HIGER BUS AIR CONDITIONING GENERAL

Service Manual of
Air Conditioning
3906_81101_ Service Manual of Air Conditioning
HIGER BUS AIR CONDITIONING GENERAL

Service manual for air conditioning

The bus air-condition is short for the bus air-conditioning, namely, the method of manpower
refrigeration and heating is adopted to adjust the indexes of temperature, moisture, airflow speed,
cleanliness, etc. in the car, thus to create a refreshing and comfortable environment in the car. The
bus is generally provided with four main functions: adjustment of the temperature in the car,
adjustment of the moisture in the car, adjustment of the airflow speed in the car and filtration and
purification of the air in the car.
If a car is directly exposed in the sun or the wind and snow, the heat insulation measures are
difficult to be taken; a large quantity of wind sand and waste gas enter into the carriage trough all
gaps during the driving of the car, which makes that the air in the carriage is polluted and the load is
increased, the driving speed of the car is variable, and stable work condition of air conditioning is
difficult to be guaranteed, etc. Therefore, the work environment of the bus air conditioning is much
severer than the air conditioning in the room. As the special work environment, the bus air
conditioning has the following characteristics: the heat load is large, other performances of the car is
affected by that the engine drive is needed for the refrigeration of the bus air conditioning, the
generality is not good, the condensation pressure is a little high, the refrigerant is easy to be leaked,
and the energy regulation and control are complex compared with other system.
This service manual mainly includes the daily maintenance of the air conditioning and the
disassembly and assembly of the system parts. However, the disassembly and assembly do not aim
at the detailed malfunctions, and the site personnel may operate with reference to related sections for
specific problems.
HIGER BUS AIR CONDITIONING GENERAL

INDEX

1 System structure diagram ·················································································· 1

1.1 Arrangement diagram for the air conditioning ·································································1
1.2 Refrigeration circulation diagram ····················································································1
1.3 KLQ6109 air conditioning system···················································································2
1.4 KLQ6758 air conditioning system···················································································4

2 Specification ······································································································ 5
2.1 Specification ···················································································································5
2.1.1 Specification of KLQ6109························································································5
2.1.1 Specification of KLQ6758························································································6
2.1.3 Specification of KLQ6796························································································7
2.1.4 Specification for 8-meter vehicle ··············································································8
2.2 Maintenance parameters··································································································8
2.2.1 Tightening moment of the bolts and nuts ··································································8
2.2.2 Tightening moment of the pipeline ···········································································9

3 Troubleshooting································································································· 9
3.1 Troubleshooting for air conditioning ···············································································9
3.1.1 Analysis and elimination for the pressure malfunction of the air conditioning system
·········································································································································9
3.1.1.1 The suction pressure is normal, while the exhaust pressure is too high.··················9
3.1.1.2 Suction pressure is too high, but the exhaust pressure is normal.·························· 10
3.1.1.3 The suction pressure is too high, and the exhaust pressure is too high. ················· 10
3.1.1.4 The suction pressure is too low, and the exhaust pressure is too low. ··················· 11
3.1.2 Unusual sound of the fan ························································································ 11
3.1.3 The refrigeration effect of the air conditioning is not good.····································· 12
3.1.4 Other malfunctions································································································· 12
3.1.4.1 No refrigeration of the air conditioning································································ 12
3.1.4.2 Condensate water is leaked in the carriage. ·························································· 13

3.2 Diagnosis of the troubleshooting for the electric system ················································ 13

3.2.1 The panel has no reaction when opened.································································· 13
3.2.2 Too shortage of the air quantity of the air conditioning··········································· 14
3.2.3 The high gear of the air conditioning has the air quantity, but the middle gear and the
low gear have no air quantity. ························································································· 14
3.2.4 The air quantity of the air conditioning is normal, and there is no malfunction
reflection on the panel, but there is no refrigeration.························································ 15
3.2.5 ER1 is displayed in the panel or the malfunction light is on. ··································· 15
3.2.6 ER1 is displayed in the panel or the malfunction light is on, and the system pressure
is too high. ······················································································································ 16
3.2.7 ER1 is displayed in the panel or the malfunction light is on, and the system pressure
is too low. ······················································································································· 16
3.2.8 Refrigeration of the air conditioning, and the ER2 is displayed in the panel. ··········· 17
3.2.9 No refrigeration of the air conditioning, and the ER3is displayed in the panel. ······· 17
HIGER BUS AIR CONDITIONING GENERAL

4 Common maintenance tools ·············································································18

4.1 Manifold gauge (fluoridation gauge) ············································································· 18
4.2 Vacuum pump ·············································································································· 18
4.3 Leak detector ················································································································ 18
4.4 Refrigerant filler valve ·································································································· 19
4.5 Multimeter ···················································································································· 19
4.6 Other special tools ········································································································ 19

5 Common maintenance items ············································································19

5.1 Vacuum pumping·········································································································· 19
5.2 leakage detection for system ························································································· 20
5.2.1 Leakage detection on appearance ··········································································· 20
5.2.2 Leakage detection for pressure ··············································································· 21
5.2.3 Precautions and methods for the filling of the refrigerant········································ 21
5.2.3.1 Attention should be paid to the following items during the filling of the refrigerant.
······································································································································· 21
5.2.3.2 Filling method of the refrigerant ·········································································· 22
5.2.4 System is filled with refrigeration oil······································································ 23

6 Disassembly and assembly of the parts ····························································24

6.1Disassembly and installation of the evaporating core body············································· 24
6.1.1 Disassembly of the core body of the evaporator······················································ 24
6.1.1 Installation of the core body of the evaporator ························································ 24
6.2Disassembly and installation of the evaporating fan ······················································· 25
6.2.1 Disassembly of the evaporating fan ········································································ 25
6.2.2 Installation of the evaporating fan ·········································································· 25
6.3.1 Disassembly of the expansion valve ······································································· 25
6.3.2 Installation of the expansion valve·········································································· 25
6.4 Disassembly and installation of the dryer ······································································ 26
6.4.1 Disassembly of the dryer ························································································ 26
6.4.2 Installation of the dryer ·························································································· 26
6.5 Disassembly and installation of the condenser······························································· 26
6.5.1 Disassembly of the condenser ················································································ 26
6.5.2 Installation of the condenser··················································································· 26
6.6 Disassembly and installation of the condensate fan ······················································· 27
6.6.1 Disassembly of the condensate fan ········································································· 27
6.6.2 Installation of the condensate fan ··········································································· 27
6.7 Disassembly and installation of the compressor····························································· 27
6.7.1 Disassembly of the compressor ·············································································· 27
6.7.2 Installation of the compressor················································································· 27
6.8 Disassembly and installation of the clutch····································································· 28
6.8.1 Disassembly of the clutch······················································································· 28
6.8.2 Installation of the clutch ························································································· 28
6.9 The disassembly and installation of the shaft sealing of the compressor ························ 28

7 Maintenance of the air conditioning ································································31

7.1 Daily maintenance ········································································································ 31
7.2 Points for attention during the application of the air conditioning·································· 35
7.3 Schedule for the items of maintenance ·········································································· 37
HIGER BUS AIR CONDITIONING GENERAL

1 System structure diagram

1.1 Arrangement diagram for the air conditioning

1 air pipeline 4 air conditioning panel

2 condenser 5 compressor
3 evaporator

Note: the arrangement diagram for the air conditioning of the right hand bus whose engine is
post-positioned is taken as a sample for integrated introduction, and the site maintainer can aim at the
specific vehicles for operation with reference to it.

1.2 Refrigeration circulation diagram

1 Expansion valve 3 Air inlet

2 Air outlet 4 Fresh air inlet

1
HIGER BUS AIR CONDITIONING GENERAL

1.3 KLQ6109 air conditioning system

2
HIGER BUS AIR CONDITIONING GENERAL

1 FRP shell bottom seat 34 Dryer 67 O-type sealing ring

2 Hoist ring 35 O-type sealing ring 68 Vent pipe 1
3 Plain washer 36 Expansion valve inlet pipe 1 69 O-type sealing ring
Standard spring
4 37 Air-in net of condenser 70 Vent pipe 2
washer
5 Hexagonal bolt 38 Condenser cover plate 71 O-type sealing ring
Condenser fan Heat preservation plate for High-pressure connecting
6 39 72
bracket I cover plate of evaporator pipe of compressor
Condenser fan
7 40 Evaporator cover plate 73 Gap bridge bracket seat
bracket II
Rubber washer for fixed Gap bridge support
8 Condenser fan 41 74
gasket assembly
9 Condenser fan fixed ring 42 Fixed gasket 75 Gap bridge wheel assembly
Sealing ring for the
10 net cover of the 43 Bolt 76 Nut M16
condenser fan
Net cover of the
11 44 Electric control box 77 Spring seat
condenser fan
12 Plain washer 45 Fuse 78 Nut M10
Standard spring
13 46 Safety piece 79 Spring washer 10
washer
14 Hexagonal bolt 47 Time relay 80 Plain washer
15 Plain washer 48 Temperature control probe 81 Fixed shaft of the generator
16 Standard spring washer 49 Relay 82 Fixed seat of the generator
Water-filtration net for fresh
17 Hexagonal bolt 50 83 Small spring
air device
Bracket for core body of the
18 51 Fresh air device assembly 84 Large spring
condenser
Air-in pipe
19 component of the 52 Evaporating fan assembly 85 Spring support rod
condenser
20 O-type sealing ring 53 Evaporating fan liner 86 Bolt M12X70
Core body assembly of the Fixed plate for core body of
21 54 87 Spring bracket
condenser the evaporator
Fixed bracket for the wiring Swing seat of the bottom
22 O-type sealing ring 55 88
harness of evaporator room seat
Internal wiring Upper heat preservation
Swing seat shaft of the
23 harness of the 56 plate of the core of the 89
bottom seat
condenser evaporator
Evaporator core body
24 Expansion valve 57 90 Bottom plate
assembly
Lower heat preservation
25 O-type sealing ring 58 plate of the core of the 91 Belt
evaporator
Inlet pipe 2 for Air return filtration net of the
26 59 92 Clutch assembly
expansion valve evaporator
Sterilization device
27 60 Temperature control probe 93 BOCK Compressor
assembly
Sterilization device Liquid outlet pipe component Low-pressure connecting
28 61 94
bracket of the condenser pipe of the compressor
29 Dryer bracket 62 O-type sealing ring 95 O-type sealing ring
Bracket 1 for liquid storage
30 O-type sealing ring 63 96 Air return pipe 2
device
Liquid storage device
31 Pipe clamp 64 97 O-type sealing ring
assembly
Bracket 2 for liquid storage
32 Gemi collar 65 98 Air return pipe 1
device
Lower fixed bracket of Internal wiring harness of the
33 66 99 O-type sealing ring
electric control box evaporator

3
HIGER BUS AIR CONDITIONING GENERAL

1.4 KLQ6758 air conditioning system

1 Evaporating fan liner 20 Sterilization device assembly

2 Support plate 1 21 O-type sealing ring
3 Support plate 22 Sealing strip
Lower sponge strip of the core body of the
4 23 Air retaining component of the condenser
evaporator
5 Cover plate of the air return pipe 24 Support plate component
6 Lower shell 25 Condensate fan
7 Right connecting plate 26 Air-in net of the condenser
8 Expansion valve 27 Condenser cover plate
9 Liquid inlet pipe of the expansion valve 28 Sealing strip
10 Temperature control probe 29 core body assembly of the condenser
11 Air return filtration net of the evaporator 30 O-type sealing ring
12 Top plate 31 Pipe clamp
Internal heat preservation plate of the
13 32 Liquid outlet pipe Ⅱ of the condenser
evaporator
Upper sponge strip of core body of the
14 33 FRP shell bottom seat
evaporator
15 Core body assembly of the evaporator 34 Control panel
16 Left connecting plate 35 DSK32 compressor
17 Fan plate 36 Low-pressure windpipe
18 Evaporating fan 37 High-pressure windpipe
19 Hoist frame 38 High-pressure liquid pipe

4
HIGER BUS AIR CONDITIONING GENERAL

2 Specification

2.1 Specification
2.1.1 Specification of KLQ6109
Refrigeration ability 25.6KW
Type KLQ6758ype BOCK FK40/560N
Working volume 555cm 3
Compressor
Cylinder number 4
Compressor oil 2.0L
Condenser Type Tubular belt
Type Axial-flow
Motor (type) Ferrite motor (112FR)
Condensate fan
800w（200X4set）
Consumed power
6800m 3/h
Inner-grooved copper
Evaporator Type tube, hydrophile
aluminum foil pipe piece
Type Centrifugal
Air flow (without airflow resistance) HI (high): 5400 m 3/h
Evaporating fan
Motor (type) Ferrite motor (T86FL)
air Consumed power 1460W
conditioning
Expansion valve Type
External balance type
Liquid storage
Volume 2.35L
device
Dryer Dryer volume 400g
High-pressure open-
circuit
2.65±0.05MPA
Pressure switch
Safety device Low-pressure open-
circuit
0.06±0.02MPA
Fusible plug 91℃
1.0±0.05MPA
Control device Condensate pressure switch
Disconnection value
Refrigerant 6.8±0.2 kg
High pressure:
1.3~1.7MPA
Normal pressure for the operation of the system
Low pressure :
0.18~0.22MPA

5
HIGER BUS AIR CONDITIONING GENERAL

2.1.1 Specification of KLQ6758

Refrigeration ability Refrigeration ability
Type DKS-32
Working volume 313cm 3
Compressor Swash plate (10-
Cylinder number
cylinder)
Compressor oil 0.5L
Condenser Condenser Tubular belt

Type Axial-flow
Condensate fan Motor (type) Ferrite motor (112FR)
400w（200X2 台）
Consumed power
3400m 3/h
Inner-grooved copper
Evaporator Evaporator tube, hydrophile
aluminum foil pipe piece
Type Centrifugal
Air flow (without airflow resistance) HI (high): 3600 m 3/h
Evaporating fan
Air Motor (type) Ferrite motor (T86FL)
conditioning Consumed power 920W
Expansion valve Expansion valve External balance type
Liquid storage
Volume 1.24L
device and dryer
Control system Automatic control
High-pressure open-
circuit
2.65±0.05MPA
Pressure switch
Safety device Low-pressure open-
circuit
0.06±0.02MPA
Fusible plug 91℃
1.0±0.05MPA
Control device Condensate pressure switch
Break value
Refrigerant 4.5±0.2kg
High pressure ：1.3-
~1.7MPA
Normal pressure for the operation of the system
Low pressure ：
0.18~0.22MPA

6
HIGER BUS AIR CONDITIONING GENERAL

2.1.3 Specification of KLQ6796

Refrigeration ability 14.3KW
Type DKS-32
Working volume 313cm 3
Swash plate (10-
Compressor Cylinder number
cylinder)
Compressor oil 0.5L

Condenser Condenser Tubular belt

Type Axial-flow
Motor (type) Ferrite motor (112FR)
Condensate fan
800w（200X4）
Consumed power
6800m 3/h
Inner-grooved copper
Evaporator Evaporator tube, hydrophile
aluminum foil pipe piece
Type Centrifugal
Air flow (without airflow resistance) HI (high)：3600 m 3/h
Evaporating fan Motor (type) Ferrite motor (T86FL)
Air Consumed power 920W
conditioning Expansion valve Expansion valve External balance type
Liquid storage
Volume 2.35L
device and dryer
Control system Automatic control
High-pressure open-
circuit
2.65±0.05MPA
Pressure switch
Safety device Low-pressure open-
circuit
0.06±0.02MPA
Fusible plug 91℃
Break value
Control device Condensate pressure switch
1.0±0.05MPA
Refrigerant 4.6±0.2kg
High-pressure ：
1.3-~1.7MPA
Normal pressure for the operation of the system
Low-pressur：
0.18~0.22MPA

7
HIGER BUS AIR CONDITIONING GENERAL

2.1.4 Specification for 8-meter vehicle

Refrigeration ability 18.3KW
Type BITZER（4TFCY）
Working volume 475cm 3
Compressor Cylinder number 4
Compressor oil 2.5L
Condenser Condenser Tubular belt
Type Axial-flow
Condensate fan Motor (type) Ferrite motor (112FR)
Consumed power 800w 6800m 3/h
Inner-grooved copper
Evaporator Evaporator tube, hydrophile
aluminum foil pipe piece
Type Centrifugal
Air flow (without airflow resistance) HI (high)：3600 m 3/h
Evaporating fan Motor (type) Ferrite motor (T86FL)
Air Consumed power 920W
conditioning Expansion valve Expansion valve External balance type
Liquid storage
Volume 2.35L
device and dryer
Control system Automatic control
High-pressure open-
circuit
2.65±0.05MPA
Pressure switch
Safety device Low-pressure open-
circuit
0.06±0.02MPA
Fusible plug 91℃
Break
Control device Condensate pressure switch
value1.0±0.05MPA
Refrigerant 5.5±0.2kg
High-pressure：1.3-
~1.7MPA
Normal pressure for the operation of the system
Low-pressure：
0.18~0.22MPA

2.2 Maintenance parameters

2.2.1 Tightening moment of the bolts and nuts

Type Tightening moment N.M Kgf.cm
M5 bolt 3.7(3.0~4.3) 38(31~44)
M6 bolt 5.0(4.1~5.9) 51(42~60)
M8 bolt 12.5(10.0~15.0) 128(102~153)
M10 bolt 26.0(20.8~31.2) 265(212~318)
M12 bolt 106~130
M5 bolt 5.4(4.9~5.8) 55(50~59)
M6 bolt 6.0(4.8~7.2) 61(49~73)
M8 bolt 14.0(11.2~16.6) 143(114~169)
M10 bolt 26.0(20.8~31.2) 265(212~318)
Self-tapping screw 2.0 20

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HIGER BUS AIR CONDITIONING GENERAL

2.2.2 Tightening moment of the pipeline

Type of joint Kgf.cm

Tightening moment N.M
3/8 17.2(14.7~19.6) 175(150~200)
1/2 22.1(19.6~24.5) 225(200~250)
5/8 31.9(29.4~34.3) 325(300~350)
3/4 41.7(39.2~44.1) 425(400~450)

3 Troubleshooting
3.1 Troubleshooting for air conditioning
Air conditioning system malfunctions of the bus are mainly that the cold air is not cold; the
refrigeration effect is not good, the unusual sound occurs, and the noise is large, etc. The malfunction
types are mainly circuit malfunction, mechanical malfunction, refrigeration malfunction, etc.
3.1.1 Analysis and elimination for the pressure malfunction of the air conditioning system

3.1.1.1 The suction pressure is normal, while the exhaust pressure is too high.

Suction pressure is normal, but the

exhaust pressure is too high

Yes
Air enters the system Re-pump vacuum, and add FI
No
Yes
Too much refrigerant Release redundant refrigerant

No
Yes
The fin of the condenser is
dirty and blocked Clean the condenser
No
Yes E
The condensate fan does not
work Replace the condensate fan N
D
No
Yes
The liquid storage dryer is Replace the liquid storage
blocked dryer

No
The pipeline is blocked Yes
Replace the liquid storage
dryer

9
HIGER BUS AIR CONDITIONING GENERAL

3.1.1.2 Suction pressure is too high, but the exhaust pressure is normal.

Suction pressure is too high, but the exhaust

pressure is normal

The air-in temperature is Yes Close the door and window or

too high the fresh air mechanism
No
The opening of the Yes Adjust the opening of the
expansion valve is too expansion opening
large
E
No
Yes N
The suction valve piece of Replace the suction valve D
the compressor is broken piece

No

The temperature sensing Yes

packet of the expansion Re-bind up the temperature
valve is not well bound up sensing packet

3.1.1.3 The suction pressure is too high, and the exhaust pressure is too high.
The suction pressure is too high, and the exhaust
pressure is too high

Yes
Too much refrigerant Drain away excrescent
refrigerant
No
Yes
The opening of the expansion adjust the expansion valve
valve is too large

No
The suction valve piece of the Yes Replace the suction valve piece
compressor is broken E
N
No D
Yes
Air enters the system Re-pump vacuum, and add FI

No
The temperature sensing
Yes Re-bind up the temperature
packet of the expansion valve
sensing packet
is not well bound up
No
The condensate fan does not Yes Replace the condensate fan
work
No
The air quantity of the Yes Check the cause and eliminate it
condensate fan is not enough

10
HIGER BUS AIR CONDITIONING GENERAL

3.1.1.4 The suction pressure is too low, and the exhaust pressure is too low.
The suction pressure is too low, and the
exhaust pressure is too low

The installation part of the Yes Tighten the bracket screws

compressor is loose
No
The clutch skids or is locked Yes Replace or adjust the cutch

No
Too shortage of the Yes Add refrigeration oil E
refrigeration oil for the system N
No
D

Too much refrigerant for the Yes

Discharge redundant refrigerant
system

No Yes
The internal parts of the Replace the internal parts
compressor is abraded

Caution: the clutch clearance of the compressor is DKS/TM0.3～0.6mm BOCK/BITZER0.3～

0.7mm.

3.1.2 Unusual sound of the fan

Unusual sound of the fan

Yes Remove the foreign body

Foreign body enters the fan
No

The installation bolt of the fan Yes Tighten the installation bolt
is loose
No
Yes E
The motor of the fan is Replace the motor of the fan
abraded or damaged N
D
No
Yes
The vanes of the fan are Adjust the mutual spacing
contacted with other parts
No
Effects of unusual voltage and Yes Eliminate the unusual voltage and
electric current electric current

11
HIGER BUS AIR CONDITIONING GENERAL

3.1.3 The refrigeration effect of the air conditioning is not good.

The refrigeration effect of the air

conditioning is not good

The system is dirty and is

blocked Replace the desiccator、clean
the expansion valve
No
Too shortage of the quantity of
Add the refrigerant
the refrigerant

No
Air enters the system Re-pump vacuum, and add
refrigerant E
No N
Too much quantity of the D
refrigerant Release redundant refrigerant
No
The compressor is damaged Replace the compressor

No
Adjust the tension of the belt
The belt skids

3.1.4 Other malfunctions

3.1.4.1 No refrigeration of the air conditioning

No refrigeration of the air

conditioning

Yes
Blowout of the fuse of the Check the cause, and replace the
compressor fuse
No

The insertion parts to connect Yes Re-connect

the clutch fall off

No
Yes Replace the coil
E
Coil of the clutch is burned out N
D
No
Malfunction of the pressure Yes Replace the pressure switch.
switch
No Yes

Refrigerant for the system is Check the cause, and re-add the
completely leaked out refrigerant

12
HIGER BUS AIR CONDITIONING GENERAL

3.1.4.2 Condensate water is leaked in the carriage.

Condensate water is leaked in the

carriage

The drainage pipe is blocked Yes Dredge the drainage pipe

No
The connection between the Yes Re-connect
drainage pipe and the unit
falls off
E
No N
The low-pressure pipe is Bind up the low-pressure pipe with D
exposed in the air duct Yes the daub

No
The installation of the
drainage pipe is not proper Yes Re-install the drainage pipe

3.2 Diagnosis of the troubleshooting for the electric system

3.2.1 The panel has no reaction when opened.

The panel has no reaction when

opened

The power switch or key Yes

Open the switch
switch of the car is not
opened
No

The fuse for the power supply Yes

Check and replace the fuse
of the panel in the electric
control box is burned out E
N
No D
The fuse for the air conditioning
in the electric control box of the Yes Check and replace the fuse
car is burned out

No
Replace the panel Yes
Replace the panel

13
HIGER BUS AIR CONDITIONING GENERAL

3.2.2 Too shortage of the air quantity of the air conditioning

Too shortage of the air

quantity of the air conditioning

The evaporating fan is Replace the fan

damaged
No

The fuse for the fan is Check and replace the fuse
damaged
No
The relay for the fan is E
damaged Check and replace the relay
N
No D
The high-speed control line is Check and find out the
open circuit breakpoints

The air return filtration net or

the evaporation core body of Clean the filtration net or
the evaporator is blocked by evaporation core body
the dusts

3.2.3 The high gear of the air conditioning has the air quantity, but the middle gear and the low gear
have no air quantity.

The high gear of the air conditioning has

the air quantity, but the middle gear and
the low gear have no air quantity

The speed-regulating Yes Check and replace the speed-

resistance for the evaporating regulating resistance
fan is damaged
No
Relevant relay with relevant Yes
wind-speed is damaged Check and replace the relay
E
No N
The control panel is damaged Yes Replace the control panel D

No
Yes
The control wiring harness has Check the internal breakpoints
open circuit

14
HIGER BUS AIR CONDITIONING GENERAL

3.2.4 The air quantity of the air conditioning is normal, and there is no malfunction reflection on the
panel, but there is no refrigeration.

The air quantity of the air conditioning is normal,

and there is no malfunction reflection on the
panel, but there is no refrigeration

The compressor is damaged Yes Check, maintain or replace the

compressor
No
Yes
Blowout of the fuse of the Check and replace the fuse
compressor E
N
No
D
The relay of the compressor is Yes Check and replace the relay
damaged
No
Open circuit of the control Yes Check and find out the
circuitry of the compressor breakpoints

3.2.5 ER1 is displayed in the panel or the malfunction light is on.

ER1 is displayed in the panel or

the malfunction light is on.

Yes
The pressure of the high- Deep check the cause for
pressure of the system is too maintenance.
high.
No Yes
The pressure of the low- Deep check the cause for
pressure of the system is too maintenance.
E
low.
N
No Yes D
The pressure switch is Replace the pressure switch.
damaged.

No

Open circuit of the pressure Yes Check and find out the
control wiring harness. breakpoints.

15
HIGER BUS AIR CONDITIONING GENERAL

3.2.6 ER1 is displayed in the panel or the malfunction light is on, and the system pressure is too high.

The pressure of the high-pressure of

the system is too high.

The condensate fan is Yes Check and replace the

damaged. condensate fan.
No

The relay or fuse of the Yes Check and replace the relay or
condensate fan is damaged. fuse.

No

The refrigerant is filled too Yes Recycle redundant refrigerant.

much.
E
No N
D
Air enters the system. Yes Re-fill refrigerant.

No

The surface of the core body of Yes Clean the surface of the
the condenser is too dirty. condenser.
No

The expansion valve is dirty Yes

and blocked or is icy and Clean or replace the expansion
blocked. valve.

No
The drying bottle is dirty and Yes Replace the drying bottle.
blocked.

3.2.7 ER1 is displayed in the panel or the malfunction light is on, and the system pressure is too low.

The pressure of the low-pressure of

the system is too low.

Yes Check the leakage points and

The refrigerant is leaked.
supplement cleaning of refrigerant

No
E
The expansion valve is dirty Yes Clean or replace the expansion
and blocked or is icy and N
valve.
blocked. D
No

The drying bottle is dirty and Yes Replace the drying bottle
blocked.

16
HIGER BUS AIR CONDITIONING GENERAL

3.2.8 Refrigeration of the air conditioning, and the ER2 is displayed in the panel.

Refrigeration of the air conditioning, and the

ER2 is displayed in the panel.

The room temperature sensor Yes

or defroster sensor is damaged Check and replace the sensor

No
Yes E
the short circuit of the room Find out the short circuit points. N
temperature sensor or
D
defroster

No

The control panel is damaged. Yes

Check and replace the panel.

3.2.9 No refrigeration of the air conditioning, and the ER3is displayed in the panel.

No refrigeration of the air conditioning,

and the ER3is displayed in the panel.

The room temperature sensor Yes

Check and replace the sensor.
or defroster sensor is
damaged.
No
E
Open circuit of the room Yes Find out the breakpoints. N
temperature sensor or D
defroster sensor.
No
Yes
The control panel is damaged. Check and replace the panel.

17
HIGER BUS AIR CONDITIONING GENERAL

4 Common maintenance tools

4.1 Manifold gauge (fluoridation gauge)

The manifold gauge is an absolutely necessary important tool for maintenance of the bus air
conditioning system, and is mainly used for pumping the vacuum for the system, adding the
refrigerant, and diagnosing the malfunctions of the refrigeration system, etc.
The manifold gauge has two pressure meters. One high-pressure meter is applied to detect the
pressure of the high-pressure side of the system, while the other low-
pressure meter is applied to detect the pressure of the low-pressure
side of the system and is also applied to display the vacuum.
As shown in the right figure on the structure, the manifold gauge
consists of a high-pressure meter, a low-pressure meter, a manual
low-pressure valve, a manual high-pressure valve, a valve body, a
high-pressure joint, and a joint of refrigerant-vacuum pumping. When
work, the high and low joint are separately connected with the high and
low valve of the compressor by the soft pipe. The middle joint is
connected with the vacuum pump or the refrigeration steel bottle.
Accessories are a high-pressure meter pipe (red), a low-pressure meter pipe (blue), a middle
meter pipe (yellow), a low-pressure fast joint and a high-pressure fast joint.

Caution: please make sure to distinguish the high-pressure and low-pressure end when using
the tools, the high-pressure and low-pressure joints can not be improperly connected. Please make
sure the measurement range of the high-pressure meter and low-pressure meter of the manifold
gauge for which can not be used over the measurement range.

4.2 Vacuum pump

During installation and maintenance of the refrigeration system, air
must enter the system, which will make icy block to the expansion valve,
increased condensate pressure and corrosion to the parts of the system,
etc. the vacuum pump is functioned to pump the vacuum and to eliminate
the air and water in the system. Vacuum pumping will not pump out the
water in the system, but will reduce the boiling point of the water after the
vacuum is produced. The water will boil under low temperature and will
be pumped out of the system in the form of steam.

Caution: before used, the oil level of the vacuum pump should be
checked, and oil should be added in time if the oil is short.

4.3 Leak detector

The leak detector is an apparatus which has a high sensitivity and

18
HIGER BUS AIR CONDITIONING GENERAL

is applied to check whether the refrigerant is leaked or not for the system. When use, the power
switch of the leak detector is opened at first, and then the probe shall be put on the detection position.
If the detection position has the leakage, the leak detector will emit alarm sound.

Caution: please take out the battery if the leak detector is not used for a long time.
4.4 Refrigerant filler valve
The refrigerant filler valve aims at filling the system with small-tank
refrigerant. The use method is to counterclockwise rotate the handle of the
filler valve till the valve needle withdraws. The filler valve shall be installed on
the refrigeration tank, and then the filler valve should be clockwise rotated till
the valve is sealed with the refrigeration tank. The plate-type nut shall be
clockwise rotated to make the valve needle pierce the refrigeration tank. If
the refrigerant is needed to be filled, the plate-type nut is counterclockwise
rotated; at this time, the refrigerant can come out of the refrigeration tank.

Caution: please confirm that there is no refrigerant in the tank before the filler valve is
dismantled, or the refrigerant in the tank will blow the filler valve away.

4.5 Multimeter
The multimeter is a common apparatus applied to check the electric apparatus part of the
system. When used, the power switch of the multi-meter shall be opened, and the conversion switch
shall be arranged on the shift of the item needed to
detect. (Resistance, voltage and electric current)

Caution: the measurement range shall be

well adjusted when used, meanwhile, please
distinguish the anode and cathode of the multi-
meter.

4.6 Other special tools

Recoverer, pipe cutter, flaring tool, valve core
key, retainer ring plier, and three jaw

5 Common maintenance items

5.1 Vacuum pumping

The vacuum pumping aims at eliminating the
air and water in the refrigeration system, which is an
extremely important work procedure for the
maintenance of the air conditioning. In order to

19
HIGER BUS AIR CONDITIONING GENERAL

pump out the air and moisture in the system, the time for vacuum pumping shall be 30~60 minutes
according to the size of the system.

Note: the right figure shows the connection method of the pipeline for vacuum pumping, and the
operation process is as follows:

a) The high-pressure and low-pressure soft pipes on the manifold pipe are separately connected
with the interface of the high-pressure valve and the low-pressure valve, and then the middle soft pipe
shall be connected with the vacuum pump.

b) The manual high-pressure valve and low-pressure valve on the manifold gauge shall be
opened, the vacuum pump shall be started, two pressure meters shall be watched, and the vacuum of
the system should be pumped to about 100kpa.

c) Manual high-pressure valve and low-pressure valve is closed to see whether the pressure
displayed by meter pointer is returned and upturned, if so, it means the leakage occurs to the system,
at this time, the leakage detection and repairing shall be carried out. If the meter pointer keeps still,
the leakage detection and repairing shall be carried out, the high-pressure valve and low-pressure
shall be opened to continue to pump the vacuum, to make the pointer of the vacuum pressure meter
stable.

d) The manual high-pressure valve and low-pressure shall be closed, and then the vacuum
pump is closed.

Caution: be sure to close the manual high-

pressure valve and the low-pressure valve at first,
and then close the vacuum pump.

5.2 leakage detection for system

The work environment of the bus air conditioning
is severe, and the refrigeration system always
vibrates with the operation of the car, which is
extremely easy to make the damage of the parts and
the looseness of the joint, and to make the leakage of
the refrigerant.

5.2.1 Leakage detection on appearance

The refrigerant and the refrigeration oil work in
the system at the same time, therefore, the leakage
position of the refrigerant is always accompanying
with the refrigeration oil. If the oil sewage is found

20
HIGER BUS AIR CONDITIONING GENERAL

somewhere, the following methods shall be applied for deep leakage detection.

5.2.2 Leakage detection for pressure

The manifold gauge should be correctly connected at first, as the figure shows; after correctly
connected, the high-pressure and low-pressure maintenance valves shall be opened. The dry
nitrogen shall be filled to the system with general pressure of
1～1.5 MPa. When the system reaches certain pressure, each
joint and weld should be smeared with the soap liquid
(especially at the oil sewage position). In large leakage
positions, slight sound and large foam occur, while in small
leakage, interrupted small foams occur, therefore, the leakage
detection should be carefully and patiently carried out.

Caution: attention should be paid to the adjustment and

the magnitude of the nitrogen pressure during the leakage
detection, avoiding people hurt by high-pressure.

5.2.3 Precautions and methods for the filling of the refrigerant

Caution: Do not mistake the refrigerant！

5.2.3.1 Attention should be paid to the following items during the

filling of the refrigerant.

Caution:
※The type and filling quantity shall be determined before filing,
and do not mistake the refrigerant. (The refrigerant used by the
New Tongchuang air conditioning, and see the attached table for the filling quantity.)
※The refrigerant shall be kept in the place where children can
not contact it.
※Do not place the refrigerant in the burning sun, or in the high
temperature close to the fire source and vehicle engine.
※Do not put the refrigerant into the fire. (Also for the empty tank)
※Do not directly heat the refrigerant or pour the refrigerant into
the water with the temperature over 40 degrees, because it is easy
to cause the increment of the pressure and the crack of the tank
body.
※Do not shake refrigerant fiercely, and do not squeeze, throw and pour it.

21
HIGER BUS AIR CONDITIONING GENERAL

※Please wear guard glasses during filling the refrigerant, and make the refrigerant enter into the
eye or contact with the skin. In case that the refrigerant enters into your eyes or contacts with the skin,
a large quantity of clean water should be used to
wash the refrigerant away and the doctor shall be
found in time or go to the nearby hospital for
treatment.
※ The filling of the refrigerant shall be
carried out in the aeration place, and the
discharging of the refrigerant in the non-aeration
place will make people anoxia asphyxia.

5.2.3.2 Filling method of the refrigerant

1) The steps to fill the refrigerant in the high-
pressure end are as follows.
a) After the vacuum pumping for the system is
finished, the manual high-pressure valve and low-
pressure valve of manifold gauge shall be closed.
b) One end of the middle soft pipe shall be
connected with the refrigerant filler valve or steel
bottom, as the right figure shows, and the
refrigerant shall be opened.
c) Manual high-pressure should be screwed to fully-open position (manual high-pressure valve is
closed.), and the refrigerant pipe shall be converted, in convenient that the liquid refrigerant shall be
filled at the high-pressure side.
d) After the liquid refrigerant with a certain quantity is filled, the hand valve of the refrigerant valve and
the manual high-pressure valve of the manifold are closed.

2) The steps to fill the refrigerant in the low-pressure end are as follows.
a) The engine is started, the rotation speed is controlled at 2000r/min, the air conditioning shall be set
to the refrigerant, the air quantity switch shall be adjusted to high-gear, and the required temperature
shall be adjusted to the minimum temperature.
b) The manual low-pressure valve of the manifold gauge is opened (now the refrigerant tank shall be
upright rather than headstand), to make the gaseity refrigerant continue to enter into the system till no
air bubbles and no excessive refrigerant observed from the liquid slight glass.
c) After filled, the filler valve on the refrigerant and the manual low-pressure valve shall be closed, the
air conditioning is closed, the engine shall be stopped, and the manifold gauge is dismantled from the
compressor with rapid action.

Caution:
※One-time filling should be carried out by the filling machine with certain quantity.

22
HIGER BUS AIR CONDITIONING GENERAL

※The liquid refrigerant is not allowed to fill at the low-pressure side (the refrigerant steel bottle shall
be filled in headstand), which will make liquid impact to the compressor or internal damage. The
system shall be filled with the refrigeration oil.

5.2.4 System is filled with refrigeration oil

General maintenance system does not need to be filled with refrigeration oil, but when the
refrigeration system parts are
replaced and severe leakage
occurs to the system, the
refrigeration oil must be
supplemented. The specific
operation steps are as follows.

1) The vacuum should be

pumped for the system at first,
and then required quantity of
the refrigeration oil shall be
filled by the graduate.

2) The low-pressure soft pipe

at one end of the connecting manifold
should be screwed down and placed into
the graduate, as the figure shows. At this
time, the refrigeration oil will be sucked into
the system. If the suction quantity is not
enough, the vacuum pump can be started
and the manual high-pressure valve can be
opened.

3) After the refrigeration oil is filled, the

refrigerant can be filled only after the
vacuum is pumped for the system.

Caution: the filled refrigeration oil

shall adopt the same trademark with the refrigeration oil used by the system, and the refrigeration oils
with different trademarks absolutely can not be mixed in case of the refrigeration oil is metamorphic,
which will cause the damage of the compressor and the system.

23
HIGER BUS AIR CONDITIONING GENERAL

6 Disassembly and assembly of the parts

6.1Disassembly and installation of the
evaporating core body
6.1.1 Disassembly of the core body of the
evaporator
6) After the flowing steps are finished, two
people can uplift the core body of the evaporator
from the
evaporating room of the air conditioning.

1) The refrigerant in the system shall be

recycled at first, and then the pressing plate nut
connected in the air duct by the low-pressure
pipe and the air return pipe of the evaporator
shall be disassembled by the wrench.

2) The M22X1.5 nut which connects the

expansion inlet pipe with the liquid storage
device and the drying bottle shall be
disassembled by the wrench and the 17/16-
14UNF nut which connects the expansion valve
and the distribution pipe shall be disassembled
by the wrench.

3) The four M8X20 bolts at left and right end

plates which connect the evaporating core body
and the core body shall be disassembled by the
wrench/sleeve.

4) The M6X25 nut which connects the
evaporating core body and the FRP bottom seat
shall be disassembled by the wrench/sleeve.
5) All connectors in the electric control box shall
be pulled out, bandage filled on the fixed frame
of wiring harness shall be cut, the temperature
sensing probe shall be pulled out, the air return
filtration net piece and the sponge strip shall be
disassembled, and the expansion inlet pipe shall
be disassembled.
6.1.1 Installation of the core body of the
evaporator
The installation of the core body of the
evaporator is reverse to the above disassembly.
Caution:
※Please carefully install the evaporator in case
of damaging the fin.
※The temperature sensor for the evaporator
shall be installed at the original position.

※Replace the O-type ring

24
HIGER BUS AIR CONDITIONING
Specification of O-type Size Quantity
ring
TR109H Φ11.2X2.4 2
6.2Disassembly and installation of the
evaporating fan
6.2.1 Disassembly of the evaporating fan
1) The bandage shall be cut by the fixed wiring
harness, and the connectors of the fan shall be
pulled out.
2) The self-tapping screws for installation of the
evaporating fan shall be removed by the self-
tapping screw gun/self-tapping screw knife.
6.2.2 Installation of the evaporating fan
1) The air outlet of the evaporating fan which is
glued with the PE-plate liner shall be aligned
with the air outlet of the FRP bottom seat.
2) The fan shall be fixed on the FRP shell by the
self-tapping screw of Φ5X16.
3) The connectors of the fan shall be connected.
4) The wiring harness shall be bound up by the
bandage.
6.3 Disassembly and installation of the
expansion valve
GENERAL
6.3.1 Disassembly of the expansion valve
1) The refrigerant in the system shall be
recycled at first.
2) The heat preservation daub enwrapped at the
exterior of the expansion shall be removed by
hand.
3) The nuts at the inlet and outlet ends of the
expansion valve should be separately removed
by two wrenches.
4) The TF3B04C bolt which connects the
expansion valve and the balance pipe shall be
removed by the wrench.
5) The shock absorption damping which is
wrapped with the temperature sensing packet of
the expansion valve on the air return pipe of the
evaporator shall be cut by an art design knife.
The screw shall be removed by a cross
screwdriver and the temperature sensing packet
shall be removed.
6.3.2 Installation of the expansion valve
1) One end of the expansion valve shall be
tightened with the connecting bolt of the liquid
sight glass.
Tightening moment: 85-90Nm
2) The other end of the expansion should be
tightened with the connecting bolt of the core
body separator of the evaporator.
25
HIGER BUS AIR CONDITIONING GENERAL

3) The expansion valve shall be connected with Caution: after the drying bottle is replaced,
the balance pipe by the wrench. a little refrigerant should be added to the system.

4) The temperature sensing packet shall be 6.5 Disassembly and installation of the

installed in the horizontal position of the air condenser

return pipe of the evaporator and is firmly fixed
by the screw. 6.5.1 Disassembly of the condenser
1) The refrigerant in the system shall be
5) The expansion valve and the temperature recycled, and the joint of the air-in pipe
sensing packet shall be well bound up by the component and the joint of the air return pipe
heat preservation daub. connected with the core body of the condenser
shall be screwed loosely by the wrench.
Caution: replace the O-type ring
2) Four M6X25 bolts of the fixed core body shall
Specification of O- Size Quantity be disassembled, and the M6X25 bolt on the
type ring
bracket of the core body of the condenser shall
TR109H Φ11.2X2.4 2
be disassembled
6.4 Disassembly and installation of the dryer
3) After the above steps are finished, two people
6.4.1 Disassembly of the dryer can uplift the condensate core body from the
1) The check valve on the connecting pipeline at condenser room.
the two ends of the dryer shall be shut off.

2) The inlet and outlet nuts of the dryer shall be

screwed loosely by the wrench, and the drying
bottle shall be removed.

3) The original O-type ring shall be replaced by

the new 11.2X2.4 O-type ring. 6.5.2 Installation of the condenser
The installation steps of the condenser are
reverse to the above disassembly steps.

Caution:
※Please carefully install the condenser in case
of damaging the fin.
※Replace the O-type ring
Specification of O-
Size Quantity
type ring
6.4.2 Installation of the dryer
TR114H Φ19.6X2.5 2
The installation of the dryer is reverse to the
above disassembly.
26
HIGER BUS AIR CONDITIONING
6.6 Disassembly and installation of the
condensate fan
6.6.1 Disassembly of the condensate fan
1) The connectors on the condensate fan shall
be pulled out.
2) Four M6X25 bolts fixed on the FRP shell shall
be disassembled by the pneumatic drilling
gun/sleeve, and then the M6X25 which connects
the fan bracket with the fan is disassembled.
6.6.2 Installation of the condensate fan
1) The installation of the condensate fan is
reverse to the disassembly. The connectors
wiring harness shall be well fixed.
2) Air conditioning is started and the normal
operation of the fan means normal condensate
fan.
Caution: plaster the sealing frame of the
condensate fan.
6.7 Disassembly and installation of the
compressor
6.7.1 Disassembly of the compressor
1) Disassembly of the gap bridge wheel
a) The refrigerant shall be recycled at first, the
pipeline connected with the compressor is
disassembled, and the belts shall be
disassembled.
GENERAL
b) The bracket shaft of the gap bridge wheel
shall be disassembled by the wrench, and then
the nut which connects the gap bridge wheel
with the bracket of the gap bridge wheel shall be
disassembled and the gap bridge wheel shall be
taken out.
2) Disassembly of the compressor
a) The first step is the same with the above (the
first step of the disassembly of the gap bridge
wheel assembly).
b) Four M12X60 bolts on the bottom plate of the
compressor shall be disassembled by the
wrench, and the compressor shall be
disassembled from the bottom plate.
6.7.2 Installation of the compressor
The compressor shall be installed on the bottom
plate and be fixed by four M12X60 bolts and
relevant nut, plain washer and spring washer.
Caution: it is forbidden to convert the
compressor during the transportation process.
27
HIGER BUS AIR CONDITIONING GENERAL
6.8 Disassembly and installation of the a) The axially tightened nut of the transition
clutch wheel shall be loosened by the wrench at first.
b) Then the stretching bolt at the top end shall
6.8.1 Disassembly of the clutch be loosened (the spring pressing rod nut shall
1) The first step is the same with the above (the be loosened when there is no transition wheel.),
first step of the assembly of the gap bridge and belt connecting the transition wheel and the
wheel assembly). clutch shall be taken out.

2) The M12X30 external hexagonal bolt shall be

disassembled, and four internal hexagonal bolts
fixing the compressor shall be disassembled Axially tightening nutStretching
and the clutch shall be taken out. bolt

2) Disassembly of clutch

Reference：Please refer to the

disassembly of the clutch in 6.8.1.

3) The felt strip is disassembled. The oil suction

felt strip can be taken out by loosening the collar
with a flat tip screwdriver.

3) The belt wheel is disassembled. The rotor of

the clutch is fixed by a wrench, and the other
wrench is adopted to loosen the bolt at the shaft
end of the clutch. When loosened to certain Collar
position (the bolt bears the clasp), the bolt is
subject to the force, continuously the rotation
belt wheel will be subject to the extrusion and be
4) Disassembly of the shaft sealing cover
loose and disconnected.
a) The check valve shall be closed, the
refrigerant in the compressor shall be recycled
4) The coil is disassembled, and four tightening
or discharged, and the semiround key on the
bolts are loosened by the internal hexagonal
crankshaft shall be removed.
wrench to disassemble the coil of the clutch.
b) The dust and grease mark on the surface of
the compressor shall be cleaned by the
6.8.2 Installation of the clutch
dishcloth which is
The installation of the clutch is reverse to the
dipped with gasoline; especially the shaft
disassembly.
sealing cover part should be cleaned.

6.9 The disassembly and installation of the

shaft sealing of the compressor
1) Disassembly of the belt
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HIGER BUS AIR CONDITIONING GENERAL

Check valve Static ring

Semiround key Sealing ring

7) All parts shall be cleaned. The shaft sealing

c) After the bolt on the shaft sealing cover is
cover, oil sealing, sealing ring and end surface
loosened by the wrench, the shaft sealing cover
of the crankshaft shall be cleaned by the
can be taken out. If the bolt is loosened, but the
dishcloth which is dipped with the gasoline, after
shaft sealing cover still can not be taken out, the
that, clean dishcloth shall be adopted to dry the
bolt can be screwed into the two symmetrical
all parts.
screw thread holes of the shaft sealing cover,
and the shaft sealing cover will be ejected out
from the body after tightly screwed.

Shaft sealing
cover

8) All parts shall be lubricated. The refrigeration

oil (BSE55) shall be adopted to lubricate the

5) The dynamic ring is disassembled. The oil shaft sealing cover, the oil sealing, the end

sealing and dynamic ring can be taken out surface of the crankshaft and new static ring and

generally by pressing the dynamic ring in the dynamic ring.

shaft sealing cover.

Dynamic
ring

6) Disassembly of the static ring

a) The sealing ring shall be slightly prized by the
flat tip screwdriver, and be careful not to
damage the sealing ring.
b) The flat tip screwdriver shall be slightly
knocked by the hammer to thrust the static ring
on the shaft sealing cover.
9) O-type ring is replaced. The O-type rings for
shaft sealing cover and for the oil sealing are
replaced and are lubricated by the refrigeration
oil (BSE55).

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HIGER BUS AIR CONDITIONING GENERAL

12) Installation of the clutch

a) Installation of the coil of the clutch
b) Installation of the belt wheel: the rotor of the
clutch shall be fixed by one wrench, while the
other wrench tightly screws the bolt at the shaft
end of the clutch.

10) Installation of shaft sealing component

a) The sealing ring and the static ring shall be
installed without damaging the surface of the
static ring 13) Installation of the belt: the relevant belts

b) The oil sealing and the dynamic ring shall be shall be sleeved with all belt wheels. The

installed with the oil hole faced upwards. stretching bolt shall be tightly screwed at first,

c) Installation of the shaft sealing cover and the locking nut at the rear of the transition
wheel shall be tightly screwed. The spring
pressing rod nut can be directly tightly screwed
if there is no transition wheel.

11) Installation of the oil felt and the semiround

key
a) The oil felt is installed (the oil felt needs to be
replaced after absorbing the oil).
Caution: the operation of the disassembly
b) The steel hammer is adopted to slightly knock
and installation shall be carried out slightly. The
the semiround key into the concave trough.
air tightness check shall be carried out after the
replacement is finished. The compressor is
installed into the system only after the
compressor is determined without leakage

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HIGER BUS AIR CONDITIONING GENERAL

7 Maintenance of the air conditioning

7.1 Daily maintenance

The work environment of the bus air conditioning is extremely severe, in order to insure the
safety and reliability of the air conditioning system and to obtain the best application effect and
performance, periodic maintenance to the air conditioning system is very important, for which not only
reduces the breakdown rate of the air conditioning system, but also improves the service life of the air
conditioning.
1）When a car is parked in summer, it should be avoided directly exposed in the sun.
In the situation where a car is exposed in the sun, the heat load of the vehicle is sharply increased. As
the increment of the load during the operation of the air conditioning, the heat dissipation is not good
and the refrigeration effect and the temperature reduction speed will be slowed down.

2) The tensioning of the belt should be check and loose belt should
be tensioned in time. After certain time operation of the air
conditioning, the belt of the air conditioning may be loosened. As
the loose belt is easy to cause the skid of the belt, thus to make
that the temperature of clutch of the air conditioning rise, the sucker
of the clutch and the coil are damage, meanwhile, the service life of
the belt is affected as the belt will emit the sharp noise.

Note:
Check method: the middle belt should be subject to a vertical pressure of 100N by the finger, and the
deflection between two belts is suitable to be 16mm/m. If the belt is found severely damaged, the belt
with the same type and the same length shall be replaced. If the belt is excessively loosen, the belt
tensioning wheel or spring rod nut of bracket of the compressor shall be adjusted in time to make the
tensioning in suitable range.

Caution: too much tension of the belt will lead to all kinds of malfunctions such as deflection of
the shaft and bearing of the air conditioning compressor, oil leakage of the shaft sealing and abrasion
of the bearing of the belt wheel, etc., finally lead to the severe aftereffect of damage of the
compressor. Therefore, checking and adjusting the tensioning of the belt in time is one of the jobs to
which each driver must pay attention.

3) All transmission belts of the air

conditioning compressor and
generator are forbidden to be
disassembled during the season
when the air conditioning is stopped.
The belt of the air conditioning is the
HIGER BUS AIR CONDITIONING GENERAL

transmission part which connects the generator and the bracket of air conditioning; meanwhile, it is
the part to determine the position and status of the bracket of the compressor. If the belt is
disassembled, the bracket of the compressor will lose the balance and shake as well as the acute
vibration during the driving of the car, which makes the pipeline of air conditioning and wiring harness
which connect the compressor are broken, or the bracket of the compressor falls off if severe, which
makes the damage of the compressor. After the belt is disassembled, the driver can not achieve the
start maintenance to the air conditioning system in the winter according to the regulations, which lead
to the lubrication of the internal mechanism of the compressor is not good and the compressor is
locked during the first start of the machine in the season when the air conditioning is used.

Caution: if the bracket of the compressor is with an air conditioning generator, it is also
forbidden to disassemble the belt between the generator and the compressor. After the belt is
disassembled, the generator will be loosened, the cable will be broken and damaged, which leads to
the damage of the air conditioning apparatus and the generator, or even causing short circuit and fire
if severe.

4) Please check the cleanliness of the air return grid filtration net
and the core body filtration net of the evaporator and clean them on
schedule. The air return grid filtration net and the core body
filtration net of the evaporator will accumulate the dust or be
blocked after long time used, which leads to the low heat exchange
efficiency of the air conditioning system, large air return quantity and bad refrigeration effect.

Note:
Cleaning method: the air return grid on the air return mouth of the air conditioning in the carriage shall
be disassembled, the filtration nets shall be taken out separately from the air return grid and the
evaporator assembly, be cleaned by the pressurized air or warm water filled with the mild detergent,
and then cleaned by the clean water. The filtration nets shall be re-installed then.

Caution: the fixed clamp of the filtration nets shall be firmly fixed when the filtration nets are re-
installed in case of the filtration nets drop.

5) Please check the cleanliness of the condenser and the cooling fin of the core body of the
evaporator and the cooling fin shall be cleaned in time. The non-cleanliness of the surface of the
cooling fin of the core body of the condenser will make the heat dissipation effect of the condenser is
not good, and the high-pressure is high, which affects the refrigeration effect of the air conditioning.
The non-cleanliness of the surface of the core body of the evaporator will make the heat exchange
efficiency of the evaporator is reduced and the evaporation of the refrigerant is not complete and the
refrigeration effect of the air conditioning is not good.

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HIGER BUS AIR CONDITIONING GENERAL

Note:
Cleaning method: the cover on top of the machine shall be opened. The water gun added with mild
detergent is adopted for cleaning, and the soft brusher can be also adopted for washing and brushing
along the fin direction, finally, the clean water is used to wash.

Caution: the water pressure shall be well adjusted during

cleaning process. The cooling fin shall not be washed down on
the ground. If the phenomenon of that the cooling fin is reversed, it
should be adjusted in time; meanwhile, during washing, do not
make the water injected into the air conditioning apparatus and
the carriage.

6) Check the phenomena of oil leakage and oil loss of the

compressor. The air conditioning which is used for long is
necessary to produce the normal consumption or non-normal consumption of the refrigeration oil of
the compressor. If the there is a shortage of the refrigeration oil of the compressor, the compressor
will be damaged.

Note:
Check method: regularly check the large quantity of oil mark at the shaft sealing and the bracket of
the compressor. After 20 minutes since the air conditioning is started, check the height of the
refrigeration oil in the oil sight glass of the compressor. The normal height should be at 1/4~3/4 of the
oil sight glass.

Caution: when a large quantity of oil marks are found at the shaft sealing and the bracket of the
compressor, or the refrigeration oil can not be seen from the oil sight glass, the air conditioning shall
be stopped at once and be reported for maintenance, which is the necessary responsibility and
obligation of each driver to avoid damage of the mechanism caused by the oil loss, oil leakage, dry
friction and looseness and so on.

7) The filing quantity of the refrigerant for the air conditioning shall be checked. After long time used of
the air conditioning system, the refrigerant will slightly bleed or leak; the shortage of the system
refrigerant will severely affect the refrigeration effect of the air conditioning.

Note:
Check method: the air return grid in the
carriage shall be disassembled, the air
conditioning is opened to set the minimum
temperature in the carriage and the

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HIGER BUS AIR CONDITIONING GENERAL

maximum air quantity, and the rotation speed of the compressor shall be controlled at
1800~2000r/min. The liquid sight glass of the air conditioning is seen as the right figure shows.

Caution: when the refrigerant is found not enough, please contact with the engaged
maintenance stations for the supplementation of the refrigerant.

8) The lubrication operation to the compressor shall be done in the season when the air conditioning
is stopped or after the air conditioning is stopped for a long time. When the air conditioning is stopped
for a long time, the refrigeration oil in the compressor will be accumulated into the oil trough,
meanwhile, as the temperature deviation of the internal and external car, part of the refrigeration oil is
accumulated in the oil trough, thus the surface of the parts which require the lubrication have a low oil
quantity. If run again, the scuffing of the cylinder bore or locking may occur to the compressor.

Note:
Operation method of the lubrication: rotate the clutch of the compressor and rotate the belt for several
rings by hand before the air conditioning is started, and then start the engine, open the door and the
window, open the fan to the maximum quantity (without refrigeration at this time) to make the fan
operated unloaded for 20 minutes, after that, start the refrigeration of the air conditioning. After 5
seconds, stop it at once (start to clock when the clutch of the compressor is sucked), restart the air
conditioning and stop it after 5~10 seconds, this operation shall be repeated for 3~5 times, after that,
start the air conditioning as normal and last it for 5~10 minutes.

Caution: when the air conditioning is stopped, the above operation shall be carried out every 2
weeks under the state of idler speed.

9) Check the pipeline, leakage of joint, abrasion, and looseness. The abrasion and looseness of the
pipeline of the air conditioning will lead to the bleed and leakage of the refrigerant of the air
conditioning, which will make the refrigeration effect of the air conditioning reduced, even no
refrigeration effect of the air conditioning system.

Note:
Check and operation method: observe the connections of each
pipeline to see whether there is oil mark or oil mud. If so, the soap
water can be adopted for detection to see whether the soap water
bubbles or not, if so, it means leakage exists. If the connecting nut is
loosened, it should be re-tightened. If the fixed position of the pipeline
is found abraded and interfered, it should be re-fixed.

Caution: the connecting nut should not be subject to excessive

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HIGER BUS AIR CONDITIONING GENERAL

large force in case of the sealing element is damaged when the connecting nut is tightened. When the
connecting nut is tightened, if leakage still exists, please find the engaged maintenance station in time
for maintenance.

10) Check the wiring harness and the connectors: the abrasion of the wiring harness of the air
conditioning, the drop of the connectors, and the looseness of the power supply line and ground cable
will cause the electric elements to be damaged and the air conditioning system can not work normally,
or even causes the fire if severe.

Note:
Check method: periodically check the connectors, power supply line and ground cable of the air
conditioning, if unusual conditions or looseness are found, please repair it at once.

11) If unusual noise, vibration, peculiar smell or other unusual situations are found, please stop the air
conditioning at once and contact with the engaged maintenance station in time for maintenance.

7.2 Points for attention during the application of the air conditioning
The application and maintenance of the
New Tongchuang air conditioning should strictly
comply with the relevant regulations in the
service manual of our company; meanwhile,
attentions should be paid to the following items.
1) Water is forbidden to enter the manipulator of
the air conditioning, especially when the car is
washed, or it is rainy or the tea cup is placed on
the car, the water should no be spilled to the manipulator, in case of the short circuit of the internal
element, which will damage the manipulator.

2) The engine is forbidden to be stopped when the air conditioning is running, or the engine is
forbidden to be started after the air conditioning is started, which will lead to excessive large instant
torsion of the clutch to burn out the clutch.

3) It is forbidden to close the air mouth or the air mouth is

blocked when the air conditioning is running, which will make
the temperature in the evaporator is too low and the air can not
be blowed out, which makes the core body or the expansion
valve ice up and the refrigerant is not fully evaporated in the
evaporator.

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HIGER BUS AIR CONDITIONING GENERAL

4) The air conditioning shall be avoided to contact with the system parts of the air conditioning during
running, as all transmission parts are running in high speed, the personnel are easy to be damaged
when contact.

5) During the long-distance slope climbing or high-speed overtaking, the air conditioning should be
closed for a while. The air conditioning needs to consume the power of 10 horsepower during running,
in order to insure the driving performance of the vehicle; the air conditioning should be temporarily
closed.

6) The electric consumption will be increased when the car is driving in rain or in night, so the set
temperature of the air conditioning at this time should not be too low, as the set temperature which is
too low makes the air conditioning work for a long time and consume more electric energy.

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HIGER BUS AIR CONDITIONING GENERAL

7.3 Schedule for the items of maintenance

Time interval
remar
Check position Check points each each eac 5000 hours 10000 hours
k
week mont h
h year
Unusual metal ☆
noise
☆ ☆ 10000
Refrigeration oil h
Compressor
quantity Repla
ce
Oil leakage of ☆
Com shaft sealing
pres Unusual noise ☆ ★
sor Clutch Clearance of
clutch
Unusual noise ☆
Transition
wheel Replace the ☆
bearing
Belt tensioning ☆ ☆
Bracket of ☆ ☆
Tightness of bolt
compressor
Damage and ☆
Exhaust pipe abrasion
Joint leakage ☆
Damage and ☆
Suction pipe abrasion
Pipe
Joint leakage ☆
line
Damage and ★ ★
abrasion
Underground
Water drop ball ☆
pipe
falls
block ☆
Con Condensate large ☆
dens fan maintenance
er Condenser damage and ★ ★
piece block
Fixed bolt tightness ☆
unusual noise ☆
Evaporating 大修 ★
fan large
maintenance
Evaporating damage and ☆
Eva
pora fin block
tor Fixed bolt tight state ☆
Dryer replace
Liquid sight refrigerant
glass quantity
Air return cleaning
filtration net

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HIGER BUS AIR CONDITIONING GENERAL

Time interval
eac each each 5000 10000 hours
check position check points remark
h month year hours
wee
k
Wiring abrasion and ☆
harness rupture
Looseness ☆
grounding
or
wire
desquamate
Looseness ☆
anode line or
Circ
desquamate
uit
Looseness ☆
connector or
desquamate
output ☆ ☆
generator
voltage
Operation operation ☆
panel
Pressure action switch ☆
switch
Internal leakage of ☆
Oth pipeline refrigerant
er connection
Heat Chap or
preservation aging
material

38