2006 GREAT WALL DEER Cooling system

AC-1
Page
Introduction ................................................................. AC-2
Electric circuit diagram of air-conditioning system ...... AC-4
System constitutes ...................................................... AC-8
General introduction .................................................... AC-9
Troubleshooting .......................................................... AC-10
Inspection for refrigerant quantity ................................ AC-11
Compressor ................................................................. AC-12
Liquid container ........................................................... AC-14
Condenser ................................................................... AC-15
Cooling device ............................................................. AC-16
Refrigerant pipeline ..................................................... AC-20
AC
Air-conditioning System

AC-3Air Conditioning System
Introduction
(c) Tighten the O-ring matching position or the threaded position
to the specified moment.
4. Take notice when connecting measuring meter at branch pipes:
(a) Connect the end of filling hose with high speed joint to the
filling valve of compressor.
(b) Letter
D
marked on the compressor near the auxiliary valve
represents the side of high voltage while
S
means the side of
low voltage, which shall be looked out when connecting the hose.
(c) Fasten the bolts by hand, and
(d) In order to prevent the hose from loosing, lubricant oil shall not
be spread at the connection position.
Remarks: after connecting the measuring meter on branch pipes to
the refrigerant container (repairing tank), the air in the hose shall be
exhausted up.
5. Take notice when vacuumizing:
After vacuumizing for 20 min, maintain the container at certain
pressure to ensure that all air in it is exhausted up, and another
inspection shall be made to see whether there is leakage.
6. Take notice when handling with the refrigerant container
(repairing tank):
(a) Do not heat it.
(b) Store the container at the place where temperature is under 40

(c) In case of heating the repairing tank with hot water, care shall
be paid to the valves at the top of tank, do not dip them into the
water, or the water will penetrate into the cooling system.
(d) The empty repairing tank is forbidden to reuse.
8. Take notice when using the high-pressure air cylinder type
inspecting device:
(a) In case the open fire is used, it is the first to ensure before using
there is no flammable material around.
(b) Be careful because toxic gas will be produced when the
gaseous refrigerant meets with the open fire. 7. Take notice in the A/C operation or when adding the liquid
refrigerant:
(a) In case the gaseous refrigerant in the cooling system is
insufficient, which can lead to the compressor burns out, and
such accidents shall be avoided.
(b) If the valve on the side of high pressure is uncovered, the
refrigerant will flow in the reverse direction, which may lead
to the break of the repairing tank, therefore, only valves on the
side of low pressure are allowed to open or closed.
(c) If the repair tank is laid in reverse direction, and the refrigerant
is added in liquid status, the liquid refrigerant will be
compressed, which may lead to failure of the compressor,
therefore, refrigerant shall be inflated in the gaseous status.
(d) Be careful not over-inflate the gaseous refrigerant, otherwise,
such failures as insufficient cooling, increase of oil consuming
or over heat of engine will be followed.
under 40

incorrect
correct
measuring meter of branch pipe
loose over-fastened
A/C operation

AC-9Air-conditioning System - General introduction
General introduction
Refrigeration cycle
1. The refrigerant at the lower pressure side is condensed by the
compressor into the HT and HP gaseous refrigerant.
2. These gaseous refrigerant flows into the condenser, where it is
turned into liquid refrigerant.
3. Those liquid refrigerant flows into the liquid tank, where the
liquid refrigerant is stored and filtered so as to satisfy the
requirement of evaporator.
diaschage vent indraft vent
compressor
curent direction
evaporator heat
heat expansionvalve
liquid tank
4. The liquid refrigerant is throttled by the expansion valve to reduce the pressure, so that the liquid refrigerant is turned
into the LT and LP mixture of liquid and gaseous refrigerant.
5. The cold and fog-like refrigerant flows into the evaporator, where it is vaporized with the given heat, which is
absorbed from the hot air flow by the evaporator core. All liquid refrigerants are turned into the gaseous refrigerant
in the evaporator, and only the heated gaseous refrigerant is absorbed into the compressor. Then repeat the above-
mentioned cycling approach.
The refrigerant released from
the evaporator expands and
inflows through the evapora-
tor pipe. During this process,
the refrigerant absorbs the
heat in the air around the ra-
diating rib and pipe and
vaporizes, so that the tem-
perature inside the vehicle
reduces gradually.
The condenser allows the heated gas-
eous refrigerant to release heat to the
cooling air of engine, therefore, the gas-
eous refrigerant is cooled and turned
into liquid state again.
The expansion valve is used
to measure the gaseous re-
frigerant entered into evapo-
rator core, which reduces the
pressure and temperature of
refrigerant gradually.
The liquid tank is used to exhaust
the water in system and to filter
the dust and dunghill. It serves as
the store to store the redundant
refrigerant.
The compressor absorbs the
gaseous refrigerant emitted
from the evaporator and com-
presses it. In doing so, the tem-
perature and pressure of gas-
eous refrigerant increases
rapidly.

AC-10Air-conditioning System - Troubleshooting
Troubleshooting
TroubleReparation approachesPage
Lack of cold airNon-pull-in performance of electromagnetic clutch:
(a) Break of ignition switch and fuse;
(b) Trouble of electromagnetic clutch;
(c) Trouble of A/C switch;
(d) Wiring or grounding trouble;
(e) Lack of refrigerant; and
(f) Trouble of pressure switch.
Abnormal operation of compressor:
(a) Looseness or break of driving belt;
(b) Compressor trouble;
Expansion valve trouble;
Systematic leakage;
Liquid tank fusible plug melting or filtering
screen blocking;
Non-work of air blower:
(a) Failure of A/C switch;
(b) Failure of air blower motor, and
(c) Wiring failure.Change the fuse and check to see whether
there is short circuit;
Check the electromagnetic clutch;
Check the A/C switch;
Repair it as requirement;
Check the refrigerant pressure;
Check the pressure switch;
Adjust or change the driving belt;
Check the compressor;
Check the expansion valve;
Conduct lubricating test for the system
Check the liquid tank;
Check the A/C switch;
Check the air blower motor;
Conduct reparation as requirement.
Inconsecutive
cold airElectromagnetic valve slip
Failure of expansion valve;
Wiring or connecting failure;
Over water content in systemCheck the electromagnetic clutch;
Check the expansion valve;
Make reparation as requirement.
Reclaim the water first, then exhaust the
system to vacuum and inflate in the refrigerant.
Cold air occurs in
high-speed conditionBlocking of radiating face of condenser;
Driving belt slip;
Compressor failure;
Insufficient or redundant refrigerant;
Air existing in systemCheck and wash the condenser
Check and change the driving belt;
Check the compressor;
Check the refrigerant quantity;
Vacuumize the system and inflate
the refrigerant;
Insufficient
cold airCondenser blocking;
Driving belt slip;
Electromagnetic clutch failure;
Compressor failure;
Expansion valve failure;
Insufficient or redundant refrigerant;
Air existing in system;
Redundant compressor lubricant;
Liquid tank blockCheck the condenser;
Check and change the driving belt;
Check the electromagnetic clutch;
Check the compressor;
Check the expansion valve;
Check the refrigerant quantity;
Reclaim the air, then vacuumize the sys-
tem and inflate the refrigerant;
Check the compressor lubricant quantity;
Check the liquid tank
Evaporator blocking or frosting
Air leakage in cooling device or air
pipeline;
Air inlet blocking;
Air blower motor failure;Clean the evaporator radiating rib
or filter;
Make reparation as requirement
Make reparation as requirement
Change the air blower motor.
Page AC-4 to 7
Page AC-12
Page AC-4 to 7
Page AC-11
Page AC-13
Page AC-12
Page AC-16
Page AC-14
Page AC-4 to 7
Page AC-12
Page AC-16
Page AC-4 to 7
Page AC-15
Page AC-12
Page AC-12
Page AC-12
Page AC-16
Page AC-11
Page AC-14
Page AC-18
Page AC-20
Possible causes
Page AC-15
Page AC-13
Page AC-12
Page AC-11
Under-speed cold air