Air – Conditioning System

Theory of air-conditioning system

The freezing cycle has 4 types of freezing action(Vapor changing cycle)

which’s called “CARNOT Cycle“.

High Condenser High

perssure pressure

Air-conditioner Expansion
Compressor Valve

Low pressure Evaporator Low pressure

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Carnot Cycle: Theory of air-conditioning system

Carnot supposed the theory of thermodynamics cycle for 2-Isothermal change and 2-Adiabatic
change and released the thermodynamic cycle.
*Carnot circulation; Isothermal expansion → Adiabatic expansion →
Isothermal compression → Adiabatic compression.

Condenser

Compressor
Expansion valve

Evaporator

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 Note]
Isothermal change : Without any thermal change,the volume changes by compression or expansion.

Adiabatic change : Without any thermal exchange between inside and

outside, the expansion or compression of gas happens.

¾The gas discharge its heat when compressed and it absorbs heat when expanded.
Pressure

Compression - Cooling –
Expansion - Evaporation

Enthalpy

Item Function State variation Temp. Pressure

Compressor Pressure rising Gas → Gas Up ←
Condensor Heat removal Gas → Liquid Steady ←
Expansion valve Pressure descent Liquid → Liquid Down ←
Evaporator Heat absorb Liquid → Gas Steady ←
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Car air-conditioner

• Moisture absorption Liquid Gas

• Coolant reserving (High temp., High pressure) (Low temp., Low pressure)

Receiver Drier
Expansion Valve
To Outside To Inside

Cooling fan Blower

Compressor
Condenser Evaporator

Gas Gas
(High temp., High pressure)
(Low temp., Low pressure)

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General

Æ VENTILATION VIA PORTS A,B,C

L D
CO
M
AR
W

IN THIS CASE AIRCO COMPRESSOR

WILL NOT FUNCTION !
Air-con Control Switches

(PORTS)

Remark (AIRCO ACTIVATED)

- When Temperature in cabin is lower then 0°C,
airco compr will turn off
- As soon as Temperature reaches 4°C,
airco compr will turn on
Air-con Circuit
COMPRESSOR

FREON
WATER
CIRCUIT
CIRCUIT CONDENSOR
(COOLING)
(HEATING)

AIRCON & HEATER

ASSEMBLY

DRIER RECEIVER

CONTROL
PANEL
-R210LC-7 (ser 1001 and up)-
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Aircon Unit
HEATER CORE (NEWER MODEL UNIT)
MOTOR-ACT
CAB AIR FLOW
VENT
FAN & MOTOR -TOP

E MOTOR-ACT
LV TEMP
R VA
TE
WA

MOTOR-ACT
FOOT/DEFROST
INTAKE AIR
FROM OUTSIDE

CAB AIR FLOW

-FOOT
E
A BL
C TC
DU INTAKE AIR FROM INSIDE
OR (RECIRCULATION)
NS
CAB AIR FLOW SE
-FRONT WINDOW

VACUUM VALVE

RESISTOR
EVAPORATOR ASSY. MOTOR-ACT
INTAKE

EXPANSION
VALVE
Air Intake Side
MOTOR-ACT
VENT

MOTOR-ACT
FOOT/DEFROST

FAN MOTOR
(BLOWER)
Resistor & Relay

CONTROLS PANEL
(FRESH AIR /
RECIRCULATION)

MOTOR-ACT
INTAKE

RESISTOR FOR FAN SPEED

CONTROL

ML
(2) HI
(4)

(3 e FAN SPEED)
(4 e FAN SPEED)
LO
MH
(1)
(3)

(1) 24V-FROM CONTROLLER 1e-FAN-SPEED

(3) 24V-FROM CONTROLLER 2e-FAN-SPEED
(2) 24V-FROM FUSE, VIA RELAY M2 3e-FAN-SPEED
OUTPUT CURRENT OUTPUT CURRENT
(4) OUTPUT CURRENT TO FAN MOTOR Æ FOR SPEED 1,2,3
TO FAN MOTOR, FOR TO FAN MOTOR, FOR
4e SPEED 3e SPEED
Main Components

2. Evaporator 2-3) Blower

2-1) Thermistor

2-2) Expansion valve

3. Compressor
3-1) Magnetic clutch

1. Refrigerant

4. Condenser

5. Receiver Drier

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 Evaporator

Evaporation is one of the two forms of vaporization. It is a process whereby atoms or molecules in a liquid state gain
sufficient energy to enter the gaseous state. It's the opposite process of condensation.

When the pressurized refrigerant goes through the expansion valve, the temperature around the evaporator will be lower
down quickly. The lower temperature air is carried to inside of the cab by a blower.

☞ Evaporator assembly contains thermistor, expansion valve and blower.

Expansion valve

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Detail of Evaporator
MOTOR-ACT CAB AIR FLOW
VENT -TOP
HEATER
FAN & MOTOR CORE
(NEWER MODEL UNIT)

MOTOR-ACT
TEMP
VE
AL
RV
A TE
W

MOTOR-ACT
FOOT/DEFROST INTAKE AIR
FROM OUTSIDE

CAB AIR FLOW LE

-FOOT CAB
INTAKE AIR
CT
CAB AIR FLOW DU FROM
OR
-FRONT WINDOW ENS INSIDE
S (RECIRCUL
ATION)
RESISTOR
VACUUM
VALVE

EVAPORATOR ASSY. MOTOR-ACT

INTAKE

EXPANSION
VALVE

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Detail of Evaporator

MOTOR-ACT MOTOR-ACT
VENT FOOT/DEFROST

FAN MOTOR(BLOWER)

7-SERIES 3-SERIES
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Duct Sensor(Thermistor)

The thermistor is a kind of resistor used to measure temperature change

To prevent the freeze of the evaporator, the evaporator core temperature is sensed by the duct sensor
which allows the compressor to be on and off.

Evaporator

Characteristics (Temp.-Resistance-Output voltage)

Temp. Resi.( Volt Temp. Resi. Volt

(℃) ㏀) (V) (℃) (㏀) (V)

30.00 1.98 0.99 2.00 7.23 2.37

25.00 2.45 1.17 1.00 7.60 2.44
20.00 3.06 1.38 0.00 8.00 2.50
Duct Sensor
15.00 3.85 1.62 -1.00 8.42 2.56
High 10.00 4.88 1.89 -2.00 8.87 2.63

Low 5.00 6.22 2.19 -3.00 9.34 2.69

Off On 4.00 6.54 2.25 -4.00 9.48 2.71

Compressor On : 4.0℃±0.5℃ 3.00 6.87 2.31 -5.00 10.37 2.82

Compressor Off : 0.5℃±0.25℃

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Duct Sensor(Thermistor) - Check

1) Check the Voltage between (2) and (3) ports of thermistor connector.

Compressor Temp. Voltage Remark

A/C ON 3.0 ± 0.5℃ 0 VOLT
A/C OFF 1.0 ± 0.5℃ 5 VOLT

2) If the output voltage from thermistor is not normal, check the inner circuit of duct sensor.

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Expansion valve

The valve is located at the inlet portion of evaporator to supply evaporator with the refrigerant of
low pressure liquid state, Until the refrigerant changes to gas state in the evaporator, the air around
the evaporator is cooling down.

EVAPORATOR

Liquid(High temp.,
High press.)

Before

Expansion Valve

After

Liquid(Low temp.,
low press.) Expansion Valve

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Blower

Cooled air from the evaporator is blown to the cab by the blower.

Blower

Air Filters
The air from outside to inside of evaporator is cleaned
by the air filter. The filter should be cleaned or
changed when necessary.
Fresh air filter

Recirculation filter
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Air Flow System

Air from outside

A/C outlet Nozzle

Defrost outlet

Cool air

A/C Door

Recirculated air

Heater/Defrost
Door
Blower
Evaporator
Heater Core

Heater outlet
Warm air

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Ventilation Piping

A
Harness housing

RECIRCULATION

Harness housing

-R210LC-7 (ser 1001 and up)-

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A/C Parts detail

NO Parts NO Parts
1 M/Act-foot/def & damper 7 Rec air filter
2 Blower(Fan & Motor) 8 Fre air filter
3 M/Act-vent & Damper 9 Resistor
4 Core assy-HTR 10 M/Act-intake & damper
5 Valve-water 11 Duct-sensor
6 Core ass’y-Evap 12 M/Act-temp

③ ④ ⑤ ⑥ ⑦

⑫ ⑪

⑩ ⑨ ⑧
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Compressor

The compressor is driven by a pulley on the engine’s crank shaft. So it runs continually while the
engine is running.
Low pressure gas(refrigerant) from evaporator is compressed and is delivered to the condenser.

Gas
Before
(low Temp., low press.)

Gas
After
(high temp., high press.)

※ Including the thermostat switch

Switch ‘on’ : below 135℃ (1.8V)
Switch ‘off’ : above 150℃ (2.2V)

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Compressor Specification

Division Specification
Model DKV14C
Type Vane Rotary
Body
Displacement 140.5cc/rev
Oil ZXL500PG (200cc)
Rotation Clock Wise
Clutch &
Pulley P.C.D ￠135mm
Pulley
Rated Voltage DC24V
Mass 7.5 kg
Refrigerant R-134a

Types of compressor

(swash plate type) vane rotary type variable wobble plate type scroll type

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Magnetic clutch

Evaporation occurs when heat is absorbed, and condensation occurs when heat is released,
The compressor shaft is designed to be separated from the pulley by the magnetic clutch according to the
signal from the thermistor.

HIGH
Magnetic clutch LOW
(on/off)
ON OFF

4.0±0.5 ℃( 9℃ ) 0.5±0.25℃( 3℃ ) : Thermistor

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 Condenser

Division Specification
Gas
(High temp., High pressure) Capacity 9,000kcal/h(10.47kW)-10% Min.

Inlet Air Velocity : 4.5 m/s

Before

Inlet Air Temp. : 35℃

Per
formance Test
Refrigerant Pressure: IN 16.7 kgf/㎠.G
Condition

SC : 5 deg ℃, SH : 25 deg ℃

Refrigerant : R-134a

Type SCC(Super Compact Condenser)

After Air Presure Drop 12.5mmAq(at 5m/s)

Liquid Size 490Wx365.7Hx22D

(High temp., High pressure) Front Area 0.18 m2

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Receiver drier

The receiver drier is used to absorb water out of the AC system and to take out any contaminants that may
clog the AC system.
The receiver drier has a small window on the unit to check if the refrigerant is fully charged.
If bubbles are discovered, it means that the refrigerant is necessary to be filled in.
The receiver drier is recommended to be replaced whenever any component is removed
TXV (THERMAL EXPANSION
VALVE)

From Condenser To TXV

1) Refrigerant storage
2) Water and contaminants separation in the desiccant section.
3) Safety (Fusible plug) : If the refrigerant temperature is raised too high
Fusible Plug
about 100∼107℃, the fusible plug melts by itself. So the refrigerant is
dumped into the air to prevent serious overheating problem of the system. Filter
pads

Dual pressure switch

Desiccant
To protect the compressor from overcharging or low charging of refrigerant

For low For high

pressure pressure
New
On refrigernt

Off
2.0±0.2 2.1±0.3 27±0.2 32±0.2 (Kg/cm2) ← R134a
2.0±0.2 2.1±0.3 21±0.2 27±0.2 (Kg/cm2) ← R12
Freon
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Expansion Valve & Duct Sensor EVAPORATOR
EVAPORATOR

Duct
Sensor(Thermistor)

Expansion Valve
Remark (Airco. activated)
- When Temperature in cabin is lower then
0°C,air-con. Compressor will turn off
- As soon as Temperature reaches 4°C,
airco compressor will turn on
AC& HEATER CONTROLLER
(14 PIN PLUG)
Water Valve

Radiator
(Heating)
Water Valve

Motor-ACT
Temp.
Electric circuit

Temp M/ACT Mode(VENT) Relay(4ST)

Inlet M/ACT Mode(D/FOOT) Resistor Relay(3ST)
Blower

CN-11

Air Conditioner

Duct sensor(Thermistor)

AC / Heater Controller
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Fan speed control - electrical (4 e FAN SPEED) (3 e FAN SPEED)

(Fan Motor)

Resistor for fan speed control

ML (2) HI (4)

LO (1) MH (3)

(1) 24V-FROM CONTROLLER 1e-FAN-SPEED

(3) 24V-FROM CONTROLLER 2e-FAN-SPEED SPEEDS: 2e (+) 4e (-)
(2) 24V-FROM FUSE, VIA RELAY M2 3e-FAN-SPEED
1e (+) 3e (-)
(4) OUTPUT CURRENT TO FAN MOTOR Æ FOR SPEED 1,2,3 Fuse Ignition

Fuse Battery

Not Conn
Stage Stage
Ⅰ Ⅳ
StageⅢ Stage
Ⅱ AC& HEATER CONTROLLER (18 PIN PLUG)
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Electric feed line for AC compressor

FUSE
El. Mot Output

Not Conn AC COMP.

REMARK
Thermostat on AC compressor
Switch on : below 135℃ (1.8V)
Switch Off : above 150℃ (2.2V)

REMARK
Pressure switch on receiver/dryer is dual PS:

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Electric motors control

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Electric motors controls

INTAKE
AIR FROM
INSIDE MOTOR-
MOTOR-ACT MOTOR-ACT
(RECIRCU ACT
FOOT/DEFROST VENT
LATION) TEMP

FAN MOTOR
(BLOWER)

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The amount of refrigerant filling

Construction Equip. Model Name Ref. Amount

R55-7/R55W-7 650±50g
R80-7
R110-7
R140LC7(R130LC7)
HL730-7
7-SERIES R160LC7 / R170W7 / R180LC7 / R210LC7
R200W7, R210LC7T2, R210NLC7
R250LC7
R290LC7 900±50g
R305-7
R320LC7 / R360LC7
HL740-7
HL757-7
HL760-7
HL770-7
R2900LC7
R450LC7
R2900LC7-CR01 1000±50g

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Amount of oil supplement
Parts Oil supplement
Ref. Recharge 30cc
Evap. core 50cc
Cond. core 30cc
Hose,Pipe 10cc
Receiver Drier 30cc

Operation of switches

3 Series 7 Series
On Off On Off
Low press.
2.25 2 2.1±0.3 2.0±0.2
(㎏/㎠)
R/Drier
High press.
26 32 27±0.2 32±0.2
(㎏/㎠)
Duct Sensor
4 ± 0.5 0.5 ± 0.25 4 ± 0.5 0.5 ± 0.25
(℃, Thermistor)
Compressor temp.(℃)
- - 135 150
(Thermostat)

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Refrigrerant Filling Procedure

GAS leakage check

Refrigerant collection

Vacuumize(Min. 15min)

Vacuum leakage check(10min) Leakage check and repair

Vacuum once more(10min)

Refrigerant filling
If leakage is
checked.
Operation and Leakage check

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Aircon Filter Inspection (1/2)

OUTER FILTER
Aircon Filter Inspection (2/2)

RECIRCULATION FILTER