General ServiceBulletins Aurora

No.
Page
Technical Information 912-100-0078 1/4
Filling and extracting of air conditioning systems
The unit has to be cleaned with dried nitrogen and to be checked on leaks. The cleaning serves
for the dehumidification of the unit.
After that, the unit must be evacuated in order to achieve a reduction of the foreign gases to
less than 2 Vol-%. At the evacuation, the pressure measured in the unit should be at < 20
mbar. It should be considered that there is no risk of a contamination of the air conditioning
system with oil from the vaccuum pump.
Equipment:
- Filling station, e.g. FSV 102 AX (maker: Kälte Fischer)
- Extraction station, e.g. FAST 6x (maker: Kälte Fischer)
- Refrigerant bottles
- Recycling bottles
- Fan heater
- Leak detector
- Service cable for optional installed magnetic valves
1. Extraction of system (in case the unit is filled)
- Connect recycling bottle to pressure side

- Connect suction side to Schrader valve between low and high pressure valves
- Open valve on recycling bottle (Caution, the red one!!)
- Switch on extraction station
- Open low and high pressure valve
- Wait about 3 hours
- Close low and high pressure valve
- Close valve on recycling bottle
- Switch off extraction station
- Remove suction side from Schrader valve
- If possible: Leave recycling bottle connected to pressure side because of the refrigerant
in the lines.
Advice: Allow blower to run when extracting, otherwise condensation may form in the heat
exchanger.
- we reserve the right to make technical modifications -
prepared: 14.07.98 by KH checked: 22.10.02 MM Released: 23.10.02 W.Le
date/name date/name date/name

a) 8314 22.10.02 KH b c d
Status: 22.10.02
No. Page
2. Evacuating the system
CAUTION:
To ensure that the magnetic valves are open at the
evacuation and filling of units with nonreturn valves
and magntic valves* it is necessary to provide the
magnetic valves with the necessary voltage (12V/24V).
* Installing method see diagram on page 3.
- Fit high and low pressure hoses to the service valves

- Open stopcock on service adapter
!! ensure correct turning direction !!
- Switch on vacuum pump
- Open valve between vacuum pump and vacuum gauge
- Open valve between vacuum gauge and low/high pressure valves
- evacuate at least 20 minutes
- search for large leaks
- Close valve between vacuum pump and vacuum gauge
- Switch off vacuum pump and check that the vaccum is stable
The gauge must only climb slowly -> system probably has no leaks
wait at least 5 minutes
If manometer rises check refrigerant connections and adjust if necessary
- Switch on vacuum pump
- Open valve again
- Evacuate after about 25 minutes
- Close valve between vacuum gauge and low/high pressure valves
- Close valve between vacuum pump and vacuum gauge
- Switch off vacuum pump
Status: 22.10.02
No. Page
Diagram showing refrigerant cycle of a unit with magnetic valves and

nonreturn valves:
* To provide the magnetic valves remove the protection housing of the magnetic coil
and apply the corresponding voltage on PIN 1 and PIN 2.
In the diagram is shown only one magnetic valve and one nonreturn valve.
In the units can be installed 2 magnetic valves and 2 nonreturn valves.
Status: 22.10.02
No. Page
3. Filling station: Filling the filling cylinder:
- Connect refrigerant bottle to filling cylinder

- Open valve on refrigerant bottle
- Heat refrigerant bottle with fan heater
- Open valve on filling cylinder
- Allow the required filling quantity to flow in
- Close both valves and switch off fan heater
Warning: Filling level depends on pressure
4. Filling the system
- Break vacuum
- Open valve for gaseous filling (at top of filling cylinder)
- Check refrigerant hose connections with leak detector
- If leaks are found, see evacuation of system; close valve again
- Wait about 5 mins.
- Close valve again
- Close high/low pressure valve !!!
- Start up air conditioning system
- Open valve for liquid filling (at bottom of cylinder)
- Open low pressure valve
- Fill with about 200 g
- Close filling valve
- Close low pressure valve
- Wait about 3 mins.
- Repeat this procedure as often as is necessary until the system is filled with the
required filling quantity.
5. Function check
Status: 22.10.02
no. page
Electronic Thermostat HCC, 12/24V

(Heating and Cooling Controller)
part no.:
412-310-0035 Electr. Thermostat with output 2 A for solenoid valve and relay
412-310-0035a Electr. Thermostat with reheat-function
412-310-0035b Electr. Thermostat with internal air sensor
412-310-0025 temperature sensor for HCC (separate)
1 Application
1.1 Controlling of temperature
1.2 Stepless control of air-flaps or water valves
2 Functional description
3 Technical data
4 Functional scheme
5 Reheat function
6 HCC with internal air sensor
AURORA
Konrad G. Schulz GmbH & Co.KG
Südring 4
D-69427 Mudau
Tel.: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com
Technical modifications reserved
estabilished: 23.03.04 KH checked: 05.02.07 Re released: 07.02.07 W.Le

a) 10188 10.01.05 KH d g j
b) 12037 07.11.06 KH e h k
c) 12367 31.01.07 KH f i l
no. page
1. Application
1.1 Controlling of temperature
The HCC can be used to control the air-outlet temperature of Frontboxes in busses. It can also be
used to control the air-outlet temperature of heating or AC-Systems for cabins.
Therefore the HCC controls a water valve (heating mode) or a solenoid valve/clutch (cooling-mode)
The air outlet temperature is measured with a sensor.
By an additional input it is possible to open the water valve 100%. So comfort-functions like defrost
or reheat can be controlled by HCC. This additional input makes it also possible to connect a pre-
heating-system to HCC.
1.2 Stepless control of air-flaps or water valves
If the temperature sensor is not connected the AURORA HCC can be used as a infinitely variable
actuator for actuation motors Bosch VMC II. The actuation of the motor is commensurate to the ac-
tuation angle on the potentiometer.
2. Functional description:
AURORA HCC
control-panel with AC-

switch and potentiometer
temperature sensor for temperature-setting
for air outlet /internal
air temperature
water valve for

heating circuit
solenoid valve
no. page
AC-switch "ON":
cooling mode:
In cooling mode the HCC closes the watervalve. The HCC controls the air-outlet temperature by
switching the solenoid valve / clutch on or off.
The temperature range is between + 5 °C and + 25 °C. This range is programmable and can so be
adapted to various applications.
AC-switch "OFF" or not connected:
Heating mode:
In heating mode the HCC controls the air-outlet temperature by the watervalve.
The temperature range ist between + 15 °C and + 60 °C. This range is programmable and can so be
adapted to various applications.
Temperature sensor NTC 10 kOhm
The air outlet temperature is measured with the sensor 412-310-0025.

The sensor has to be used with the electronical Thermostat HCC 412-310-0035a/b.
no. page
3. Technical Data
Voltage supply: 8 to 32 VDC

stand by current < 20 mA
Inputs: NTC-temperature sensor 10 kOhm

potentiometer 0-10 kOhm (0-5 VDC)
AC-switch (mode-selection)
water valve 100% (defrost/reheat function or adaption of preheating
system)
Outputs: Actuation motor Bosch VMC II; calibration at every start up

Solenoid valve 2 A (or relay)
Features: microprozessor based

valve curve programmable
temperature-ranges programmable
hysteresis programmable
protection against vibration (epoxy-resin filling)
Dimensions : length: 90 mm
depth: 60 mm
height: 30 mm
EMC: conform to: 89/336/EEG

2006/28/EC
no. page
4. Functional scheme
5. Reheat-function
In cooling mode the HCC 412-310-0035 closes the watervalve.

Therefor the HCC 412-310-0035a has a additional reheat-function.
If power supply AC (pin 5) as well as power supply water valve (pin 3) are applied, the air conditio-
ning unit and the water valve can be used at the same time.
6. HCC with internal air sensor
The HCC 412-310-0035b is designed for an internal air sensor. The functions without the sensor are
the same as HCC 412-310-0035a.
Important: The position of the sensor has to be always in the air flow.
Temperature range: 18°C - 28°C
no. page
Condenser unit cpl. 24V TF
part no: 175-TX2-0001 (no longer available)

175-TX2-0002 (with anti-icing thermostat)
1 Safety advises
2 Construction of the condenser unit

2.1 Condenser
2.2 Condenser blower
2.3 Receiver drier
2.4 Pressure switch
3 Mounting advises
4 Connection to the refrigerant circuit
5 Electrical connection
6 Maintenance
7 Spare parts
8 Fault diagnosis
AURORA
Südring 4
D-69427 Mudau
Tel.: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com
author: 16.08.04 KH checked: 23.07.07 MK approved: 23.07.07 W.Le

a) 10379 13.07.05 KH d) 11293 10.05.06 KH g j
b) 10676 15.07.05 KH e) 12770 19.07.07 KH h k
c) 11282 16.02.06 KH f i l
no. page
1 Safety advises Maintenance work on the refrigeration

circuit:
Please note the following information
for your own safety. • The unit must always be emptied before
any work is carried out on the refrig-
In general you should note the following eration circuit. This may only be done
advice: by specialist personnel.
• Make sure that maintenance and repair • Only refrigerant R134a according to DIN
work is only carried out by specialised 8960 and/or safety data sheet according
and authorised personnel. 91/155/EWG must be used.
• Do not reach into the unit and never • Please follow the safety data sheet for
stick objects into the condenser blowers. refrigerant R134a.
• Only carry out maintenance work when • Do not discharge refrigerant to the en-
the engine is stationary. vironment.
• Attention! Danger of burning! Please • Liquid refrigerant must not come into
do not get into contact with the con- contact with the skin.
denser and the connections. Refrigerant • Safety glasses must be worn when
tubes and hoses can be hot and stand handling refrigerants.
under pressure. Be careful by touching
them. CAUTION! Risk of explosion!
• At maintenance work and repairs wear • Never carry out soldering or welding
necessary protective clothing. work directly on parts in the closed re-
frigeration circuit or in its vicinity. Due to
Advice for installation and maintenance the strong heating effect the pressure
work: will increase within the unit giving a risk
Please pay attention to the rules for the of explosion.
prevention of accidents. • Refrigerant bottles must never be
thrown around or subjected to lengthy
periods of sunshine or other heat
sources when filled. The highest per-
mitted temperature of a filled refrigerant
bottle must not exceed 45°C.
CAUTION! Risk of contamination!
• It is essential that the refrigeration sys-
tem is kept free from chlorine and sub-
stances containing chlorine, as well as
oils and greases. Consequentially it is
necessary to invest in separate evacua-
tion and filling systems which are exclu-
sively used for R134a.
no. page
2 Construction of the condenser unit:
The condenser unit consists of an condenser and a sheet with three axial blowers and a re-
ceiver drier with pressure switch.
The condenser unit is exclusive working with refrigerant R134a.
Condenser unit 175-TX2-0001 has only one plug at the cable set.
Condenser unit 175-TX2-0002 has an additional thermostat for icing protection and 2 cable
set plugs (a plug for blower and a plug for pressure switch and thermostat).
The thermostat prevent the start of A/C-Unit if the temperature less than nearly 2°C.
2.1 Condenser 2.2 Condenser blower
The compressed refrigerant is condensed The 3 condenser axial blower sucks the air
in the condenser, the refrigerant passes from the bottom up through the condenser.
from the gaseous to the liquid state. The air takes the heat of the refrigerant.
The liquid refrigerant leaves the condenser. The gaseous refrigerant is cooled and con-
The capacity of the condenser is essen- densed.
tially influenced by the air flow quantity and
air temperature. The most favourable air
temperature is that of the direct outside air.
The condenser consists of a serpent coil
and fins so as to create the greatest possi-
ble cooling surface. The fins are attached
solidly to the tubes to achieve good heat
transfer.
no. page
2.3 Receiver drier 2.4 Pressure switch, 2-poles
The receiver drier serves as an expansion On the receiver drier there is a pressure
vessel as well as a storage container for switch to protect the compressor and avoid
the refrigerant. consequential damage on the air condi-
The drier can chemically bind a small tioning unit..
amount of water and thus remove it from To protect the compressor the pressure
the circuit. switch will switch off the electromagnetic
clutch if the condenser pressure cross over
If there are signs of rust or a coating on the or under the following values (atmospheric
sight glass the liquid tank should be ex- overpressure):
changed.
OFF ON
Caution: The drier should be replaced fol-
lowing any intervention in the refrigeration low <1,8 bar >2,5 bar
circuit, but however no later than every two pressure
years. high 22 ± 2 bar 14 ± 2 bar
pressure
If the system has to be opened several times
for a repair the receiver drier only needs to
be renewed once.
CAUTION
Do not leave a new receiver drier open or it
will become unusable due to the air humid-
ity.
3 Mounting advises 4 Connection to the refrigerant cir-

cuit
Caution! Please pay attention to the safety
advises (chapter 1) Inlet condenser:
3/4“-16UNF, male thread
The fan sheet has 2 plates with slotted
holes 12x9 mm for the mounting of the Outlet receiver drier:
condenser unit to the steel cover frame. 5/8“-18UNF. male thread
Please note: Installation work shall only

carried out by qualified specialist. Please note: The condenser is filled with
an inert gas. After removal of the protective
caps the inert gas must audibly escape
no. page
Please note:
Please check the inert gas filling during Because of safety reasons during mainte-
installation. If there is no inert gas filling, nance work on the refrigerant cycle we
the condenser unit has to be handled with recommend to set a label with the following
care and checked of leakage. A leakage of text: „Caution! unit is under pressure! Re-
the component is possible. frigerant R134a“ on a visible place into the
In general a leakage control has to be vehicle.
made after filling the unit with refrigerant.
5 Electrical connection
Please note: Do installation work only in a

voltage-free state.
175-TX2-0001: 175-TX2-0002:
no. page
6 Maintenance State of heating hoses and refrigerant

hoses
CAUTION: Check of the fixing, leak control and laying
Please pay attention to the security ad- of the hoses and fittings. The hose fixings
vice (chapter 1) during all maintenance are to be tightened if necessary.
work.
Electric
Maintenance work is only carried out by
Check electric connection pipes and plug
wellinformed and authorised personnel.
connections on correct state and firm posi-
Please pay attention to the tion.
rules for the prevention of acci-
dents. State of the condenser
Unscrew and remove the cover for the
When the weather is damp or if it is raining cleaning of the condenser. The condenser
the refrigeration circuit must not be opened unit is now accessible and can be cleaned
outside. topdown by blow-out or spraying between
the air blades of the axial blowers.
We recommend the following mainte-
(do not use a high-pressure cleaner).
nance intervals:
Fins that were pushed down by external
influences can be adjusted.
every two years –authorised workshop:
The receiver-drier has to be changed every State of the receiver drier
2 years and/or on every intervention into If there are signs of rust or a coating on the
the cooling circuit. sight glass the liquid tank should be ex-
changed
every six months – authorised work-
shop: monthly sight checks - Operator
The complete unit has to be checked The following sight check have to be car-
twice a year through well-informed per- ried out by operator monthly.
sonnel of an authorised workshop.
State of heating hoses and refrigerant
Check of the cooling circuit on refriger- hoses
ant filling quantity: Check of the fixing, leak control and laying
renew contaminated refrigerant and oil of the hoses and fittings. The hose fixings
are to be tightened if necessary.
no. page
State of the condenser

Unscrew and remove the cover for the 7 Spare parts
cleaning of the condenser. The condenser
unit is now accessible and can be cleaned The condenser, the condenser blower, the
topdown by blow-out or spraying between receiver drier, the holder for the receiver
the air blades of the axial blowers. drieer, the pressure switch, the thermostat,
(do not use a high-pressure cleaner). refigerant tubes and O-ring can be deliv-
Fins that were pushed down by external ered as spare parts.
influences can be adjusted. See spare part list: 075-TX2-0001 and/or
075-TX2-0002 (please order list from
Please note: AURORA)
Attention and acidity are most important by
the engagement into the refrigerant circuit.
Sucked off refrigerant may not be used Installation of replacement parts
again. • When installing replacement parts the
Components of the refrigerant circuit may sealing plugs must only be removed just
not be stored open. prior to installation so that no moisture
can get into the unit. This is because if
weekly sight checks - Operator moisture gets into the unit the cooling
performance is reduced and the com-
The cleaning interval of the condenser has pressor can also be damaged.
to set to weekly sight checks if the con-
denser unit power is reduced. • During assembly it is important to en-
sure that all connections are clean and
undamaged.
• Always use new sealing rings
• To avoid damage to sealing surfaces
and sealing rings it is advisable to wet
this parts with refrigerant machine oil.
• When tightening up the connections a
screwdriver should always be used as a
counterbrace to avoid damage to the
soldered joints.
Please note: The condenser is filled with
an inert gas. After removal of the protective
caps the inert gas must audibly escape.
no. page
8 Fault diagnosis
Fault cause remedy

Insufficient air supply at Contamination of Clean cooling fins with water jet
condenser cooling fins on Note: Do not use high pressure cleaner
condenser
Receiver drier satu- replace receiver drier.
rated or blocked A test can be made for a blocked drier dur-
ing operation by measuring the refrigerant
temperature at the drier inlet and outlet. A
temperature difference of 2 to 3°C indicates
a blocked receiver drier.
Axial blower will not plug loosely Check plug and mount correctly if necessary
work
Connecting cable Replace cable.
damaged or torn out
loss of refrigerant interruption of the re- check all pipes for leaks through external
frigerant pipe influences or chafing
leak within the unit evacuation, filling, leakage check and repair
to be made
no. page
A/C unit, 24V

part no.: 171-TX2-0001
1 Safety advises
2 Usage
3 Unit description
4 Function description
5 Installation advises
6 Operation
7 Technical data
8 Maintenance
9 Spare parts
10 Optional accessories
11 Fault diagnosis
AURORA
Südring 4
D-69427 Mudau
Tel.: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com
established: 13.07.05 KH checked: 15.11.06 EB approved: 17.11.06 W.Le

a) 11032 23.11.05 KH d g j
b) 11293 11.05.06 KH e h k
c) 12039 14.11.06 KH f i l
no. page
1 Safety advises
Maintenance work on the refrigeration
Please note the following information circuit:
for your own safety.
• The unit must always be emptied be-
• Make sure that maintenance and repair fore any work is carried out on the re-
work is only carried out by specialised frigeration circuit. This may only be
and authorised personnel. done by specialist personnel.
• Do not reach into the unit and never • Only refrigerant R134a according to
stick objects into the blowers. DIN 8960 must be used and please
• Attention at maintenance and spare follow the safety data sheet for refrig-
parts work. On the evaporator and heat erant R134a.
exchanger there are sharp fins. • Never heat up refrigerant bottles with a
• At maintenance work and repairs wear naked flame.
necessary protective clothing. • Do not discharge refrigerant to the
• Maintenance work is to be carried out environment.
only when the motor is not running. In • Liquid refrigerant must not come into
order to avoid injuries, the blower is to contact with the skin.
be separated from the current circuit. • Safety glasses must be worn when
• Attention! Danger of burning. Please handling refrigerants.
do not get into contact with heat ex- • The unit has been sufficiently evacu-
changer and the tube connections. This ated before starting the filling. Please
also applies to the resistance on the follow the technical information 912-
blower when working at the opened unit 100-0148, page 5.
and the construction part has not com- CAUTION! Risk of explosion!
pletely cooled down. • Never carry out soldering or welding
• In emergency situations switch off the work directly on parts in the closed re-
unit. frigeration circuit or in its vicinity. Due
to the strong heating effect the pres-
Caution! sure will increase within the unit giving
• The resulting condensate shall not be a risk of explosion.
used as drinking water. • Refrigerant bottles must never be
thrown around or subjected to lengthy
Advice for installation and maintenance periods of sunshine or other heat
work: sources when filled. The highest per-
mitted temperature of a filled refriger-
The rules for the prevention of accidents
ant bottle must not exceed 45°C.
as well as other recognises technical and
CAUTION! Risk of contamination!
labour medical security regulations must
be observed. It is essential that the refrigeration system
is kept free from chlorine and substances
containing chlorine, as well as oils and
greases. Consequentially it is necessary to
invest in separate evacuation and filling
systems which are exclusively used for
R134a.
no. page
2 Usage Description of the components:
The unit was developed for the air condi- evaporator

tioning and heating of an excavator. The liquid refrigerant is injected into the
evaporator block, the heat necessary for
The heating/air conditioning unit and the evaporating the refrigerant is drawn out of
installed location are carefully matched the air which is blown through, thereby
together with respect to the particular ve- cooling the air.
hicle to ensure trouble-free installation.
expansion valve:
The unit works in the air conditiong The expansion valve is fitted directly on
exclusively with refrigerant R134a. the evaporator. It controls the amount of
liquid refrigerant which is injected into the
3 Description of the unit evaporator.
The unit housing upper part consists of a Icing protection:

steel sheet of 5 mm and a service cover. The thermostat prevent an icing up of the
In the housing there are the following evaporator fins by freezing condensate
components: water. The thermostat probe is positioned
• a twin radial blower DRG 975, 24V between the evaporator fins.
• a evaporator with expansion valve The fixed settings on the thermostat switch
• a firmly adjusted thermostat used as an off at -1,0°C±0,6°C and on again at
icing protection +2,2°C.±0,6°C.
• a cable set for thermostat and blower
• a flat tube heat exchanger with connec- heat exchanger
tion diameter 16 mm The flat tube heat exchanger has a con-
• a heating and cooling controller HCC nection diameter of 16 mm.
with reheat-function. The water valve ∅16/16 mm has to inte-
Further information about the HCC can be grated into the inlet with the clamp and two
seen in technical information 912-100- hexagon screws with washer.
0305.
• relays twin radial blower
• a filter G4 The DRG 975 is adjustable with 3 speeds.
• a mechanical with an bowden wire The blower is protected from overload with
control actuated air flap for external air a micro-temperature- fuse (MTF) installed
or recirculation air operation. at the resistor.
On the air outlet side there are a round External air / recirculation air flap
nozzle RD100 for the driver´s foot area With the mechanical external/recirculation
and 3 sockets ∅60 mm for the air distribu- air flap the unit can be operated with ex-
tion in the cabin. ternal air, recirculation air or mixed air.
In cold regions it is possible to heat the
On the housing bottom there are two water cabin faster with the recirculating air op-
outlets. eration and the achievable final cabin
temperature is also higher. It is however
always important to ensure a suitable flow
A water valve ∅16/16, a clamp, 2 hexagon
of external air.
screws and two wahers are delivered
loosely in a plastic bag according A/C kit.
no. page
4 Description of the unit Installation of the A/C unit:

The unit shall be installed below the
The blower sucks in the air depending the driver´s place.
air flap position and presses the air
through the filter, evaporator and heat ex- Connection of the device:
changer. The air is cooled down on the The following intersection has to be set:
evaporator. The entrained air moisture is • connection of the water valve with the
condensed in the evaporator which results clamp.
in a reduction in the air humidity. • connection of the water hoses to the
After that the air can flow through the heat heat exchanger connection.
exchanger. • the electrical connection
At the heat exchanger the air warms up • connection of the refrigerant hoses
corresponding to the water valve position
and the water forward stroke temperature. Please note:
Advice: The evaporator is filled with an
inert gas, after removal of the seals on the
Reheat-function of the HCC: block valve the inert gas must audibly es-
To open the water valve also in cooling cape.
mode, the HCC software has a reheat
function. If power supply AC as well as Please check this inert gas filling during
power supply water valve are applied, the installation. If there is no inert gas filling,
air conditioning unit and the water valve the device has to be handled with care
can be used at the same time. and be checked on leaks. A permeability
of the component is possible.
5 Installation advice
In general there has to be a check on
Installation work is only carried out by well- leaks during the refrigerant filling of the
trained and authorized personnel. unit.
Transport and handling of the air condi- Please note:

tioning unit: We recommend, to fix a label with the fol-
Lift and transport the device only on the lowing text on a viewable position into the
housings. diesel engine forklift.
Don’t lift or transport the device on the "Caution! A/C unit is under pressure! Re-
heat exchanger tubes or the cable set. frigerant R134a"
Don’t pull at the cable set. Otherwise the This is needed to ensure safety by main-
plug can tear off. tenance works.
Use suitable and unobjectionable lifting
devices and load lifting members.
no. page
CAUTION
The air conditioning unit must be filled
Please note: The air hoses, water hoses by well-trained personnel of an author-
and refrigerant hoses has to be fixed after ized specialist workshop.
the connection to the A/C components
Please follow the instructions of the tech-
with suitable fixing clamps to avoid dam-
nical information 912-100-0148, page 5.
ages of the connections by vibrations.
Only refrigerant R134a according to DIN
8960 must be used.
Important Information:
To guarantee a correct installation and
The unit has to be cleaned with dried ni-
operation of the compressor, please take
trogen and to be checked on leaks. The
note of the Technical Information 912-100-
cleaning serves for the dehumidification of
0148 Compressors – Applications, condi-
the unit.
tions of use and liability.
After that, the unit must be evacuated for
Make sure that the compressor is the last
at least 45 minutes in order to achieve a
component in the refrigerant circuit to be
reduction of the foreign gases to less than
attached. The refrigerant circuit must not
1,5 vol-%. At the evacuation, the pressure
be open when the refrigerant is attached
measured in the unit should be at < 20
because the lubricating properties of the
mbar. Please, make sure to avoid any
refrigerant oil could be lost as a result of
risk of a contamination of the air condi-
exposure to moisture. Prolonged exposure
tioning system with oil from the vacuum
to moisture produces acids that damage
pump.
the bearings in the compressor and the
hoses.
Fill the unit according to the instructions of
the manufacturers of the filling ward.
FILLING AND STARTING OF THE UNIT
Fill the unit with sufficient refrigerant.
Please note: CAUTION

The heating/-air conditioning unit shall only
Do not overfill the unit. This would re-
be used for the specificated usage and
duce the refrigeration capacity and can
only in valid environment. See the techni-
cause damage to the unit.
cal supplement to guarantee.
The maximum refrigeration performance is

achieved with the maximum blower speed.
6 Operation
The operation is made with vehicle-side

operation elements.
A A/C on/off switch, a 3-speed switch for
the blower and a potentiometer for the
water valve can be offered.
The control of the external air/recirculation

air flap is made with an bowden wire con-
trol with knob, integrated in the unit.
no. page
7 Technical data Refrigeration circuit

• During any intervention into the refrig-
Theoretical power data: eration circuit all the openings must be
• closed and made airtight so that no
heating power Q 80 = 12,5 kW moisture can get into the unit.
•
at V air = 600 m3/h. • When the weather is damp or if it is
• raining the refrigeration circuit must not
cooling power Q 0 = 7,3 kW be opened outside.
•
at V air = 600 m3/h
(30°C, 60% relative humidity) The unit is built in such way, that the
blower, the filter, HCC and relays can be
dismounted bottom up after removing the
8 Maintenance, service, repairs service cover.
CAUTION: We recommend the following maintenance

intervals:
Please pay attention to the safety ad-
Maintenance intervals:
vice (chapter 1) during all maintenance
work. every two years –authorised workshop:
Maintenance work is only carried out by The receiver-drier has to be changed
wellinformed and authorised personnel. every two years and/or on every interven-
Repairs on the refrigeration cycle may tion into the refrigerant circuit.
only be carried out if the air conditioning
unit has been emptied. every six months – authorised work-
Take off defect parts immediately. shop:
Faults have to be eliminated instantly. The complete unit has to be checked twice
For filling and starting of the unit pay a year through well-informed personnel of
attention for the instructions in chapter an authorised workshop.
5.
Check of the cooling circuit on refriger-
For the installation of spare parts ant filling quantity:
please see chapter 9. renew contaminated refrigerant and oil
State of refrigerant and heating hoses
Advice for installation and maintenance Check of the fixing, leak control and laying
work: of the hoses and fittings. The hose fixings
The rules for the prevention of accidents are to be tightened if necessary.
as well as other recognises technical and Change hoses if the material is not in or-
labour medical security regulations must der.
be observed. State of the receiver drier
If there are grid or moisture into the sight
glass the receiver drier has to be changed.
Residual pressure
Residual pressure may still remain even
after the unit has been emptied. This should
initially be released with extreme care by
first slowly loosening the connections.
Thereafter the connections can be fully
separated.
no. page
every month sight checks - Operator CAUTION!

The following checks should be carried out The sight tests have to be carried out
every month by the operator: even if the air conditioning unit is not
used.
Please also put the air conditioning unit
Check of the fixing, leak control and laying
into operation once a month in order to
of the hoses and fittings. The hose fixings
prevent the shaft sealing in the com-
pressor from drying out and becoming
Change hoses if the material is not in or-
brittle. Otherwise, there could be a
der.
danger of refrigerant escaping. By do-
ing so the compressor parts are also
Electric regularly lubricated.
Check electric connection lines and plug
Attention and acidity are most important by
connections on correct state and firm po-
the engagement into the refrigerant circuit.
sition.
Sucked off refrigerant may not be used
again.
State of the evaporator
Components of the refrigerant circuit may
Clean contaminated evaporator. The
not be stored open.
cleaning is carried out by blow-out or
spraying (do not use a high-pressure
cleaner). Cooling water circuit:
When refilling the cooling water quality has
Check a good evacuation of the conden- to be considered. When using AURORA
sate water. Clean water membrane, if water valves the warranty expires when
necessary. defects occur due to contamination in the
Fins that were pushed down by external water circuit. (see TI 971-190-0003 anti-
influences can be adjusted. corrosion/antifreeze solution. Here also
Check thermostat tracer on leaks and po- the valid cooling mediums are listed.
sition. Please order in case of need)
Filter G4 The heat exchanger, the evaporator and

Check filter and clean or renew if neces- the blower are in principle maintenance-
sary. The interval is depending on the us- free. But we recommend to clean this
age situation and has to be temporised, if components regularly.
necessary.
The filter is reclaimable by blowing out,
beating or rinsing.
no. page
a counterbrace to avoid damage to the

9 Spare parts soldered joints.
CAUTION
The following components, for example,
can be delivered as spare parts: There may be a protective filling in certain
Heat exchanger, evaporator, expansion closed replacement parts. The sealing plugs
valve, o-rings, thermostat, blower DRG must therefore be removed with care.
975, resistor, water valve and cable set. Please check this inert gas filling during
The complete indications including part installation. If there is no inert gas filling ,
numbers can be seen on the spare part list the device has to be handled with care
071-TX2-0001. (Please order list, if and be checked on leaks. A permeability
needed) of the component is possible.

Installation of spare parts leaks during the refrigerant filling of the
• The installation of spare parts has to unit.
be carried out only by wellinformed
and authorised personnel. During the 10 Optional accessories
installation please note the safety ad-
vises in chapter 1. Optional accessories upon request.
See also www.aurora-eos.com
• When installing replacement parts the
sealing plugs must only be removed
just prior to installation so that no
moisture can get into the unit. This is
because if moisture gets into the unit
the cooling performance is reduced
and the compressor can also be dam-
aged.
• During assembly it is important to en-
undamaged.
screwdriver should always be used as
no. page
11 Fault diagnosis
Fault Cause Remedy

Blower will not work Fuse defective or loose Is the fuse correctly seated? If neces-
sary insert correctly. Renew defective
fuses. If a new defect occurs within a
short time this indicates a possible
short-circuit.
Examine blowers for a blockage or an-
other type of defect and rectify the
cause.
Interruption of line Test the lines on loose contacts or
breaks
Blower motor defective Exchange blower
switch for blower defective test switch and change it if necessary
Blower cannot be Short-circuit in cable or blower Rectify short-circuit, if necessary install
switched off switch new cable(s) and/or switch.
Blower only operates Contacts contaminated clean plug contacts. Proceed carefully to
at reduced power avoid
electrical lines under dimen- lay cables with recommended diameter
sioned
Heat exchanger fins contami- Check heat exchanger and clean it if
nated necessary. CAUTION: pay attention to
the safety advises
Blowers will not oper- Micro-temperature fusing (MTS) Exchange resistor and check the blower
ate at all speeds has been triggered motor for the cause of functional faults
Connecting plug has become Check plug connection at rear of unit for
loose proper seating. If not assemble it cor-
rectly
Check connection on blower switch
resistor defective Exchange resistor
No or insufficient Water supply temperature to Wait until the motor is warm
heating power low
Water valve will not open fully Check & renew water valve and bowden
wire if necessary
Vehicle thermostat defective Exchange thermostat
nated necessary
filter contaminated clean or change filter
Water lines kinked or squashed Eliminate fault by installing correctly
Water pump pressure insuffi- Heat exchanger does not have cooling
cient water flowing through it. Install additional
pump or a more powerful one
no. page
Fault Cause Remedy

Water escaping from Hose connection has come Check hose seating and tighten hose
the unit loose clamps
Water hose damaged Install and connect new hose
Heat exchanger damaged Install and connect original replacement
part. Warning! Follow safety instructions!
Air flap no more ad- foreign body blocks flap check flap, remove foreign body
justable
flap bearing defective check and exchange flap bearing, if
necessary
bowden wire corroded check wire and change if necessary
bowden wire control defective change bowden wire control
cooling power:
Fault Cause Remedy

Compressor does not Interruption in the magnet coil of check current flow to the clutch
work the compressor
v-belt loose or torn adjust belt tension, change belt
v-belt slides or does not turn on check, repair, change compressor

the v-belt even though coupled
compressor clutch slides repair clutch or change compressor
operation element defective check and change, if necessary
evaporator flooded expansion valve is stuck in change expansion valve

open position and/or clings
evaporator icy thermostat tracer in the wrong tracer must be newly positioned
position
Expansion valve or thermostat renew expansion valve or thermostat
defective
evaporator clogged cooling ribs contaminated clean evaporator
loss of refrigerant interruption of the refrigerant check all pipes for leaks through exter-
pipe nal influences or chafing
leak within the unit evacuation, filling, leakage check and
repair to be made
no. page
Fault Cause Remedy

cooling performance Blower flow impeded Check air ducts and outputs for block-
insufficient ages, eliminate fault
Too little refrigerant in system Carry out leak test; top up system
(service fitter)
Moisture in system Empty air conditioning unit, exchange
receiver drier, evacuate and fill new
(service fitter)
receiver drier saturated or change receiver drier
blocked
Unit cools with inter- interruption of lines Check lines, repair or renew as neces-
ruptions sary
Blower motor defective renew blower
Unit making a lot of noise:
Fault Cause Remedy

Unit making a lot of V-belts loose or excessively Increase tension of V-belts or renew
noise worn
Clutch noisy Repair clutch
Retainer of refrigerant com- Repair retainer; renew refrigerant com-
pressor loose or inside parts pressor
defect
Excessive wear of blower motor Renew blower
Refrigerant system overfilled Extract refrigerant until high pressure
display is normal
Too little refrigerant in system Carry out leak test;
top up system
no. page
part no.:
171-TX2-0001 A/C unit, 24V, with mechanical external air/
recirculation air flap and integrated operation element
171-TX2-0003 A/C unit, 24V with electrical external air/
recirculation air flap, for operation with CBD
1 Safety advises
2 Usage
3 Unit description
4 Function description
5 Installation advises
6 Operation
7 Technical data
8 Maintenance
9 Spare parts
10 Optional accessories
11 Fault diagnosis
AURORA
Südring 4
D-69427 Mudau
Tel.: 0 62 84 / 92 02-0
Fax: 0 62 84 / 92 02 99
info@aurora-eos.com
www.aurora-eos.com
established: 13.07.05 KH checked: 21.01.08 EB approved: 21.01.08 W.Le

a) 11032 23.11.05 KH d) 13328 14.01.08 KH g j
b) 11293 11.05.06 KH e h k
c) 12039 14.11.06 KH f i l
no. page
Maintenance work on the refrigeration

1 Safety advises circuit:
Please note the following information • The unit must always be emptied be-
for your own safety. fore any work is carried out on the re-
frigeration circuit. This may only be
• Make sure that maintenance and repair done by specialist personnel.
work is only carried out by specialised • Only refrigerant R134a according to
and authorised personnel. DIN 8960 must be used and please fol-
• Do not reach into the unit and never low the safety data sheet for refriger-
stick objects into the blowers. ant R134a.
• Attention at maintenance and spare • Never heat up refrigerant bottles with a
parts work. On the evaporator and heat naked flame.
exchanger there are sharp fins. • Do not discharge refrigerant to the
• At maintenance work and repairs wear environment.
necessary protective clothing. • Liquid refrigerant must not come into
• Maintenance work is to be carried out contact with the skin.
only when the motor is not running. In • Safety glasses must be worn when
order to avoid injuries, the blower is to handling refrigerants.
be separated from the current circuit. • The unit has been sufficiently evacu-
• Attention! Danger of burning. Please ated before starting the filling. Please
do not get into contact with heat ex- follow the technical information 912-
changer and the tube connections. This 100-0148, page 5.
also applies to the resistance on the CAUTION! Risk of explosion!
blower when working at the opened unit • Never carry out soldering or welding
and the construction part has not com- work directly on parts in the closed re-
pletely cooled down. frigeration circuit or in its vicinity. Due
• In emergency situations switch off the to the strong heating effect the pres-
unit. sure will increase within the unit giving
a risk of explosion.
Caution! • Refrigerant bottles must never be
• The resulting condensate shall not be thrown around or subjected to lengthy
used as drinking water. periods of sunshine or other heat
sources when filled. The highest per-
Advice for installation and maintenance mitted temperature of a filled refriger-
work: ant bottle must not exceed 45°C.
The rules for the prevention of accidents CAUTION! Risk of contamination!
as well as other recognises technical and It is essential that the refrigeration system
labour medical security regulations must is kept free from chlorine and substances
be observed. containing chlorine, as well as oils and
greases. Consequentially it is necessary
to invest in separate evacuation and filling
systems which are exclusively used for
R134a.
no. page
2 Usage Description of the components:
The unit was developed for the air condi- evaporator

tioning and heating of an mobile fuel loa- The liquid refrigerant is injected into the
ding machine. evaporator block, the heat necessary for
. evaporating the refrigerant is drawn out of
The heating/air conditioning unit and the the air which is blown through, thereby
installed location are carefully matched cooling the air.
together with respect to the particular ve-
hicle to ensure trouble-free installation. expansion valve:
The expansion valve is fitted directly on
The unit works in the air conditiong the evaporator. It controls the amount of
exclusively with refrigerant R134a. liquid refrigerant which is injected into the
evaporator.
3 Description of the unit
Icing protection:
The unit housing upper part consists of a The thermostat prevent an icing up of the
steel sheet of 5 mm and a service cover. evaporator fins by freezing condensate
In the housing there are the following water. The thermostat probe is positioned
components: between the evaporator fins.
• a twin radial blower DRG 975, 24V The fixed settings on the thermostat
• a evaporator with expansion valve switch off at -1,0°C±0,6°C and on again at
• a firmly adjusted thermostat used as an +2,2°C.±0,6°C.
icing protection
• a cable set for thermostat and blower heat exchanger
• a flat tube heat exchanger with connec- The flat tube heat exchanger has a con-
tion diameter 16 mm nection diameter of 16 mm.
• a heating and cooling controller HCC The water valve ∅16/16 mm has to inte-
with reheat-function. grated into the inlet with the clamp and
Further information about the HCC can be two hexagon screws with washer.
seen in technical information 912-100-
0305. twin radial blower
• relays The DRG 975 is adjustable with 3 speeds.
• a filter G4 The blower is protected from overload with
• a mechanical with an bowden wire con- a micro-temperature- fuse (MTF) installed
trol actuated air flap (at 171-TX2-0001) at the resistor.
or a electrical with servo-motor actu-
ated air flap (az 171-TX2-0003) for ex- External air / recirculation air flap
ternal air or recirculation air operation. 171-TX2-0001: With the mechanical ex-
ternal/recirculation air flap the unit can be
On the air outlet side there are a round operated with external air, recirculation air
nozzle RD100 for the driver´s foot area or mixed air.
and 3 sockets ∅60 mm for the air distribu- In cold regions it is possible to heat the
tion in the cabin. cabin faster with the recirculating air op-
eration and the achievable final cabin
On the housing bottom there are two wa- temperature is also higher. It is however
ter outlets. always important to ensure a suitable flow
of external air.
A water valve ∅16/16, a clamp, 2 hexagon 171-TX2-0003: in this unit is a electrical
screws and two wahers are delivered flap inbtegrated.
loosely in a plastic bag according A/C kit.
no. page
4 Description of the unit Installation of the A/C unit:

The unit shall be installed below the
The blower sucks in the air depending the driver´s place.
air flap position and presses the air
through the filter, evaporator and heat Connection of the device:
exchanger. The air is cooled down on the The following intersection has to be set:
evaporator. The entrained air moisture is • connection of the water valve with the
condensed in the evaporator which results clamp.
in a reduction in the air humidity. • connection of the water hoses to the
After that the air can flow through the heat heat exchanger connection.
exchanger. • the electrical connection
At the heat exchanger the air warms up • connection of the refrigerant hoses
corresponding to the water valve position
and the water forward stroke temperature. Please pay attention to circuit diagram
912-200-0058 for electrical connetion of
171-TX2-0001 and circuit diagram 912-
Reheat-function of the HCC: 200-0076 for 171-TX2-0003.
To open the water valve also in cooling
mode, the HCC software has a reheat Please note:
function. If power supply AC as well as Advice: The evaporator is filled with an
power supply water valve are applied, the inert gas, after removal of the seals on the
air conditioning unit and the water valve block valve the inert gas must audibly es-
can be used at the same time. cape.
5 Installation advice Please check this inert gas filling during

installation. If there is no inert gas filling,
Installation work is only carried out by well- the device has to be handled with care
trained and authorized personnel. and be checked on leaks. A permeability
of the component is possible.
Transport and handling of the air con-
ditioning unit: In general there has to be a check on
Lift and transport the device only on the leaks during the refrigerant filling of the
housings. unit.
Don’t lift or transport the device on the
heat exchanger tubes or the cable set. Please note:
Don’t pull at the cable set. Otherwise the We recommend, to fix a label with the
plug can tear off. following text on a viewable position into
Use suitable and unobjectionable lifting the diesel engine forklift.
devices and load lifting members. "Caution! A/C unit is under pressure! Re-
frigerant R134a"
This is needed to ensure safety by main-
tenance works.
no. page
CAUTION
The air conditioning unit must be filled
Please note: The air hoses, water hoses by well-trained personnel of an author-
and refrigerant hoses has to be fixed after ized specialist workshop.
the connection to the A/C components
Please follow the instructions of the tech-
with suitable fixing clamps to avoid dam- nical information 912-100-0148, page 5.
ages of the connections by vibrations.
Only refrigerant R134a according to DIN
8960 must be used.
Important Information:
To guarantee a correct installation and
The unit has to be cleaned with dried ni-
operation of the compressor, please take
trogen and to be checked on leaks. The
note of the Technical Information 912-100-
cleaning serves for the dehumidification of
0148 Compressors – Applications, condi-
the unit.
tions of use and liability.
After that, the unit must be evacuated for
Make sure that the compressor is the last
at least 45 minutes in order to achieve a
component in the refrigerant circuit to be
reduction of the foreign gases to less than
attached. The refrigerant circuit must not
1,5 vol-%. At the evacuation, the pressure
be open when the refrigerant is attached
measured in the unit should be at < 20
because the lubricating properties of the
mbar. Please, make sure to avoid any
refrigerant oil could be lost as a result of
risk of a contamination of the air condition-
exposure to moisture. Prolonged exposure
ing system with oil from the vacuum pump.
to moisture produces acids that damage
the bearings in the compressor and the
Fill the unit according to the instructions of
hoses.
the manufacturers of the filling ward.
Fill the unit with sufficient refrigerant.

FILLING AND STARTING OF THE UNIT
CAUTION
Please note:
Do not overfill the unit. This would re-
The heating/-air conditioning unit shall
duce the refrigeration capacity and can
only be used for the specificated usage
cause damage to the unit.
and only in valid environment. See the
technical supplement to guarantee.
The maximum refrigeration performance is
achieved with the maximum blower speed.
no. page
6 Operation
The operation is made with vehicle-side

operation elements.
171-TX2-0001:
The control of the external air/recirculation
air flap is made with an bowden wire con-
trol with knob, integrated in the unit.
A A/C on/off switch, a 3-speed switch for
the blower and a potentiometer for the
water valve can be offered.
171-TX2-0003:
The unit 171-TX2-0003 can be controlled
with a Compakt Bedienelement CBD (part
no. 335-521-0006). Please see also the
technical information for the CBD (912-
100-0403).
7 Technical data
For the installation of spare parts
Theoretical power data: please see chapter 9.
•
heating power Q 80 = 12,5 kW Advice for installation and maintenance
• work:
at V air = 600 m3/h.
•
The rules for the prevention of accidents
cooling power Q 0 = 7,3 kW as well as other recognises technical and
• labour medical security regulations must
at V air = 600 m3/h be observed.
(30°C, 60% relative humidity)
Residual pressure
8 Maintenance, service, repairs Residual pressure may still remain even
after the unit has been emptied. This
CAUTION: should initially be released with extreme
Please pay attention to the safety ad- care by first slowly loosening the connec-
vice (chapter 1) during all maintenance tions. Thereafter the connections can be
work. fully separated.
Maintenance work is only carried out
Refrigeration circuit
by wellinformed and authorised per-
• During any intervention into the refrig-
sonnel.
eration circuit all the openings must be
Repairs on the refrigeration cycle may closed and made airtight so that no
only be carried out if the air condition- moisture can get into the unit.
ing unit has been emptied.
• When the weather is damp or if it is
Take off defect parts immediately.
raining the refrigeration circuit must
Faults have to be eliminated instantly.
not be opened outside.
For filling and starting of the unit pay
attention for the instructions in chapter
5. The unit is built in such way, that the
blower, the filter, HCC and relays can be
no. page
dismounted bottom up after removing the Check a good evacuation of the conden-
service cover. sate water. Clean water membrane, if
necessary.
We recommend the following mainte- Fins that were pushed down by external
nance intervals: influences can be adjusted.
Maintenance intervals: Check thermostat tracer on leaks and po-
sition.
every two years –authorised workshop:
The receiver-drier has to be changed Filter G4
every two years and/or on every interven- Check filter and clean or renew if neces-
tion into the refrigerant circuit. sary. The interval is depending on the us-
age situation and has to be temporised, if
every six months – authorised work- necessary.
shop: The filter is reclaimable by blowing out,
The complete unit has to be checked twice beating or rinsing.
a year through well-informed personnel of
an authorised workshop.
CAUTION!
Check of the cooling circuit on refrig- The sight tests have to be carried out
erant filling quantity: even if the air conditioning unit is not
renew contaminated refrigerant and oil used.
Please also put the air conditioning
Check of the fixing, leak control and laying
unit into operation once a month in
of the hoses and fittings. The hose fixings
order to prevent the shaft sealing in the
compressor from drying out and be-
Change hoses if the material is not in or-
coming brittle. Otherwise, there could
der.
be a danger of refrigerant escaping. By
State of the receiver drier
doing so the compressor parts are also
If there are grid or moisture into the sight
regularly lubricated.
glass the receiver drier has to be
changed. Attention and acidity are most important
by the engagement into the refrigerant
circuit.
every month sight checks - Operator Sucked off refrigerant may not be used
The following checks should be carried out again.
every month by the operator: Components of the refrigerant circuit may
not be stored open.
Check of the fixing, leak control and laying Cooling water circuit:
of the hoses and fittings. The hose fixings When refilling the cooling water quality
are to be tightened if necessary. has to be considered. When using
Change hoses if the material is not in or- AURORA water valves the warranty ex-
der. pires when defects occur due to contami-
nation in the water circuit. (see TI 971-
190-0003 anticorrosion/antifreeze solution.
Electric
Here also the valid cooling mediums are
Check electric connection lines and plug
listed. Please order in case of need)
connections on correct state and firm posi-
tion.
The heat exchanger, the evaporator and
the blower are in principle maintenance-
State of the evaporator free. But we recommend to clean this
Clean contaminated evaporator. The components regularly.
cleaning is carried out by blow-out or
spraying (do not use a high-pressure
cleaner).
no. page
9 Spare parts
CAUTION
The following components, for example,
can be delivered as spare parts: There may be a protective filling in certain
Heat exchanger, evaporator, expansion closed replacement parts. The sealing
valve, o-rings, thermostat, blower DRG plugs must therefore be removed with care.
975, resistor, water valve and cable set. Please check this inert gas filling during
The complete indications including part installation. If there is no inert gas filling ,
numbers can be seen on the spare part the device has to be handled with care
list 071-TX2-0001 and/or 071-TX2-0003. and be checked on leaks. A permeability
(Please order list, if needed) of the component is possible.

Installation of spare parts leaks during the refrigerant filling of the
• The installation of spare parts has to unit.
be carried out only by wellinformed
and authorised personnel. During the 10 Optional accessories
installation please note the safety ad-
vises in chapter 1. Optional accessories upon request.
See also www.aurora-eos.com
• When installing replacement parts the
sealing plugs must only be removed
just prior to installation so that no
moisture can get into the unit. This is
because if moisture gets into the unit
the cooling performance is reduced
and the compressor can also be dam-
aged.
• During assembly it is important to en-
undamaged.
screwdriver should always be used as
a counterbrace to avoid damage to the
soldered joints.
no. page
11 Fault diagnosis
Fault Cause Remedy

Blower will not work Fuse defective or loose Is the fuse correctly seated? If neces-
sary insert correctly. Renew defective
fuses. If a new defect occurs within a
short time this indicates a possible
short-circuit.
Examine blowers for a blockage or an-
other type of defect and rectify the
cause.
Interruption of line Test the lines on loose contacts or
breaks
Blower motor defective Exchange blower
Blower cannot be Short-circuit in cable or blower Rectify short-circuit, if necessary install
switched off switch new cable(s) and/or switch.
Blower only operates Contacts contaminated clean plug contacts. Proceed carefully to
at reduced power avoid
electrical lines under dimen- lay cables with recommended diameter
sioned
nated necessary. CAUTION: pay attention to
the safety advises
Blowers will not oper- Micro-temperature fusing Exchange resistor and check the blower
ate at all speeds (MTS) has been triggered motor for the cause of functional faults
Connecting plug has become Check plug connection at rear of unit for
loose proper seating. If not assemble it cor-
rectly
Check connection on blower switch
resistor defective Exchange resistor
No or insufficient heat- Water supply temperature to Wait until the motor is warm
ing power low
Water valve will not open fully Check & renew water valve and bowden
wire if necessary
Vehicle thermostat defective Exchange thermostat
nated necessary
filter contaminated clean or change filter
Water lines kinked or squashed Eliminate fault by installing correctly
Water pump pressure insuffi- Heat exchanger does not have cooling
cient water flowing through it. Install addi-
tional pump or a more powerful one
no. page
Fault Cause Remedy

Water escaping from Hose connection has come Check hose seating and tighten hose
the unit loose clamps
Water hose damaged Install and connect new hose
Heat exchanger damaged Install and connect original replacement
part. Warning! Follow safety instructions!
Air flap no more ad- foreign body blocks flap check flap, remove foreign body
justable
flap bearing defective check and exchange flap bearing, if
necessary
bowden wire corroded check wire and change if necessary
bowden wire control defective change bowden wire control
Servo motor defective Change servo motor
cooling power:
Fault Cause Remedy

Compressor does not Interruption in the magnet coil check current flow to the clutch
work of the compressor
v-belt loose or torn adjust belt tension, change belt
v-belt slides or does not turn on check, repair, change compressor

the v-belt even though coupled
compressor clutch slides repair clutch or change compressor
operation element defective check and change, if necessary
evaporator flooded expansion valve is stuck in change expansion valve

open position and/or clings
evaporator icy thermostat tracer in the wrong tracer must be newly positioned
position
Expansion valve or thermostat renew expansion valve or thermostat
defective
evaporator clogged cooling ribs contaminated clean evaporator
loss of refrigerant interruption of the refrigerant check all pipes for leaks through exter-
pipe nal influences or chafing
leak within the unit evacuation, filling, leakage check and
repair to be made
no. page
Fault Cause Remedy

cooling performance Blower flow impeded Check air ducts and outputs for block-
insufficient ages, eliminate fault
Too little refrigerant in system Carry out leak test; top up system (ser-
vice fitter)
Moisture in system Empty air conditioning unit, exchange
receiver drier, evacuate and fill new
(service fitter)
receiver drier saturated or change receiver drier
blocked
Unit cools with inter- interruption of lines Check lines, repair or renew as neces-
ruptions sary
Blower motor defective renew blower
Unit making a lot of noise:
Fault Cause Remedy

Unit making a lot of V-belts loose or excessively Increase tension of V-belts or renew
noise worn
Clutch noisy Repair clutch
Retainer of refrigerant com- Repair retainer; renew refrigerant com-
pressor loose or inside parts pressor
defect
Excessive wear of blower motor Renew blower
Refrigerant system overfilled Extract refrigerant until high pressure
display is normal
Too little refrigerant in system Carry out leak test;
top up system

General ServiceBulletins Aurora

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General ServiceBulletins Aurora

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Filling and extracting of air conditioning systems

1. Extraction of system (in case the unit is filled)

- Connect recycling bottle to pressure side

- we reserve the right to make technical modifications -

prepared: 14.07.98 by KH checked: 22.10.02 MM Released: 23.10.02 W.Le

date/name date/name date/name

2. Evacuating the system

- Fit high and low pressure hoses to the service valves

Diagram showing refrigerant cycle of a unit with magnetic valves and

3. Filling station: Filling the filling cylinder:

- Connect refrigerant bottle to filling cylinder

Warning: Filling level depends on pressure

4. Filling the system

Electronic Thermostat HCC, 12/24V

412-310-0025 temperature sensor for HCC (separate)

6 HCC with internal air sensor

Technical modifications reserved

estabilished: 23.03.04 KH checked: 05.02.07 Re released: 07.02.07 W.Le

date/name date/name date/name

1.1 Controlling of temperature

1.2 Stepless control of air-flaps or water valves

control-panel with AC-

water valve for

AC-switch "OFF" or not connected:

Temperature sensor NTC 10 kOhm

The air outlet temperature is measured with the sensor 412-310-0025.

Voltage supply: 8 to 32 VDC

Inputs: NTC-temperature sensor 10 kOhm

Outputs: Actuation motor Bosch VMC II; calibration at every start up

Features: microprozessor based

EMC: conform to: 89/336/EEG

In cooling mode the HCC 412-310-0035 closes the watervalve.

6. HCC with internal air sensor

Condenser unit cpl. 24V TF

part no: 175-TX2-0001 (no longer available)

2 Construction of the condenser unit

4 Connection to the refrigerant circuit

- we reserve the right to make technical modifications -

author: 16.08.04 KH checked: 23.07.07 MK approved: 23.07.07 W.Le

date/name date/name date/name

1 Safety advises Maintenance work on the refrigeration

2 Construction of the condenser unit:

The condenser unit is exclusive working with refrigerant R134a.

2.1 Condenser 2.2 Condenser blower

2.3 Receiver drier 2.4 Pressure switch, 2-poles

3 Mounting advises 4 Connection to the refrigerant cir-

Please note: Installation work shall only

Please note: Do installation work only in a

6 Maintenance State of heating hoses and refrigerant

State of the condenser

Fault cause remedy

A/C unit, 24V

- we reserve the right to make technical modifications -

established: 13.07.05 KH checked: 15.11.06 EB approved: 17.11.06 W.Le

date/name date/name date/name

2 Usage Description of the components:

The unit was developed for the air condi- evaporator

The unit housing upper part consists of a Icing protection:

4 Description of the unit Installation of the A/C unit:

Transport and handling of the air condi- Please note:

Please note: CAUTION

The maximum refrigeration performance is