAIR INSTRUCTIONS ON-VEHICLE SERVICE CONDENSER KAA7C200 1 Condenser 2 Bolt N m (35-53 lb-in) 3 Condenser Fan 4 Sub Fan (Gasoline Engine) 5 Resister (Gasoline Engine)

20 7C-20 MANUAL & SEMIAUTO-HVAC Removal & Installation Procedure 1. Disconnect the inlet and outlet pipes of condenser. Notice: Before disconnection, evacuate the refrigerant from the system. Tightening Torque Inlet Side to 10-15N m (7-11 lb-ft) Outlet Side to 4-6 N m (35-53 lb-in) KAA7C210 Notice: When installing, check the O-ring and apply compressor oil. 2. Remove the mounting bolts (2EA) and condenser assembly. Installation Notice Tightening Torque 4-6 N m (35-53 lb-in) KAA7C Remove the main condenser fan from condenser. KAA7C Installation should follow the removal procedure in the reverse order.

21 RECEIVER DRIER MANUAL & SEMIAUTO-HVAC 7C-21 KAA7C240 1 Condenser 2 Receiver Drier 3 Bolt N m (35-53 lb-in) 4 Bolt N m (44-71 lb-in) 5 Bracket

22 7C-22 MANUAL & SEMIAUTO-HVAC Removal & Installation Procedure 1. Disconnect the negative(-) terminal from the battery. 2. Discharge refrigerant from the system. Notice: By connecting a manifold gauge connection hose to High/Low pressure line, discharge the refrigerant. KAA7C Disconnect the inlet and outlet pipes of receiver drier. Notice: When installing, check the O-ring and apply the compressor oil. Installation Notice Tightening Torque 4-6 N m (35-53 lb-in) 4. Remove the bracket bolt and then remove the receiver drier. Installation Notice Tightening Torque 5-8 N m (44-71 lb-in) 5. Installation should follow the removal procedure in the reverse order.

23 AIR-CONDITIONER COMPRESSOR MANUAL & SEMIAUTO-HVAC 7C-23 KAA7C260 1 Compressor Bracket 2 High Pressure Hose 3 Low Pressure Hose 4 Compressor Removal & Installation Procedure 1. Disconnect the negative (-) terminal from the battery. 2. Discharge refrigerant from the system. Notice: By connecting a manifold gauge connection hose to High/Low pressure line, discharge the refrigerant. 3. Disconnect the high/low pressure pipe and wire connectors. KAA7C Remove the mounting bolt from the compressor bracket and remove compressor assembly. Notice: Place the removed compressor in vertical position. 5. Installation should follow the removal procedure in the reverse order. KAA7C280

24 7C-24 MANUAL & SEMIAUTO-HVAC HEATER AND AIR CONDITIONER CONTROL BOX KAA7C290 1 Blower Switch 2 Recirculation Switch 3 Mode Switch 4 A/C Switch 5 Temperature Control Lever 6 In-vehicle Sensor

25 MANUAL & SEMIAUTO-HVAC 7C-25 Removel & Installation Procedure 1. Remove the switch panel. Notice: Be careful not to damage the switch panel. 2. Remove the fixing screws (4 screws) of the control box. KAA7C Disconnect the wire connectors and remove the control box. 4. Installation is reverse order of the removal. KAA7C310 AIR FILTER Removal and Installation Procedures Replacement Interval Every 10,000 km Notice: Replace earlier if air pollution is heavy. 1. Open the glove box and pull it inward to release the upper left and right locking portion. Notice: Remove the glove box by unscrewing lower 2 screws, if necessary. KAA7D Press the 2 filter cover holds and remove the air filter cover. 3. Remove the 2 air filters. Notice: For installation, remember the installed direction of the air filter before removal. KAA7D140

FULL AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SECTION 7D FULL AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM FATC (Full Automatic Temperature Control) is full automatic heater and airconditioning system that detects