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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