HVAC Service

Training

Prepared by:
Mobile Climate Control

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 Table of Contents
I. Introduction
A. Principals of Refrigeration
B. General A/C Plumbing Schematic
C. Installation Schematic
D. System Electrical Schematics
E. Safety when Servicing an A/C System
II. System Components
A. Heater / Evaporator
1. Blower
2. Heater Coil
3. Evaporator Coil
4. Expansion Valve
5. Thermostat
B. Heater Valve
C. Condenser
D. Compressor
E. Control Panel
F. Receiver Drier
1. Pressure Switch
G. Hose Assembles

III. System Service and Maintenance

A. Service Guide
B. Troubleshooting
1. By Machine Operator
2. By Technician
3. A/C Service Record
4. A/C Charging Procedure
IV. Tools for Service
A. Basic field diagnostics kit.
B. Tools required by a full service dealer

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I. Introduction
Our purpose is to give you knowledge, and confidence in your ability to
work on offroad heating and air conditioning systems. Your working
speed and trouble shooting skills will improve with experience.

The purpose of a Heater/Air Conditioner is to provide comfort. Most

people feel comfortable between 70 to 80 degrees. The A/C system is
designed to turn itself on and off by the action of the thermostatic and or
pressure sensitive devices. This on and off action is what maintains a
comfortable temperature range for the driver.

The Air Conditioning Systems are relatively easy to understand. They are
a little different from most other mechanical systems. That is because it is
a closed (sealed) system and has to function under pressure to work
properly. You will become familiar with a few of natures laws that most
of us take for granted. These concern how heat really works and the
effects of pressure under different conditions.

In this manual we will be talking about air conditioning in general to give

you basic knowledge on how an A/C system works. We will break down
the components and talk in detail what each component does and how it
works in the A/C system. We will cover electrical requirement and
trouble shooting as well as the tools that will be required to work on an
A/C system.

Safety is very important to all of us. We will talk about safety in detail in
this manual. You will be handling engine coolant and air conditioning
refrigerant in your work. Both chemicals are safe to work with when used
correctly.

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I. Air Conditioning Basics
A. Principles of Refrigeration

A brief overview of the principals of refrigeration is necessary to relate

the function of the components, the technique of troubleshooting, and the
corrective action necessary to put the air conditioning unit into top
operating performance.

Too frequently the machine owner and HVAC technician overlook the
primary fact that no air conditioning system will function properly unless
it is operated within a completely controlled cab environment. Running
the machine with doors or windows open will usually result in a system
that has performance problems.

The circulation of air must be a directed flow. The cab interior must be
maintained for cleanliness. Dust, dirt, leaves and other debris can find its
way into the system and clog the intake side of the evaporator and destroy
the performance of the system.

Refrigeration – the act of cooling

1. There is no process known for producing cold; there is only heat
removal.
2. Heat is always attracted to cold objects. This principal is the basis for
the operation of an air conditioning unit. As long as the cold object
has a temperature lower then the heat source, this heat transfer will
occur.
3. Heat is a form of energy whose effect is produced by the acceleration
of molecules. When heat is added to a substance or brought into an
environment, the temperature increases. The heat of a machine’s
engine, the rays of the sun, the machine’s operator and a number of
other factors all quickly raise the temperature within the machine’s
cab.

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I. Air Conditioning Basics
A. Principles of Refrigeration (Continued)

4. All objects have a point at which they will turn into a vapor. Water
boiling is the most common example of the heating until vapor is
formed. Boiling is the rapid form of evaporation. Steam is a great
deal hotter then boiling water. The water will not increase in
temperature once brought to a boil. Heat energy is used in the
evaporation process.
5. Reversing the process, (removing heat from the water vapor) will
return it to the liquid state. Heat from air is attracted to a cooler object.
Usually the moisture from the air condense on the cooler object.
6. The boiling point of a liquid is directly affected by pressure. Water
boiling at high altitudes where the pressure is low has a hard time to be
heated enough to cook food, because it boils or vaporizes at a lower
temperature. Utilizing this pressure relationship scientifically is a
means by which the boiling point and temperature at which a vapor
will condense can be controlled. When a liquid is heated and
vaporized the gas will absorb heat without changing pressure.
7. Refrigerants such as R134a lend themselves to air conditioning
systems because of their low boiling point (-26.8 degrees C.) at normal
atmospheric pressures. If released into a room the refrigerant would
absorb heat from the air and immediately vaporize. This same basic
principal is at work in the air conditioning system. Liquid R134a is
released into the evaporator where warmer air is passed through. The
refrigerant evaporates and absorbs heat from the air, which in affect
gives you the cold air.

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I. Air Conditioning Basics

B. General A/C Plumbing Schematic

The air conditioning system refrigerant flow

In an air conditioning system the refrigerant is circulated under pressure

through five major components in a closed circuit. At these five points
in the system the refrigerant goes through pressure and temperature
changes.
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I. Air Conditioning Basics
B. General A/C Plumbing Schematic (Continued)
The air conditioning system refrigerant flow (Continued)
Refer to Plumbing Schematic
1. The compressor takes in low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates,
pressurizes the heat laden refrigerant and forces it through the
discharge valve (high pressure side) on to the condenser.
2. Ambient air passing through the condenser removes the heat from
refrigerant resulting in physical state change in the refrigerant from a
gas to a liquid.
3. The liquid refrigerant moves on to the receiver/drier where impurities
such as moisture and dirt are filtered out. The receiver/drier also
serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high-pressure flows) then flows to the
expansion valve.
4. The expansion valve meters the amount of refrigerant into the
evaporator coil. As the refrigerant passes through the expansion
valve, it again changes its physical state. It becomes a low
temperature, low- pressure liquid and saturated vapor. The low-
pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine’s cab is drawn or
blown into through the evaporator by the evaporator fan. Since the
refrigerant is colder then the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The
moisture in the air condenses on the evaporator coil and drips into the
drain pan, which directs the water out of the cab.
5. The refrigerant cycle is completed when the heated low-pressure gas
is again drawn into the compressor.

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I. Air Conditioning Basics
C. Installation Schematic

This schematic shows all of the components for an A/C and Heat system
and how they are connected in series to form the system. You can use
this as a guide for installing a system.

Please feel free to refer back to this schematic as we discuss each

component in detail thought this manual. 8
I. Air Conditioning Basics
D. System Electrical Schematic

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I. Air Conditioning Basics
E. Safety when Servicing an A/C
System.

In servicing A/C and heater systems you will be exposed to high

pressures, temperatures and several chemical hazards. Moving belts
and pulleys are normal shop hazards

In addition to exercising caution in your work, DO WEAR SAFETY

GLASSES OR A FACE SHIELD when you are using R-134a or a leak
detector, adjusting service valves or the manifold gage set connectors.
Safety glasses or a transparent face shield are practical safety items and
one or the other is absolutely required.

R-134a inside a canister or in an A/C system is a liquid under pressure.

When it escapes or releases into the air, ITS TEMPERATURE
DROPS TO 21.6 F DEGREES “INSTANTLY”. If it spills on your
skin or in your eyes you should flood the area with cool water and
SEEK MEDICAL ATTENTION FAST! It is a good idea to were
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gloves to prevent frost bite if you should get refrigerant on your hands.
 I. Air Conditioning Basics
E. Safety when Servicing an A/C
System.
Best Practices for safe handling of Refrigerant
R-134a refrigerant is a safe product when used and handled correctly.
Here are some safety tips to follow.
A. Store refrigerants in a clean,
dry area out of direct sunlight.
Never heat cylinders or small
cans of refrigerant above 125°F
(52°C). When exposed to these
high temperatures, the pressure
can increase dramatically and
cause the container to rupture.
B. Do Not store refrigerant
containers in your vehicle.
On hot, sunny days the
temperature in a parked vehicle
(passenger compartment and the trunk) can reach 150°F (65°C)
C. Never tamper with cylinder valves or pressure relief devices.
D. Never refill disposable cylinders with anything. Do not use
disposable refrigerant cylinders as compressed air tanks.
E. Wear protective clothing such as gloves and eye protection
when handling any refrigerant.
F. Avoid contact with liquid refrigerant because frostbite may
occur.
G. Avoid exposure to vapors through spills or leaks.
H. Evacuate the area if a large spill occurs. Return only after the
area has been properly ventilated.
I. Verify the cylinder is hooked properly to the changing
equipment before opening the valves.
J. Open cylinder valves slowly.
K. Avoid rough handling of refrigerant cylinders.
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L. Always ventilate the work area before using open flames.
II. System Components
A. Heater/Evaporator

The Evaporator / Heater Unit

Unit that delivers the cold air for A/C and warm air for heat into
the cab.
Unit contains the blower, heat & A/C coils, thermostat and
expansion valve.
The Evaporator / Heater unit is generally mounted inside the cab or just
outside the cab blowing air directly into the cab depending on how a
particular unit is designed to work. We will break down the
components that make up the Evaporator / Heater in the pages to
follow.

MCC has several units to choose from as well as the capability to

custom design a system for high volume orders.
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II. System Components
A. Heater/Evaporator
1.Blower

The blower is used to push or pull air through the heater and evaporator
coils and into the cab.

The operator controls the blower speeds with the fan switch or potentiometer
that is located on the control panel. The blower pulls the air from the outside
filter and the recirc filter.

MCC has several different blowers to choose from depending on how much
air flow is required in the cab.

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II. System Components
A. Heater/Evaporator
2. Heater Coil

Supplies warm air into the cab by passing air through the coil.
The Heater coil is pressure tested at 150 P.S.I.

The heater coil works similar to the evaporator coil in the fact that they
both are used to remove heat. The heater system is also a sealed system
that operates under pressure but the pressure is much lower than the air
conditioner.
A heater system uses engine coolant to carry excess heat energy to the cab
air. The water pump forces hot coolant through a hose from the engine
block to the heater coil and through the coil. Air blowing through the coil
removes the heat from the coolant and blows it into the cab.
The heat valve is used to control the amount of coolant that enters the coil
and is adjusted by the machine operator to there desired comfort level.

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II. System Components
A. Heater/Evaporator
3. Evaporator Coil

Removes the heat from the cab air and delivers cooled air to the cab
Evaporator coil is tested at 150 P.S.I.

The Evaporator cools and dehumidifies the air before it enters the cab. As
with the condenser there is a change of physical state in the evaporator. The
liquid refrigerant is dumped into the evaporator through the expansion valve.
The instant the low-pressure liquid is released into the evaporator it begins to
boil or evaporate into a vapor. The latent heat of evaporation is the heat
absorbed by the expanding refrigerant in the evaporation process.
Some liquid refrigerant must be supplied throughout the entire evaporator for
capacity of the evaporator. As the process of heat transfer from the air to the
evaporator takes place, any moisture in the air, condenses on the surface of
the evaporator coil and is drained off as drain water. 15
II. System Components
A. Heater/Evaporator
4. Expansion Valve

The Expansion Valve controls the amount of the refrigerant

entering the evaporator coil.

When refrigerant coming from the evaporator warms up, gas in the
diaphragm expands and unseats the metering valve to allow more
refrigerant to flow into the evaporator.
The expansion valve is located at the inlet of evaporator and provides the
function of controlling the liquid refrigerant to the evaporator coil. The
refrigerant flow is restricted creating a pressure drop across the valve.
The expansion valve separates the high-pressure side of the system from
the low-pressure side of the system. The state of the refrigerant entering
the expansion valve is a high-pressure liquid The refrigerant exits the
expansion valve as a low-pressure liquid. The valve controls the amount
of refrigerant into the coil by sensing the heat load on the coil. It senses
the super heat exiting the evaporator coil in the refrigerant gas and adjusts16
the refrigerant flow accordingly.
II. System Components
A. Heater/Evaporator
5. Thermostat

Controls the temperature of the evaporator coil. Acts to prevent icing in

the evaporator coil

The Thermostat is used to control the operation of the electromagnetic clutch

on the compressor. The thermostat serves a temperature control and prevents
the evaporator from freezing. The thermostat has a sensing devise that is
inserted into the fins of the evaporator coil. When the coil is warm the switch
is on and there is power to the clutch. When the coil is cold and senses
temperatures that could cause the drain water to freeze, the switch is off and
the clutch is disengaged.
The thermostat generally is designed to kick out around 30-32° F, and kick in
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around 35-37° F.
II. System Components
B. Heater Valve

The Heater Valve is used to control the amount of engine coolant that
flows to the heater coil.

The machine operator controls the valve with a cable or a potentiometer on

the control panel.
The cable or potentiometer and heat valve act as temperature control. If the
A/C switch is on the potentiometer can be adjusted the temperature to the
desired setting.
The valve can be opened while the A/C is running to achieve defrost of the
windows in the cab. So be sure the controls are turned all the way to the left
or the blue side of the decal to get the optimum performance from the Air
Conditioner. As it is turned more towards the red more hot engine coolant
will be directed to the heater coil.
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II. System Components
C. Condenser

Removes the heat picked up at the evaporator.

The Condenser receives the high pressure, high temperature refrigerant vapor
from the compressor and condenses it into a high temperature liquid.
Condensing of the refrigerant is the change of state of the refrigerant from a
vapor to a liquid. The action is affected by the pressure of the refrigerant in
the condenser coil and the air flow through the condenser. Condensing
pressure in the system is the controlled pressure of the refrigerant, which
affects the temperature at which it condenses to a liquid, giving off a large
amount heat in the process. The condensing point is high to create a wide
temperature differential between the hot refrigerant vapor and the air passing
over the condenser’s fins and tubes. This temperature difference allows rapid
heat transfer from the refrigerant to the air.

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II. System Components
C. Condenser (Continued)

A radiator mount condenser can mounted in front of the radiator and utilizes
the radiator fan to move the air through the coil. The radiator mount
condenser can be used when the machine has a suction fan pulling air from
the outside into the machine. It is important to note that when installing the
condenser on the radiator the condenser face must have the ambient outside
air temperature pass through this first before going through the radiator or oil
coolers.
If the machine will not allow a radiator mount condenser, an Electric
Condenser can be used. Electric Condensers use electric fans in a self
contained unit to move air through the condenser coil.

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II. System Components
D. Compressor

The Compressor is the pump that circulates refrigerant throughout the

system.

It raises the pressure of the refrigerant for heat transfer through the
condenser and evaporator.
To create high pressure, the compressor’s pistons draw in refrigerant through
the suction valve and force it out through the discharge valve. With the
piston on the down side, the suction valve is opened to allow low-pressure
gas to enter. With the piston in the upstroke, the refrigerant is forced
through the discharge valve, which divides the high-pressure side of the
system from the low-pressure side of the system.

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II. System Components
E. Control Panel

The Control Panel has three separate components.

The Fan Switch - This can be a 4 position rotary switch which are off, 1, 2,
& 3. It could also be a potentiometer with 270° of rotation from off to fully
on. When the fan switch is in the off position the A/C will not engage. But the
heat valve will operate, it is controlled by the ignition power.

The Heater Control - This controls the Heat Valve. It can be a manual cable
or a potentiometer. This can be used in conjunction with the A/C for defrost
of the windows and temperature control.

The A/C Switch - This is a lighted rocker switch that illuminates when the
A/C is engaged. It sends a signal to the compressor clutch through the
thermostat and pressure switch.
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II. System Components
F. Receiver/Drier

The Receiver/Drier serves a couple of functions in the air conditioning

system.
It receives the liquid refrigerant from the condenser and removes
moisture and foreign matter from the system.
The receiver/drier also stores extra refrigerant until needed by the
evaporator.
The sight glass can be used to determine if the system is low on refrigerant. If
bubbles are present in the sight glass, it is likely that the system is low on
refrigerant.
It is recommended that the drier be replaced if a system is opened for service.
*Please make note of the flow through the drier. It is very important that
the drier be hooked up properly. Both fittings on the drier are the same size so
the hoses could be hooked up incorrectly causing the oil in the system to
accumulate in the drier and in turn cause compressor failure due to the
bearings drying up.
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II. System Components
F. Receiver/Drier
1. Pressure Switch

Will disengage the compressor clutch at high pressure reading of 384

psi.

Will not allow the compressor clutch to engage at low pressure reading
of 28 psi on the high side.

The pressure switch is generally located on the drier assembly. It is threaded

onto a shreader valve so if it would ever need to be replaced, it is sealed with
a valve to prevent the loss of refrigerant charge.

The pressure switch is a safety device used to protect the A/C compressor if
the system should run too high or lose refrigerant. It is connected in line to
the power going to the clutch and is designed to cut the power if the pressure
runs over 384 psi on the high side or if it senses very low pressure (28 psi )
on the high side, which generally indicates loss of refrigerant.
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II. System Components
G. Hose Assemblies

MCC uses a Nylon Barrier hose. The hoses are rated for over 2000 psi
burst, and have bead lock style couplings crimped with triple bubble dies.

MCC uses all steel fittings for better durability. All hoses are supplied with
the O-ring seals and dust caps for protecting the system from contaminates.
When installing be sure to check for the O-ring to insure a proper seal.

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 III. System Service and Maintenance
A. Service Guidelines
General Air Conditioning Service Guidelines
Routine maintenance such as cleaning filters and checking the compressor belt
tension are routine procedures that the machine operator should be able to
handle. However, only trained HVAC technicians should perform air conditioning
service for mobile equipment. Proper HVAC tools and equipment is an absolute
necessity to ensure the service is done correctly.

Along with using a trained HVAC technician, there are several simple service rules that should
be followed during an initial installation or during service work.

Compressor Oil Charge – This is often a topic of many opinions. Generally there is
enough oil charge in the compressor to handle a system with a refrigerant charge
of around 3 lbs. The compressor is filled with PAG oil (Poly Alkelene Glycol).

To retain a valid warranty on the compressor, Seltec ZXL 100 PAG oil should only
be used. Add the oil at the suction port on the compressor prior to vacuuming the
system, or use the automatic oil injector found on most refrigerant charging stations.

Component Replacement and Refrigeration Leaks – The other instance when oil
may need to be added to the system is when there is a refrigerant leak or when
the evaporator, condenser or receiver drier needs to be replaced. When one of
these components is replaced, 1 ounce of oil should be added for each
component replaced.

If there is a refrigerant leak, the system should have the remaining refrigerant
evacuated. The best way to determine where the leak is located is to charge the system
with dry nitrogen. Use a spray bottle filled with soap and water to spray on all of the
connections to find where the leak is occurring. Most charging stations also have the
ability to inject leak detection fluid and then use a light or sniffer to determine where the
leak is.

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III. System Service and Maintenance
A. Service Guidelines
General Air Conditioning Service Guidelines

Once the leak is found replace the bad connection. Also, whenever the system is opened
to the atmosphere or there has been a leak in the system, the receiver/drier must be
changed.

Generally the air conditioning system is very sensitive to any contaminants or non-
compressibles, such as dirt and moisture. Extra care is required when installing or servicing
the air conditioning system to eliminate the possibility of contaminants entering the system.

Never leave hose fittings, compressor fittings or the components uncapped. Dirt and
moisture will harm the system performance very quickly and this is the number one cause of
compressor failure. Most compressor failures never receive warranty due to contamination in
the system.

When installing or servicing air conditioning components only new or properly cleaned
components should be used. Before charging the system with refrigerant, the system
should be pulled into a vacuum for a minimum of 45 minutes. This will allow for any
moisture in the system to be removed.

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III. System Service and Maintenance
B. Troubleshooting
1. By Machine Operator

SYSTEM TROUBLESHOOTING FOR MACHINE OPERATOR

Regular Maintenance by Machine Operator

The fresh air filter must be cleaned sometimes as often as twice a day, depending on the operating
environment. The filter can be cleaned by removing and shaking it. A small amount of air pressure can be
used to clean the filter. However the fresh air filter should changed at least 2-4 times per year in normal
off road conditions. In extremely dusty conditions the fresh air filter may need to be changed weekly.

The recirculation air filter is made of open cell foam and should be cleaned with water. A
mild detergent may also be used. It does not require cleaning as frequently as the fresh
air intake filter.

The A/C system is recommended to be turned on for at least 5 minutes weekly throughout the year to
lubricate the internal components.

Inspect the sight glass on the Receiver Drier (RD) weekly, or if the A/C system does not perform to its
fullest capacity. Bubbles indicate that the system is due for recharging. This occurs approximately every
second year. If the RD is equipped with a moisture indicator, make sure the color is blue (OK). If beige,
the system needs to be recharged and refrigeration oil replaced.

It is a good rule to regularly inspect (weekly) the compressor drive belt tension and wear. The condenser
should be kept clean and should be checked frequently.

Basic Troubleshooting Procedure by Machine Operator

How cold is the louver temperature at 85 degrees F.?
Run the machine for 15 minutes. The louver temperature should be between 36-53 degrees F. depending
on the amount of humidity in the air.

Is there any noise from the blower motor?

If the fan motor is noisy or does not operate correctly, replace the motor or the blower.

Has mud or dirt adhered to the condenser?

Remove any mud and dirt since this drastically reduces heat radiation.
Check airflow direction through the condenser.
Do not scratch or bend the condenser fins.
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III. System Service and Maintenance
B. Troubleshooting
1. By Machine Operator

SYSTEM TROUBLESHOOTING FOR MACHINE OPERATOR

Basic Troubleshooting by Machine Operator

Is the compressor clutch engaging when A/C switch is on?

Note: Look at the center of compressor clutch to make sure it is spinning with the pulley.
If not: Check fuse on the machine for A/C system.
Check for power to the clutch – If no power:
Check for power into pressure switch There should be no resistance across the switch
If power is found - Call for service, the system is probably out of refrigerant.
If no power:
Check the Thermostat
Check the sensor by measuring the resistance. At 68degF (20degC) the resistance should be 10 Ohm.
If OK:
If power in but no power out, replace thermostat.
If no power in:
Check A/C switch to see if power in and out to thermostat.
If power in but no power out, replace switch. There should be no resistance across the switch
If no power in:
Check blower switch to see if power in and out.
If power in but not out, replace blower switch. There should be no resistance across the switch
If no power in:
Check fuse again.
Note!
For Heater check
If Heat Valve does not open or close:
Check potentiometer for resistance of 10 Ohm.

Is there any noise from a loose compressor drive belt?

A loose or worn drive belt makes various squeaking and slapping noises. If such noises are heard, check
and adjust the drive belt tension. Replace drive belt if it is worn.

Is there any noise from the compressor area?

Check the compressor and bracket for loose bolts and tighten them if necessary.

Is there any noise from the compressor?

Suction/Discharge valve damage and internal wear are possible sources of noise from within the
compressor.

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III. System Service and Maintenance
B. Troubleshooting
1. By Machine Operator

SYSTEM TROUBLESHOOTING FOR MACHINE OPERATOR

Basic Troubleshooting by Machine Operator

Is there any compressor oil contamination on hose fittings or around the compressor?
Oil contamination at such places indicates that refrigerant from the system is leaking together with
compressor oil. If oil contamination is discovered, check for leaks using a leak detector and replace parts
as necessary. Carefully check the compressor gaskets, O-rings and shaft seals.

Is engine coolant bypassing the heater valve?

Check to see if the heater line into the heater coil is warm or hot. If it is this suggests that the heater
valve is leaking.

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III. System Service and Maintenance
B. Troubleshooting
1. By Machine Operator

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 III. System Service and Maintenance
B. Troubleshooting
2. By Technician

SYSTEM TROUBLESHOOTING CHART

Blower motor does not operate

Possible Cause Inspection Solution
1. Blown Fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or Check the fan motor ground and connectors. Repair the wiring or
bad connection. connector.
3. Fan motor Check the lead wires from the motor with a Replace Motor.
malfunction. Circuit tester.
4. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient
Possible Cause Inspection Solution
1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction. Clean evaporator fins with air
or water.
2. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
Insufficient cooling although air flow and compressor operation are normal
Possible Cause Inspection Solution
1. System low on The high side pressure will be low and Repair any leaks and
refrigerant. bubbles may be present in sight glass on recharge the refrigerant to
receiver drier. the correct level.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
The compressor does not operate at all, or operates improperly
Possible Cause Inspection Solution
1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt Replace compressor.
malfunction. slips.

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 III. System Service and Maintenance
B. Troubleshooting
2. By Technician

SYSTEM TROUBLESHOOTING CHART

Magnetic clutch related

3. Low battery Clutch slips. Recharge the battery.
voltage.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch Clutch slips. Replace or clean the clutch
surface. surface.
6. Open oil. Clutch does not engage and there is not Replace clutch.
reading when a circuit tester is connected
between the coil and terminals.
7. Broken wiring or Clutch will not engage. Inspect the ground Repair.
poor ground. and connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation.
components. thermostat, Relay, etc,

GAUGE PRESSURE RELATED TROUBLESHOOTING

Normal compressor suction (low side) and discharge (high side) pressures at ambient temperatures of 86-96
degrees F (30-38 degrees C) and compressor speed of approximately 3300 rpm are:
High pressure side pressure: 210-300 psi
Low pressure side pressure: 15-33 psi
As a rule of thumb the high side pressure will be around 8 times greater then the low side pressure.

Possible Cause Inspection Solution

Low pressure side The low pressure side pressure normally
Too high. becomes too high when the high pressure
side pressure is too high. As this is
explained below, the following inspection is
only used when the low pressure side is too
high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective The high and low pressure side gauge Replace compressor.
compressor. pressures equalize when the magnetic
clutch is disengaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and Repair any leaks and
charge. bubbles may be present in sight glass on recharge the refrigerant to
receiver drier. the correct level.

33
 III. System Service and Maintenance
B. Troubleshooting
2. By Technician

SYSTEM TROUBLESHOOTING CHART

3. Restriction Frost on the line between drier and Flush system or replace
between drier and expansion valve. A negative low pressure hose.
expansion valve. reading may be shown.
4. Thermostat The evaporator is frozen. Adjust probe
malfunction Placement or replace
Thermostat.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Clean fins
performance
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. Above 325 P.S.I. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil The high pressure side will be high. Evacuate system. Remove
charge. oil from condenser and
compressor. Measure oil
from compressor and add
correct oil charge back into
compressor. Flush system
with nitrogen. Replace drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
Refrigerant
5. Restriction in drier, High pressure side will be high, and low Evacuate and flush system
condenser or high pressure side will be low. replacing defective parts.
pressure line.
High pressure side
Too low
1. Low refrigerant The high side pressure will be low and Repair any leaks and
charge. bubbles may be present in sight glass on recharge the refrigerant to
receiver drier. the correct level.
System pressures
Equal
1. Clutch not See magnetic clutch related topics above.
operating.
2. Compressor not Equal high and low pressures. Replace compressor
pumping.

Operation to Return Oil to Compressor

1. Open All doors and windows
2. Turn A/C fan on high 34
3. Run machine at Idle for 20 minutes
III. System Service and Maintenance
B. Troubleshooting
2. By Technician
Normal Evaporator Range Normal Condensing Range
Off Coil Air Temp PSI Outside Air Temp PSI
26 15.69 53 110.20
28 17.04 54 112.10
30 18.43 55 114.10
32 19.87 60 124.30
34 21.35 62 128.50
36 22.88 64 132.90
38 24.47 66 137.30
40 26.10 68 141.90
42 27.79 70 146.50
44 29.52 72 151.30
46 31.32 74 156.10
48 33.17 76 161.10
50 35.07 78 166.10
52 37.03 80 171.30
54 39.05 82 176.60
55 40.09 84 182.00
60 45.48 86 187.50
65 51.27 88 193.10
70 57.47 90 198.90
75 64.10 95 213.70
80 71.19 100 229.40
85 78.75 105 245.80
90 86.80 110 263.00
95 95.40 115 281.10
100 104.40 120 300.10
101 106.30 125 320.00
102 108.20 130 340.80

Range shown in BOLD

35
III. System Service and Maintenance
B. Troubleshooting
3. A/C Service Record
AIR CONDITIONING SERVICE REPORT
Service Company/Phone Number:
Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Explain services required:

Post Service Conditions 15 minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature into Condenser
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

36
III. System Service and Maintenance
B. Troubleshooting
4. A/C Charging Procedure

Charging Procedure
1. Check to see that the hand valves are closed on the manifold gage set.
2. Connect the gage set to the charge ports on the system. Red hose on
high side, blue to low side.
3. Connect the yellow hose to the vacuum pump.
4. Start the vacuum and open both hand valves on the gage set
5. Run the vacuum for 45min to ensure the moisture is boiled out of
the system.
6. Close hand valves and turn off the vacuum pump. Take note of the
vacuum pressure indicated on the low pressure gage. Let stand for 5-
10 min. and recheck the pressure to see if it has changed.
7. If the pressure drops slightly and then stabilizes there is some air in the
system continue to vacuum until air is removed. If the pressure
continues to fall there is a definite leak. Check all fittings and O-rings
and return to step 4. 37
III. System Service and Maintenance
B. Troubleshooting
4. A/C Charging Procedure

8. If the pressure stays the same remove the vacuum pump and attach the
refrigerant container to the yellow hose.
9. Place the refrigerant container on a charging scale for predetermined
charge amount and zero the scale.
10. Open the valve on the refrigerant container and open the low pressure
hand valve on the manifold gage set. Allow the vacuum to pull in the
refrigerant until the pressure stabilizes.
11. Start the engine and turn on the A/C with the fan on high. Watch the
scale until predetermined amount is reached.
12. Turn off the valve on the container and turn off the hand valve on the
gage set.
13. Turn off the engine and remove charging equipment.

38
IV. Tools For Service
A. Basic Field Diagnostic Kit

The basic air conditioner and heater service tools include some special
tools and test equipment as well as your normal tool chest items. We will
describe and explain the use of basic tools, test and other equipment and
safety. Some of the special equipment described is expensive but often
justified in a busy shop.
TOOLS FOR BASIC SERVICE
R134a Dispensing Valves ( larger R134a containers contain valves )
Manifold Gage Set ( including hoses )
Charge Scale ( for bulk containers )
Vacuum Pump - 3 CFM Free Air Displacement of Higher
Leak Detector - Electronic or Black light with dye
Thermometer
Safety Glasses
Fin Comb

39
IV. Tools For Service
A. Basic Field Diagnostic Kit
R134a Dispensing Valves
A dispensing valve is used to release R134a from its container. The large
bulk refrigerant containers have there own dispensing valve. Bulk
containers should always be used with a scale or charging station capable
of measuring the amount of refrigerant you put into a system.
CAUTION : All containers are under pressure. Any heat will increase the
pressure. The containers are not designed to with stand excessive heat even
when empty, and they should never be exposed to high heat or flame
because they can explode. A small can dispensing valve assembly has the
means to pierce a hole in the can and allow the refrigerant to flow through
the valve. It is very important to fasten the valve securely to the container
before piercing.
We will describe the use of the charging scale or charging station later in
this section.
Manifold Gage Set
The manifold gage set is a tool used for internal system diagnosis and
service. A typical manifold has two screw type hand valves to control
access to the system, two gages and three hoses. The gages are used to
read system pressure and vacuum. The manifold and hoses are for access
to the inside of the system, to remove air and moisture and to put in or
remove refrigerant.
Two hoses connect to the low and high sides of the system. The center
hose is used to remove air and moisture when connected to the vacuum
pump, or add refrigerant when connected to the dispensing valve. Gages
are calibrated for either high or low pressure and vacuum. The term
compound gage set is often used because the low pressure gage responds to
pressure and vacuum.
Most manifold gage sets are color coded. The red is for high and blue for
low pressure. Yellow is used for the center hose connects to the vacuum
pump or refrigerant source.
The gage set is a calibrated tool and should be handled with care to ensure
proper readings.
40
IV. Tools For Service
A. Basic Field Diagnostic Kit
CAUTION : Never attempt to hook up the gage set with the engine
running. Never attempt to hook up the gage set until you have checked to
be sure the hand valves on the gage set are closed.
Vacuum Pumps
Air and moisture inside an air conditioner contaminate the system. They
combine with R134a and refrigerant oil to form acid and sludge. Moisture
inside a system can freeze the expansion valve orifice, blocking the flow of
refrigerant temporarily. The result is erratic system function. A vacuum
pump is used to remove air and moisture form inside the hoses and
components of the air conditioner.
When the vacuum pump is hooked up to the system through the manifold
gage set ( and the service valves are open ), the pump sucks air out. The
result is a negative pressure or vacuum. The air is removed quickly, in just
a few minutes. However, the humidity in the air may condense inside the
system and this moisture must be removed.
Moisture will vaporize in a vacuum when a sufficient vacuum level is
reached. ( -30 Inches of mercury ) Vacuum level is measured in inches of
mercury. The vacuum pump must operate long enough to cause any
condensed moisture inside to vaporize so the pump can suck it out of the
system. It is recommended that a vacuum pump operate for a minimum of
45 minutes to ensure that all moisture has been removed.
Leak Detectors
Electronic leak detectors have a probe that is moved around the A/C
system. Where R134a is present, a change in current flow inside the probe
is sensed by an electrical circuit. This activates a buzzer to signal the user
about the presence of an R134a leak. These detectors will detect a leak as
small as 1/2 ounce per year. Also a black light could be used to find a leak.
Dye is installed in the Bobcat A/C system at the factory which can be seen
at the leak point with a black light.
Charging Scales
Earlier we mentioned scales or charging meters and charging stations.
They are all designed to provide an accurate measure of the R134a you use
charging the A/C system. The more expensive charging stations can
combine several tools into one machine. When using a charging station be
sure to read the manual for the station. There are several different 41
charging stations that all work slightly different.
IV. Tools For Service
B. Tools for Full Service Dealer

TOOLS FOR FULL SERVICE

R134a Recovery & Recharge Station
Complete Set of Wrenches
Leak Detector - Electronic or Black Light and Dye
Thermometer
Safety Glasses
Fin Comb

42