2008 GEELY CK Workshop Manual

298evaporator (6) via the expansion valve (5) for compression and generates high temperature and pressure
vapor which then is cooled into liquid through the condenser (2) and dried in the receiver/drier (3), then
restrict the expansion valve and enable certain amount of refrigerant liquid to be vapored into low tempera-
ture and pressure vapor in the evaporator, meanwhile, absorb large amount of heat and perform heat ex-
change with the air sucked in by the blower, then distribute the cooled air to the vehicle compartments. Cycle
the operation until the compartments gets the desired temperature.
See Table 1 for the Refrigeration system parameter.
Table 1 Refrigeration system parameterParameter
Control the mixture of c ool and hot air
N o m in a l R e f r ig e r a t io n / W 4 2 0 0
Displac ement/(mL/r) 108
Model SW-5H11
Elec tromagnetic Clutc h Pow er Diss ipation/W 45
SW-100/135
Maximum Airflow /(m3/h)400
Airflow adjustment 4th Shift Manual
Motor Pow er Consumption/W 180
Dimension/mm 18×302×630
Heat Exchange/W 9400
Air Resistance/Pa
≤156
Fan Motor Current/A
≤8
Fan Motor RPM /(r/min) 2900±200
Dimension/mm 86×213×235
Refrigeration/W 4200
Thermal Expansion Valve Inner Balanc e 1.5 ton
4PK830
630±20 Re f r ig e r a n t F ill/ g Blo w e r
Condens er
Evapor ator
D r iv e b e lt Item
Temperature adjustment method
Compr es s or
Lubric ant /mL

299Section 2 Heating SystemHeating system uses mixed temperature adjustment which controls both cold and hot air and is featured in
outstanding temperature adjustment performance. The cold and hot air can be completely mixed at each
outlet and achieve continuous temperature adjustment. The air duct arrangement on the instrument panel is
shown in Figure 2. The air flow channel system is shown in Figure 3.I. Heating System Parameter and StructureHeating system uses water heating structure which uses the engine coolant as the heat source, leads the the
coolant into the heating radiator installed in the vehicle compartment and has the interior or exterior air blow
across the radiator with the blower to increase its temperature. The system consists of the blower assembly,
heating control assembly and heater assembly.Figure 2 Heating Duct ArrangementInside and Outside Air Switch Door Outdoor AirIndoor AirDefoggerIntermidiate outletHeaterBlower MotorEvaporatorAir Mix DoorHeating RadiatorFigure 3 Air Flow Channel System Illustration

3001. Heating System Parameter
Heating system radiating power, blower fan diameter, power dissipation and heater radiator dimension are
show in the table 2.
Table2
Heating System Parameter
2. Blower
Blower is located at the lower part of the goods
compartment. The door inside the blower case is con-
trolled by the servomotor. The exchange of the air in-
side and outside the door can be achieved by adjusting
the door to import the outdoor air and recirculate the
indoor air.
Blower motor uses Permenant magnet DC motor with multple blade fan. In addition, there are a set of
resistance on the blower which adjust the fan, called as adjusting resistor. Blower provides wind supply not
only to the heating radiator, but also to the evaporator in the refrigeration system.
3. A/C Control Mechanism
A/C control mechanism is located in the middle of the instrument panel. All adjustment except the A/C switch
and inside and outside circulation switch are made by rotating the control knob. The A/C control panel is
shown in Figure 4.
1Temperature adjustment control knob: control the mix ratio of the cold and hot air by adjusting the air mix
door, use the control knob to achieve continuous temperature adjustment.
2Outlet control knob: use 4 ranges, different types of air flow adjustment available.
3Inside and outside circulation switch: It can toggles between the introduction of outdoor air and recirculation
of the indoor air. (press the switch for inside circulation)
4Blower switch: when the plum blossom range is closed, the remaining four ranges are used to adjust the
air flow.
5A/C switch: as the switch of the refrigeration system, use press-button with built-in A/C indicator.Dissipation Power/W 4000
Air Flow/(m3/h)280
Power Consumption /W 180
Fan Diameter/mm 140
Overall Radiator Dimension 159.4mm×140mm×49mm Figure 4 A/C Control Panel

301 4. Heater
Figure 5 Heater Door Control Diagram
The heater comprises the heater radiator (heat exchanger), the plastic case forming the air duct, connecting
rods adjusting different air ducts and the door. The two groups of combination doors in the heater case are
connected to the heating control mechanism by the cable. The first group is the two couple action doors
adjusting the air mix ratio that are located in the outlet and inlet each; the second group comprises 4 doors
controlling the air outlet vents, where the upper center one controls the front outlet vent, each of the upper
left and right sides controls a defogger outlet vent and lower foot outlet vent. Figure 5 shows the working
principle of temperature adjustment door. The d) , c) , e) , f) in the figure indicate the outlet air flow direction
as the result of the adjustment of the control knob in the heating control mechanism panel.Hot Wind LocationCold Wind LocationLinkageRadiator CoreRadiator CoreTemperature Adjustment
Door Working PrincipleFoot OutletTo Front OutletTo DefrosterRadiator CoreTo Front OutletRadiator CoreFoot OutletFoot OutletTo Defroster

302Section 3 A/C controlling systemI. Introduction and CompositionIn order to ensure the effective opeation of the A/C system in any operating condition, some advanced
electric control devices are used to protect the A/C system in adverse engine operating condition.
The electrical control part consists of: A/C switch, relay, evaporator temperature sensor, water temperature
sensor, pressure switch, ECU...etc.
A/C system circuit diagram is shown in Figure 6.II. controlling system feature(1) The condenser fan's power is 90W;
(2) The performance of the condenser fan is controlled by ECU, pressure switch;
(3) Cut off the electrical power of the A/C compressor clutch when the water temperature reaches 109°C;
(4) Connect blower switch 9 to rotate the blower motor 6 to ensure A/C normal operation. Connect A/C
switch 10 to output A/C request signal to ECU.
(5) After ECU receives the request signal and the one from the evaporator temperature sensor 17, if the
engine is at idle, ECU first increases the engine speed to 950 ± 50r/min, lest the A/C operation enhance
the load and lower the engine speed or result in engine off. And then the ECU can respond. If the engine
is in accelerating condition, ECU does not respond immediately either, and respond 5 seconds later after
the end of the accelerating condition. ECU send out a A/C control signal from pin 22 to relay 7, command
the relay to suction in. With the low pressure switch 11 closed, the compressor 12 starts to work when the
magnetic clutch suction on. The condenser relay holds in and condenser blower 13 rotates. When high
pressure switch 15 is closed, have the relay 7 hold in and the water tank fan 14 rotates. When the water
temperature sensor 16's temperature is higher than 109°C, ECU shut off the output signal of the pin 22
and A/C stops operation.
(6) When the Refrigeration system pressure is over 1.7MPa, radiator fan will rotato. Disconnect A/C
compressor Refrigeration system power supply when the pressure is over 2.6MPa or less than 0.25MPa;

303Figure 6 A/C System Electrical Appliance DiagramIII. Protecting Device1. Low temperature protection
Evaporator temperature sensor, when the sensed temperature is lower than 3°C, the compressor clutch
is de-energized and stops operation.
2. High temperature protection
Water temperature sensor, when the sensed water temperature reaches 109°C, the compressor clutch is
de-energized and stops operation.
3. Low pressure protection
When pressure sensed by the pressure switch is lower than 0.25MPa, the compressor clutch is de-
energized and stops operation.
4. Voltage protection
When the pressure sensed by the pressure switch reaches 1.7MPa, radiator fan rotates.
5. High pressure protection
When the pressure sensed by the pressure switch reaches 2.6MPa, the compressor clutch is de-energized
and stops operation.
6. Normal pressure
When system pressure reaches 0.25MPa~2.4MPa, control the A/C idle speed. Color of wire:R-Red Bl-Blue Y-Yellow Lg-Light green Br-Brown B-Black P-Pink G-Green W-White Gr-Gray
1. Battery 2. Main Fuse Box 3. Alternator 4. Ignition Switch 5. Idle Rise Valve 6. Blower 7. Relay
8. Blower Regulating Resistance 9. Blower Switch 10. A/C Switch 11. A/C Low Pressure Switch
12. Compressor 13. Condensor Fan 14. Radiator Fan 15. A/C High Pressure Switch
16. Water Temperature Sensor 17. Evaporator Temperature Sensor 18. Electronic Wind Door Actuator Switch
19. Electronic Wind Door Actuator 20. Revolution Sensor 21. Engine ECU

304Section 4 Service Caution & NoticeI. Service CautionRefrigerant Treatment
•During the treatment, the operator shall be careful not to inhale A/C refrigerant or lubricant vapor. Long-
term exposure to the A/C environment will cause the operator's eye, nose and throat liable to stimulation.
In addition, based on the consideration on the environment influence, when discharging the HFC-134a
from the A/C system, we suggest using the recyclable and rechargeable devices. If sudden system fault
occurs, it is recommended to place the device on a ventilated place before starting service.
•For HFC-134a service equipment, it is recommended not to perform the pressurization check or leakage
inspection. If these mixture combust, it may result in severe human injury or property loss.
•Please be noticed not to let the refrigerant leak near the spark or other hot objects. If the refrigerant gas
contacts the spark or similar heat source (e.g. cigarette or heater), it may generate poisonous gas. The
refrigerant is extremely liable to leakage during the transportation. In this case, please eliminate or remove
the heat source mentioned above and keep good ventilation.
•It is very dangerous to handle the liquid refrigerant. Only a drop of refrigerant can result in local frostbite
on skin if dropped on the skin of the operator. Therefore, it is specified that the operator shall always
wear glove and eye protection during the handling of the liquid refrigerant. If liquid refrigerant gets in
your eyes or on your skin, Wash the area with much cool water. Go immediately to hospital for professional
treatment.
Refrigerant Preservation
• Refrigerant preservation container is a high pressure resistant equipment. If it is put in hot treatment, the
explosion may arise, and the resulting metal fragments and the splashed liquid refrigerant will result in
severe human injury. It is recommended to preserve the refrigerant below 40°C.II. Service NoticeInsufficient Refrigerant Handling
•If the refrigerant is founded to be insufficient during the fault diagnosis, it is recommended not to add
refrigerant because of the following facts: the pressure readings indicated by different pressure gauge
are different, thus you will be unable to determine the exact amount of the refrigerant to be added, and
excessive or insufficient refrigerant may cause a series of chained negative effects such as damaged
refrigerant circulation parts or deteriorated refrigeration effect. Therefore, if the refrigerant is found to
be insufficient, it is recommended to drain the refrigerant from the refrigerant circulation pipeline and fill
specified amount of the refrigerant.
Compressor Oil Handling
•For this type of vehicle, it is recommended to use SW-100 type compressor oil. Use of PAG compressor
oil other than the SW-100 type may cause the A/C compressor to be damaged.
•During the operation, please be noticed not to splash the SW-100 type compressor oil onto the vehicle
surface. Therefore, if this happens, please wipe it off immediately, otherwise the compressor oil will
damage the paint on the vehicle surface.

305•Compared with the early used mineral oil, the SW-100 type compressor oil is of comparatively high
moisture absorption performance. If you mix the moisture object with the SW-100 type compressor oil, it
will damage the Refrigeration system. Therefore, after treating the compressor oil or removing the
refrigeration system components, the lid shall be covered immediately to prevent the SW-100 type
compressor oil from absorbing the moisture.Section 5 The Refrigeration System Operation ProcedureI. Refill RefrigerantNotice:•During the filling of refrigerant into the refrigeration system, be careful that it is required to
have the professionals operate under the specified standard and procedure, otherwise it will
reduce the A/C efficiency greatly and even damage the refrigeration system components.
Refill the HFC-134a refrigerant
Refill Preparation1. Install the inflating equipment.
2. Connect the low pressure tube to the low pressure
refill valve.
3. Connect the high pressure tube to the high pressure
refill valve.
4. Connect the intermediate tube to the vacuum pump.Vacuumization:1. Open all valves.Notice:•Close all valves of the manifold gauge immediately after the vacuum pump stops operation. If
the valve is still open after the vacuum pump stops operation, then the vacuum pump oil will
return to refrigerant circulation loop and reduce the A/C efficiency.2. Start the vacuum pump and run it for 15min.
3. Check if the readings at high and low sides of the manifold gauge fall within the range of -101 kPa{-760
mmHg }. Close the valves of the manifold gauge.Check the air tightness:1. Stop the vacuum pump and have it wait for 5min.
2. Check the high pressure side of the manifold gauge and the reading at the low pressure side.
•Check for leakage if the reading changes and vacuumize it again.
•Refill the new HRC-134a refrigerant if the reading doesn't change.To low pressure fill valveLow Pressure GaugeHigh Pressure
GaugeConnect the high
pressure refill valveLow Pressure TubeHigh Pressure TubeLow Pressure
Manual ValveHigh Pressure
Manual ValveVacuum PumpIntermediate Tube
Refrigerant Steel Jar