INTRODUCTION OF

AIR CONDITION SYSTEM

 Contents
• AC S
System
t
• Assemblyy Practices &
Precautions
• Compressor Oil
• Runningg In
• Audit Observations
 Variants

•NEF Single
g AC

•NEF
NEF D
Duall AC
 components

• Compressor
C
• Compressor Mounting Bracket
• HVAC with Control Panel
• Rear Cooling Unit
• Condenser
• Condenser Fan & Shroud
• Hoses & Tubes
• Kitti & Accessories
Kitting A i
 Lay Out – Single AC
Control Panel

HVAC

Hose Suction
Tube & Acc Hose Discharge
Condenser
Assembly

Compressor
Lay Out – Dual AC
Rear Cooling Unit

Piping – Rear AC
 XYLO VARIANT WITH RR AC UNIT

Third Row Seating

AC GRILL

GRILL SHUTTER KNOB

LH SIDE

RR AC UNIT
Second Row Seating BLOWER SPEED
CONTROL KNOB

AC GRILL
 Compressor

5 pistons, double acting swash type – SLIM series ( smaller in size, high cc)
Capacity - 130 cc
 Compressor Functioning
Low pressure vapour
from Evaporator
Cylinder block
Suction port
Sh
Shoe-piston
i t
Piston
Front head cover
ea head
Rear ead co
cover
e
Shaft

Swash plate

Discharge port
High pressure vapour
discharge to condenser
 IRD Condenser

NEF – Single AC NEF – Dual AC

•IRD – integrated receiver dryer (sub cool type condenser)

•Multi flow with 4 pass tubes
 AC System
S
Sensing
i bulb
b lb Evaporator

TXV
Heater

Conditioned
Passenger Air
cabin

Engine
room

Receiver Drier
Compressor

HP Condenser

LP Air
HVAC
 AC PIPES

RELAYS

RH`D’ PILLAR

RR AC COOLING UNIT
Assembly Practices &
Precautions
Assembly Practices
Assembly Practices
Examples of claims due to wrong Assy.
Assembly Practices
Examples of claims due to wrong Assy.
Assembly
y Practices
Tightening Torques
 Tightening Torques

Joint Type Location Tube Thread Nut A/F Union Tightenin

Size Size A/F g Torque
Liquid Line Dia 8 M16x1.5 19mm 17mm 120 – 150
mm Kgf-cm
g
Discharge Dia M22x1.5 24mm 22mm 200 – 250
Line 1/2” Kgf-cm
Suction Dia M24x1.5 27mm 24mm 300 – 350
Line 5/8” Kgf-cm
Compresso Pad Bolt
r Joint Spec 80 – 120
M6x1.0 Kgf-cm
(6T or
8T)

Condenser Pad Bolt

Joint Spec 80 – 120
M6x1.0 Kgf-cm
(6T or
8T)
 Tightening Torques

Bolt Size 4T 5T 6T 7T 8T

M6x1 0
M6x1.0 55 +/
+/- 10 65 +/
+/- 10 80 +/
+/- 15 110+/-20
110+/ 20 N/A
Kgf-cm Kgf-cm Kgf-cm Kgf-cm

M8x1 25
M8x1.25 130+/-25
130+/ 25 160+/-30
160+/ 30 195+/-35
195+/ 35 260+/-50
260+/ 50 300+/-60
300+/ 60
Kgf-cm Kgf-cm Kgf-cm Kgf-cm Kgf-cm

M10 1 25
M10x1.25 260+/-50
260 / 50 330+/-65
330 / 65 400+/-80
400 / 80 530+/-105
530 / 105 620+/-120
620 / 120
Kgf-cm Kgf-cm Kgf-cm Kgf-cm Kgf-cm

Over tightening of bolts/ joints may result in leakage or failure of

components
Examples of claims due to wrong Assy.
Assembly Practices
Effects of Refrigerant Leakage

Loss of
l b i ti oilil
lubricating
Effects of Refrigerant Leakage

Lack
Compressor Oil
 Compressor
p Oil

• ND-8 Compressor Oil

– Hydroscopic-Do not expose to atmosphere
– Mixes with R134a refrigerant
• For Lubrication of O-Rings
– 1-2 drops before assembly
• For Top-up
– 40 cc while recharging
– Not required if compressor is replaced
 Recommended Q
Quantity
y of Oil

Oil Top
p up
p recommended during
g servicing
g:

Replacement of
- Condenser - 60 cc
- Evaporator - 60 cc
- Hoses/Tubes
/ - 40 cc
- Compressor - Nil

Refrigerant Charging 40 cc

Total system oil ---- 100 ( +20, 0)

 Notes

If condenser and evaporator are replaced together,

then add only 60cc (not 120)

If evaporator and hoses are replaced together

together,
then add only 60 cc ( always higher limit)
Running In
Note:
Precautions during installation of new AC components/
replacement of compressor/ vehicle not used for many
days.
y

Keep the vehicle in idling with AC on for 2 to 3 minutes

(Do not race the engine), so that oil is circulated inside
the compressor and compressor seizure is avoided
 Necessary Precautions
A. For
o custo
customer
e information
o at o
• Cleaning of condenser surface every 15 to 20 days
• Cleaning of Filter every 15 to 20 days
• Using Recirculation mode with a/c ON
• Keeping floor carpet clean

B. For Dealer workshop

• Cleaning of condenser with high pressure water spray
• Add desired quantity of compressor oil in a/c system
• Replace Receiver Drier/zeolite filter when replacing compressor or when fitting
repaired compressor
• Plug all open joints immediately
• Do not leave compressor oil in open condition
• Flush complete a/c system using Nitrogen before installation of
N
New or R
Repaired
i dC Compressor
• Use recovery recycling system for correct refrigerant charging
• Never charge refrigerant with inverted cylinder
q compressor
• Never Over torque p mountingg bolts
• Use Torque wrench where ever recommended
• Do not use gloves
THANK YOU