Manual

Air Conditioner Complete 965219

Liquefaction Unit 964097
 Content

- General Product Information Page 2

- Use Page 3

- Technical data Page 3

- Hints for Installation Page 4 ... 6

- Handling Coolants Page 7 ... 9

- First Aid Page 9

- Cooling Circuit Page 10

- Filling Instructions Page 11

- Operation Page 12... 13

- Function Check Page 14

- Maintenance Page 14

- Circuit Diagram Page 15

- Fault Diagnosis Page 16...17

1
A) General Product Information

Wölfle - R134a – Air Conditioners

1. Coolant Used R134a

Technical data:
a) Symbol : CH2FCF3
b) Designation : 1,1,1,2 tetraflourethane
c) Characteristics : - No color, no smell, non-irritating
- Non toxic (tested: PAFT = program for alternative flour-carbon
toxicity test)
- Chemically stable
- Does not have destructive effects on material structure
- Ozone decomposing potential (ODP) = 0
- Greenhouse effect (GWP) = 0.24 – 0.29
d) Further characteristics see European Index for known substances (EINECS)

2. Lubricant PAG (Polyalkylenglycol)

- Used: ZXL 100 PG

3. Materials
Basically all metallic materials commonly used for plant construction, in the area of air
conditioning technology mainly copper and steel.
Seals are from HNBR and released by all leading manufacturers.

4. Coolant Conduits
All tubes and fittings used comply with the required specification SAE J 2064.
Additional vibration tests (suitability for construction machines) were passed without problems.

5. Components
As R134a/PAG – systems are used worldwide on a large scale; product availability is also
established worldwide.
Only components suitable for R134a may be used for Wölfle-R134a-air conditioners.

6. Labeling
To avoid mistakes, R134a-components are unambiguously labeled as such.

7. Disposal and Recycling

Coolants must not be exhausted into the atmosphere, and must be properly disposed of.
Materials and components comply with the common recycling standard.

8. Wölfle Air Conditioners comply with the regulations valid in the manufacturing
country as well as the worldwide common standards.

2
B) Use
Wölfle’s air conditioner 965219 was specially developed to air condition the driver cabs of Fuchs / Terex
– construction machines, in an especially robust version.

C) Technical data

Air conditioner complete

Manufacturer Wölfle GmbH
Type R134a/ Air
Nominal voltage 24 V
Coolant R134a
Coolant oil PAG

Air conditioning device

Nominal voltage 24 V
Air throughput blower max. 1050 m³/h (free blowing)
Refrigeration capacity 4.0 kW
Blower steps 3
Current consumption max. ca. 11 A

Liquefaction unit
Nominal voltage 24 V
Air throughput max. 2400 m³/h free blowing
Thermal power ca. 11 kW
Blower steps 1
Current consumption max. 12 A
Weight ca. 15.8 kg

Compressor
Type Seltec TM – 15HD
Nominal voltage 24 V
Rpm max. 6000 rpm
Circulation quantity 147 m³
Rotation direction clockwise or counter-clockwise
Oil ZXL100PG (PAG-oil)
- Filling quantity 150 cm³
Weight without oil 7 kg
Current consumption max. 3.75 A

Filter dryer
Content 0.7 l
Filter efficiency up to particle size >6µm
Water consumption of the dryer plug 16 g
Weight 1 kg

3
Filling quantities
Coolant R134a 1350 g (determined at MHL 331 No.: 3311100530)
Coolant oil PAG 150 g

D) Hints for Installation

1. Compressor

The compressor should be installed within the angles of inclination outlined in picture 1.
Installation outside these angles of inclination has a negative effect on the lubrication behavior of
the compressor.

Tips for Installation

The compressor contains 150cm³ PAG-oil and nitrogen (N2).

1. Remove the plastic cover of the low-pressure side of the compressor (carefully release the
nitrogen)

Attention: Compressor oil must not escape!

2. Rotate the compressor in your hand several times for better oil distribution.
3. Mount the compressor (keeping the angles of inclination mentioned); ensure no tension is
occurring on the casing.
Washers are supplied with the compressor.

4
2. Installation of O-ring-connections

Attention:
Remove the caps of the individual components only immediately before installation!!!

Lubricate O-ring-fitting and flange area with coolant oil.

Ensure that fitting and counterpart smoothly fit together, afterwards forcefully press parts
together.
Then tighten nut by hand.

When finally fastening always use a wench on the fixed side to get traction.

5
Filter dryer,

Also called collective dryer, or just dryer, contain collector, dryer, filter, and Inspection glass in
compact construction.

Technical data:
- Seal test 35bar
- Bursting pressure test 130bar
- max. leakage rate 5g R134a / year

The dryers are cleaned, dried and sealed airtight.

If possible, the dryers should be installed vertically, so that the component’s capacity can be
completely used (deviating installation situations are explicitly stated).

Since the special oil in the compressors has a strongly hygroscopic behavior, ensure that the
individual components are closed as long as possible when installing.

6
E) Handling Coolants

If coolant circuits are opened the content can escape as liquid or steam. This process will be the
more forceful, the higher the pressure is in the circuit.

Wear protective goggles!

Put on protective goggles. It will prevent the coolant from getting into your eyes causing severe
frost damage.

Wear protective gloves!

Coolants are good solvents for greases and oils. In case of skin contact the protective grease layer
will therefore be removed. Degreased skin however is sensitive to cold and germs. Suitable
protective gloves will protect your hands against degreasing.

Skin must not be exposed to liquid coolants!

The purpose of a coolant is to cool. For this, it must evaporate. This happens as long as fluid is
available. The heat necessary for evaporation is drawn from the surrounding, which may be skin.
In this process, very low temperatures may be reached. The result is local frost bite.

Do not inhale coolant vapor in higher concentration!

Any coolant – even those fluid at room temperature – volatilize when the circuit is opened. The
vapors mix with the surrounding air.
All types of coolant with the exception of R11 and R113 incur the risk that the air necessary for
breathing is displaced (danger of suffocation).

Ensure good ventilation!

In order to prevent higher concentrations always ensure that workstations are well ventilated.
Observe the maximum operating concentration.

Suction!
In some cases opening windows and doors is not sufficient, suction must be used as closely as
possible to the outlet or near the floor. This is especially necessary if liquid coolants such as R11
and R 113 are used openly.

Do not smoke!
Coolants can also disintegrate in cigarette embers. The substances generated in this process are
poisonous and must not be inhaled.

Warning against misuse!

Because of the narcotic effect and the danger of oxygen displacement the vapors of highly
concentrated coolants must not be inhaled.
This is an explicit warning against misuse!

7
Cooling Systems
The coolant in cooling systems exists in a liquid and a steam phase under pressure. When
carrying out repair works on cooling systems these circumstances must be considered.

Remove leakage at cooling systems immediately!

Leakages of cooling systems not only impair their function but if operating with larger filling
quantities dangerously high concentrations of coolant might occur in the surrounding air.

Do not let coolant escape when filling or carrying out repair works; it must be collected in a
recycling container!
When coolant escapes in closed rooms it is possible that high concentrations build up resulting in
danger of life due to narcotic effects or lack of oxygen. Coolant from systems in want of repair
must always be collected in recycling containers, put into intermediate storage and be refilled into
the system after the repair works have been carried out, or returned to the retailer.

Ensure good ventilation!

To prevent occurrence of a high concentration, the workrooms must be well ventilated. In some
cases it is not sufficient to open the windows and doors, and a suction device must be installed
near the outlet, at least however close to ground.

In case of sudden occurrence of high concentrations of coolant (e.g. burst pipes) immediately
leave the room and only come back after it has been sufficiently ventilated!
With all types of coolant, with the exception of R11 / R113, the foremost risk is that the oxygen
in the air necessary for breathing is displaced (danger of suffocation).

In case of high concentrations of coolant in the surrounding air, use a breathing apparatus
that works independently of the surrounding atmosphere!
Filter masks with breathing filter A (solvent) are only to a lesser degree able to remove coolant
vapors from air. They may only be used if the concentration does not exceed 0.5 Vol.-% (see
leaflet concerning breathing protection). If the concentration is too high, the danger of suffocation
is especially imminent in mines and shafts, because coolant vapors are heavier than air. In case of
doubt always use a breathing apparatus that works independently from the surrounding
atmosphere.

Carry out welding or soldering work on cooling systems only in well-ventilated rooms!
In the flame of blowtorches and welding torches as well as in voltaic arches coolants disintegrate.
The products of this disintegration are poisonous and must not be inhaled.

8
Before carrying out welding or soldering work on cooling systems remove coolant from the
system part concerned; remove residue by blowing out with air or nitrogen!
The products of disintegration that are generated from the coolant when heated are not only
poisonous but also highly corrosive, so that tubes and system parts may be affected. For coolants
containing chloride this is mainly hydrogen chloride, hydrogen fluoride and elementary chloride.
In some circumstances, Phosgene might be generated. H-FKW may generate hydrogen fluoride
as a dangerous disintegration product.

Pungent smell indicates disintegration of coolant by overheating: Leave room immediately,

ventilate thoroughly or use filter mask with breathing filter B (acid gases)!
If a pungent smell occurs, the described disintegration products have already been generated.
Avoid by all means inhaling these substances as otherwise the respiratory tract, the lungs and
other organs might be damaged. These disintegration products are effectively held back with a
filter mask with breathing filter B (acid gases); observe instructions for use!

F) First Aid

1. In case of contact with eyes or mucous membranes immediately rinse with running water and
consult and eye specialist.

2. In case of skin contact immediately remove wet clothing and rinse skin with plenty of water.

3. In case highly concentrated coolant vapors were inhaled expose the person concerned to fresh
air. Call a doctor. In case of breathing problems apply oxygen. If the person concerned
breathes only with difficulties or not at all, bend head backwards and give artificial
respiration.

4. Information for the doctor: Highly concentrated coolants can lead to limited consciousness
and even unconsciousness. Since coolants sensitize the heart against catecholamines,
adrenomimetica must not be used. After inhalation of disintegration products the lungs may
develop edemas even after an uncertain latency.

9
G) Cooling Circuit

10
H) Filling Instructions

Please observe the user manual supplied with the filling device!!!

At first establish the type of coolant and cooling system oil that can be used to operate the
system. For this, check the instruction label on the air conditioner components (compressor, dryer
container, etc.).

Mixing different coolants or oils may destroy the air conditioner.

1. Evacuation

Evacuate the system according to the user manual supplied with the filling device!
If this is not available please follow the instructions below:

Evacuation with Leakage Check

- Connect filling tubes to the fast couplings

- Open both filling tubes
- Leave vacuum pump to suction off for ca. 30 min.
- On blue manometer (low pressure) display nearing 1 bar
- Use powerful pump
- Close manometer valve and watch possible rising pressure. If the pressure remains
constant there are no major leaks
- Connect coolant flask instead of pump. Open flask valve and red manometer valve (high
pressure side), so that a small amount ca. 100 g coolant can flow into the system. (Weigh,
if possible)
- After that check all connecting parts for leakage, using the leakage detector (R 134 a-
suitable) or leakage spray

2. Filling the System

Fill the system according to the user manual supplied with the system!
If this is not available please follow the instructions below:

- For checking purposes, weigh coolant flask before and during the filling process
- Fill in the required quantity of coolant
- After that, check system for leaks and dismantle filling device

11
I) Operation

Installation Location

The heater-air conditioner 920184 is in the foot area of the cab, type seat console.

In the cab are the following operation parts:

- Turning switch heater (in side console, right)

- Turning switch with main switch air conditioning (in side console, right)
- Turning switch blower (in side console, right)
- Turning switch fresh air/air recycling (on the right, behind the seat)

Turning switch fresh air/

Recycling flap

Blower
Evaporator
Heat exchanger

Foot area jet

Condensed water drain Connection nozzle for air

distribution front and rear area

Turn on

12
Heater

Turn on the heater by turning the temperature regulator clockwise. At the same time, the blower
switch must be turned on to transport the heated air into the cab.

By operating the turning switch fresh air/recycled air select either fresh air or cab air for the
heater.

Air Conditioning

The air conditioner only operates when the motor is on.

For air conditioning only, ensure that the heater is turned off.
Turn on the main switch (Check lamp on). Using the turning switch for thermostat setting air
conditioning, select the desired cooling temperature; at the same time, turn the blower switch to
at least setting 1.
The room temperature in the cab will fall.
The higher the selected cooling performance of the air conditioner (using the thermostat setting
air conditioning), the higher blower setting should be selected.
To achieve maximum cooling of the cab:
- Turn the thermostat switch air conditioning as far as possible clockwise
- Select the highest blower setting
- Ensure the heater is tuned off
- Set the air flap for recycling air
- Close the cab

The air conditioner can also be operated in the cooler season. Turned on together with the heater,
the air in the cab stays dry and, so that no condensing water collects on the windows. For this, it
is sufficient to set the thermostat switch of the air conditioner at the lowest performance.

13
J) Function Check

When the system is completely filled and has been checked for leaks, carry out a function check:

- Turn off heater

- Blower setting 1
- Air conditioner maximum performance
- Open jets
- Flap setting recycling air
- Close cab

After a short while (depending on outside temperature) a temperature < 6°C should be measured
on the foot area jet. The air conditioner is working flawlessly.

K) Maintenance

The heater-air conditioner 920184 is basically a low maintenance appliance.

Depending on use, only check and, if necessary, clean or replace the air filters.
Filter cleaning: The filters can be blown out or washed.

At least once every month the air conditioner must be turned on for a short time. Operation is
necessary to lubricate the compressor.
At the beginning, in the middle and at the end of a cooling period carry out the following
maintenance work:
- Check tension of the V-belt and compressor mounting
- Check coolant filling
. For this, the coolant must visibly flow in the inspection glass of the fluid container with
the motor running and the air conditioner on full power.

- Cleaning of the liquefactor:

. The sheets of the liquefactor must be cleaned carefully and without high pressure, they
would otherwise bend.
Carry out an annual inspection in your workshop at the beginning of a cooling period.

14
L) Circuit Diagram

15
M) Fault Diagnosis
The system is cooling insufficiently, what can I do?
Cause
Air turnover in cab too low
Too little coolant in the system
Filter dryer dirty
Alien gases in system
V-belt loose or worn
Liquefactor dirty
Liquefactor blower defective
Error identification
- Check filter (recycling air
and fresh air)
- Leaks in the air conduits
- Temperature sensor defect
(evaporator iced-up)
- When operating the air
conditioner the inspection
glass reveals bubbles
- Very low temperature
difference between suction
and blowing tube, on both
high- and low pressure sides
- Temperature of the suction
tube falls insignificantly
- Filter dryer perceptively
colder than conductor (up to
dry icing-up)
- Also air bubbles in the
inspection glass
- Air bubbles in the inspection
glass
- High- and low pressure too
high
- Temperature of suction
conduit falls insignificantly
- Singing noise
- Visual inspection
- Visual inspection (when
operating the air conditioner
the liquefactor blower is
running)
16
Removal
- Clean filter, if necessary
replace
- Seal leaks
- Replace sensor
- Check system for leaks
- Repair leaks
- Fill system until you see
bubble-free flow in
inspection glass
- Replace filter dryer
- Exchange coolant (evacuate
system thoroughly)
- If necessary, replace dryer
- Tighten V-belt, if necessary
replace
- Clean sheets (carefully,
without pressure; sheets
must not bend)
- Check electric connections
conduits and fuses; if
necessary exchange blower
Too much coolant in the system
Expansion valve defective
Compressor damage
- High- and low pressure too - Suction off coolant from the
high system
- Insufficient cooling in
liquefactor
- Compressor switches on
briefly; high pressure rises
extremely fast to
overpressure. Compressor
turns off briefly to reach
normal pressure; compressor
turns on briefly...
- High- and low pressure too - First check any other
high possible source for faults
- Pressure compensation - If necessary, replace
expansion valve
- Abnormal noises - Replace compressor
- High compressor - Clean
temperature
- Oil and other lubricants on
belt disc
17
 Replacement of the heater blower
(valid for all machines with Aurora air conditioner)

ƒ slide the drivers seat to the front and turn it

down
ƒ now the access to the heater blower (1)
can be reached

ƒ remove all bolts (2)

ƒ remove cover plate (1)

NOTE
Size of bolts = Torx 20
1

ƒ remove filter (1)

ƒ if the resistor (2) is broke, let it stay on the
blower and just loosen the cables
ƒ if the resistor (2) is not broke, remove it
2
from the blower and let the cables
1 connected
3
ƒ disconnect plug (3)

NOTE
The resistor is not included in the shipment of
the blower, if it is broke it has to be ordered
additionally (see valid spare parts
documentation)

NOTE
Remember how the cables have been
connected to the resistor!

Produced: A.Munn Terex Deutschland GmbH Page 1 of 2

Area of buisness TEREX Fuchs
Industriestraße 3 - D76669 Bad Schönborn
 ƒ remove bolts (1) (4x)
ƒ take out the blower
ƒ install new blower

ƒ install resistor (2)

ƒ connect plug (3)
ƒ insert filter (1)
2

3 1

ƒ position cover plate (1)

ƒ fasten bolts (2)

NOTE
Size of bolts = Torx 20
1

Produced: A.Munn Terex Deutschland GmbH Page 2 of 2

Area of buisness TEREX Fuchs
Industriestraße 3 - D76669 Bad Schönborn