2008 GREAT WALL FLORID ect

Downloaded from www.Manualslib.com manuals search engine 203Air Conditioning System
Areas of Importance
1. When putting in a new compressor, adjust the new compressor's inner lubricant to make it the same
level as of the old compressor's.
2. When the air conditioner malfunctions, if the pipeline, condenser or evaporator is the source of the
damage leading to its replacement, just add model number RS20 profession\
al lubricant 5-10 ml.
3. The compressor is a high speed operating component, the smallest impurity in the air conditioning
system can lead to the compressor's damage, therefore the entire air conditioning system must be
cleaned.
4. In order to avoid liquid damage to the compressor, pay careful attention when filling the refrigerant.
When the vehicle stopped, fill the liquid refrigerant from the high pressure side. When in operation, fill
the liquid refrigerant from the low pressure side.
5. When undergoing maintenance, pay attention that the amount of refrigerant being added is 510±10 g.
Observe through the check glass to determine if there is sufficient new refrigerant charge.
ItemParameter
Compressor
ModelRotary vane compressor (JSS-96TV4-4)
Discharge capacity96 ml/r
Number of vanes5
Normal rotational speed range800-7800 r/min
Max. speed8400 r/min
Weight4.744 kg (without clutch)
Pressure resistanceLow pressure side 50 kg/cm2, High pressure
side 75 kg/cm2
Leakage≤14 g/year
Direction of rotationClockwise (looking from the clutch)
RefrigerantR134a
Lubricant numberRS20
Lubricant capacity 200±10 ml
Clutch

Min. pull-in voltage7.5 V (12 V)
Pulley style 4PK810
Weight2.1 kg
Rated voltage12 V (DC)
Power consumption≤45W (20oC DC 12 V)
Static friction torque≥40 N·m
Pulley diameterφ110 mm
Coil resistance(3.5±5%) Ω
Thermal protectorOperating temperatureOn / Off (130±5)oC/(150±5)oC
Rated voltage, current16 V, 5 A

Technical Parameters

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual204
FailureSymptoms Cause analysis
Air con-
ditioning
system fails
to produce
cold air
Compressor
does not work
Blown fuse, compressor relay damaged
Pressure switch contact broken, short circuited, or open circuit
Compressor electromagnetic clutch open circuit
Switch burnt out
Main relay burnt out
Clutch slips
Compressor belt broken or loose
Compressor failure
Insufficient coolant, system pressure below 0.196 MPa
System pressure exceeds 3.14 MPa
Engine water temperature is too high
Clutch voltage is below 7 V
Compressor
pulling in
Compressor relay often open contact bond, system coolant leaks severely,
system has no coolant
Blower does not work
Blower has no windBlown fuse
Blower motor brush damaged
Blower switch damaged
Wiring connector detached or open circuit
Speed regulation module damaged
Blower has no wind at high speeds, high speed relay damaged
Note: Blower's non operational process has a resistance value of 0, with a
open circuit resistance value of
The cool-
ing system
sometimes
works, some-
times not
Compressor operates
normally
Cooling system has ice blockage
Thermistor or thermometer bulb malfunction
Abnormal A/C switch contact
Condenser blower damaged
Compressor operates
abnormally
Clutch slides, clutch coil loose, clutch coil bad connection
Insufficient
cooling




Low wind volume

Blower fan normal: air pipe damaged
Cooling fan operates abnormally:
(1) Blower switch abnormal
(2) Supply voltage low
(3) Speed regulation module damaged
Wind vol-
ume normal

Compressor operates normally
(1) High and low pressure side's pressure is low
(a) Expansion valve is blocked
(b) Expansion valve opening is too small
(2) High and low pressure pipe's pressure is high
(a) High pressure pipeline malfunction, uneven flow
(b) Thermistor failure
(c) Expansion valve opening is too big
(d) Too much refrigerant oil
(e) Too much refrigerant
(f) Poor condenser heat dissipation
Note: When the speed is at 2000 r/min, cooling fan at max gear, and air tem-
perature at 30-35oC, the system's low pressure side pressure should be 147-
192 KPa, and high pressure side pressure 1373-1668 KPa

Troubleshooting

Downloaded from www.Manualslib.com manuals search engine 205Air Conditioning System
FailureSymptoms Cause analysis
Insufficient
cooling
Wind vol-
ume normal
Compressor operates normally
(3) High pressure side pressure is too low
(a) Low pressure pipeline damaged
(b) Low pressure pipeline blocked
(4) Low pressure side pressure is too low
(a) Evaporator frost
(b) Expansion valve is blocked
(c) Low pressure pipeline not clear
(d) Thermal speed adjustive resistance failure
(5) Low pressure side's pressure sometimes normal, sometimes negative,
moisture in the cooling system, and ice blockage
(6) Low pressure side's negative pressure, high pressure side's pressure too
low, blockage in the cooling system
(7) Low pressure side pressure too low, high pressure side pressure too high
(a) Inner portion of the condenser is blocked
(b) High pressure pipeline blocked
(8) Low pressure side pressure too high, high pressure side pressure \
too low
(a) Compressor leaks
(b) Compressor valve damaged
(9) Low wind volume of the condenser blower can lead to poor heat dissipation
Compressor operates abnormally
(1) Compressor internal malfunction
(2) Compressor belt loose, slides
(3) Electromagnetic clutch malfunction
(a) Supply voltage low
(b) Interference between the stator and the rotor
(c) Idling stabilizing amplifier malfunction
(d) Circuit broken, connector detached
(e) Bad switch and relay operation
(f) Short, open circuit
(g) Bad ground
Other causes
Dysfunctional Carriage seal
Cooling
system is
too noisy
Noise too loudBelt loose or overly worn
Compressor's mounting bracket set screw loose
Compressor's mounting bracket damaged
Compressor's internal components are damaged
Refrigerant too little or empty
Clutch slip noise
Clutch bearing lacks oil or is damaged
Blower motor bearing damaged
Blower bracket broken or loose
Blower vane broken or loose
Blower vane rubs against other components
Troubleshooting (Continued)

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual206
FailureSymptoms Cause analysis
Heating sys-
tem
No or insuffi-
cient heating
Air conditioner blower malfunction
Blower relay damaged
Hot air duct blockage
Cooling water pipe blockage
Temperature change throttle actuator damaged
Coolant insufficient
Blower does
not work
Fuse blown or ill switch contact
Blower motor burnt out
Blower's high speed relay broken
Speed adjustive resistance damaged
Open circuit
Water leakageHeater water pipe degradation, poor connection
Over heatedFan's speed adjustive resistance damaged
Temperature change throttle actuator damaged
Defroster’s hot
air insufficient
Mode cable damaged
Vent is not in place
Air outlet blockage
Insufficient heating
Air duct mounting
Open circuit
Troubleshooting (Continued)

Downloaded from www.Manualslib.com manuals search engine 207Air Conditioning System
Air Conditioning System's Structure Diagram and Fundamentals
Air Conditioning System Overview
Basic composition
Composed of air conditioner, compressor assembly, condenser
assembly, pipeline, defroster system, heating & ventilation
system, etc. The air conditioner also includes evaporator and
blower components.
Function
This system is a manually controlled air conditioning
system, with steam compression as its cooling method.
Residual heat water warming is the heating method the
engine adopts. Inner & outer circulation, blowing mode,
and cold & warm temperature adjustment are all controlled
by individual cables from the air conditioning controller. It
achieves ventilation, warming, and cooling integration.
Caution: While starting the compressor, you must open
the air regulation knob first, otherwise it cannot start.
Operation
The compressor is driven directly by the engine. High
temperature and high pressure refrigerant vapor exhausted
from the compressor will pass through the high pressure
pipe into the condenser, dissipate the heat via temperature
difference, and then form a high pressure liquid. High
pressure liquid passes through the accumulating dehydrator
into the expansion valve, and after passing through the
throttle valve, it becomes a low pressure liquid. Heat
exchange via the evaporator will cool down the room’s air,
and then the refrigerant inside the system will become a low
temperature and low pressure vapor, which is then sucked
into the compressor and compressed into high temperature
and high pressure air again. Thus a cooling cycle is formed.
The circulation continues, which maintains a comfortable
temperature inside the vehicle.
Expansion valve
Compressor
Condenser fan
Condenser
Pipeline
Air conditioner
Accumulating dehydrator

Downloaded from www.Manualslib.com manuals search engine 209Air Conditioning System
Compressor Removal
1. Hoist the vehicle with a jack.
2. Remove the bottom mudguard.
3. Remove the compressor.
Compressor Installation
Before installing, manually rotate the compressor several
circles, allowing each component in the relative motion to be
covered with lubricant.
Clearance between the compressor's auricular branch and
bracket should be less than 0.1 mm. If the clearance is too
big, fill the clearance with a washer.
1. Loosen the engine's adjusting bolt firstly, take down the
engine belt, and then change the compressor belt.
2. Fix the compressor bracket onto the engine body with
the bolts. The bracket must be fastened tightly with suf-
ficient intensity. Fix the compressor bracket onto the
engine with four M10 ×1.25 (Q1461030 FD) bolts and
a tightening torque of 45±5 N·m, and then install the
compressor onto the bracket with a tightening torque of
22±3 N·m.
3. Ta k e o ff t h e s u c t i o n a n d e x h a u s t c a p . S e l e c t t h e
suction duct and exhaust duct that matches the size
of the suction and exhaust port to connect with each
other (size of suction and exhaust port shown in the
diagram). Then tighten the coupling bolt.
Water pump pulley
Engine pulley
Tensioner pulley
Steering pump pulley
Crank pulleyCompressor pulley
Suction port (S-end) sizeExhaust port (D-end) size
C-C 2:1B-B 2:1
4. Put the 4PK850 type compressor belt onto the pulley,
and then adjust the bracket to make the belt reach the
specified tension. That is, if a force of 100-120 N is
used on the belt, deformation of the belt is 8-10 mm.
5. Insert the thermal protector plug into the relevant plug
of the air conditioning system's wire harness.

Downloaded from www.Manualslib.com manuals search engine GWFLORID Maintenance Manual210
Electromagnetic Clutch
Clutch composition
Electromagnetic clutch consists of an armature, a solenoid,
and a pulley.
Areas of importance during clutch usage
B e c a u s e t h e j o i n t o f t h e e l e c t r o m a g n e t i c c l u t c h
operates under high speeds, separation-joint marks on
the pulley and armature are completely normal, and do
not harm clutch usage.
The clutch's operating voltage must be consistent with
the specified voltage rating. Too high or too low will
affect its normal usage.
The clearance between the coil and the pulley is
very important. If too big, the effect of the magnetic
field reduces. If too small, the high speed pulley rubs
against the fixed coil, causing the clutch to burn.
The clearance between the armature and the pulley
is also very important. If too big, it leads to insufficient
clutch pull-in force. If too small, it may cause armature
damage.
Clutch removal
1. Seize the clutch's triangular piece and secure the
clutch's armature with a clamp. Then take down the
inner hexagon lock screws of the main shaft with an
inner hexagon spanner.
2. After removing the lock screws, manually grasp the
triangular piece and take out the armature, at the same
time remove the clamp spring with the circlip pliers.
3. Remove the clutch's pulley with pullers as shown, and
remove the compressor pulley and its bearing.
4. The gasket on the main shaft is used to adjust the
clearance between the pulley and the armature. Use it
to adjust the clearance value to be as specified during
installation, and do not lose it during removal.
5. Remove the mounting screw from the solenoid coil
connector with a screwdriver, and use circlip pliers to
take down the retaining ring inside the coil and remove
the solenoid coil.

Downloaded from www.Manualslib.com manuals search engine 211Air Conditioning System
Clutch Installation
1. Install the solenoid coil at the place pressing up against the head cover's end surface and pay atten-
tion to insert the dowel pin of the solenoid coil into the bottom hole of the head cover. Put the retaining
ring into the groove with circlip pliers, and press the solenoid coil's connecting wire onto the pressing
line plate on the head cover with a SST.
2. Put the compressor on a specially designed fixture or platform, with its head cover facing upwards.
Press the pulley into the head cover shaft, and put the pulley bearing's retaining ring into the groove
with circlip pliers.
3. Install the armature onto the main shaft's spline and seize the clutch's triangular piece with a clamp.
Then tighten the inner hexagon lock screws and washers with a torque wrench. Screw torque should
be between 150-180 N·m. After installation is done, make sure to check if the clutch's pulley and
armature are able to operate freely, and also check the clearance between the pulley and armature,
which should be 0.3-0.6 mm.
Vacuuming and Charging Refrigerant
Initiate vacuum pumping by using the manifold pressure
gauge connected to the air conditioner (compressor) pipeline
and vacuum pump. When the vacuum pumping starts, open
the manifold pressure gauge's high and low pressure valve,
and open the vacuum pump's end surface valve (if equipped),
then press the "ON" button to start the vacuum pump, and let it
run for at least 20 minutes. When the manifold pressure gauge
shows -760 mmHg or lower, close the high and low pressure
valve, and press the switch to turn off the vacuum pump.
Low pressure gaugeHigh pressure gauge
Manifold gauge
Yellow
BlueYellowRed
Air purge
Blue
Yellow
Red
Close
Refrigerant tank
Refrigerant tank
Blue
Red
Yellow
Low pressureHigh pressure
OpenOpen
Quick coupler
Red
Manifold gauge
Low pressure pipe
Quick couplerHigh pressure pipe
Vacuum pump
Low pressureHigh pressure
Blue
Inspect air tightness
After shutting off the vacuum pump, continue to inspect
the pressure reading of the manifold pressure gauge. If the
pressure reading remains unchanged for 20 minutes after
the vacuum pump stops operating, the refrigeration system
is proven to have no leak. One may continue to the next
step. If the reading changes, the system has a leak. Carry out
an inspection, and after repairing the leaking section, start
vacuum pumping once more.
Charge refrigerant
After verifying the system's air tightness, connect the
refrigerant tank (or gas cylinder) and yellow air supply hose
head. Connect the yellow air supply hose's other head with
the injection port in the middle of the manifold pressure
gauge. Ensure the refrigerant tank and air supply hose's nut
is tightly connected, then open the refrigerant tank's valve.
At this time, the high and low pressure valve is closed. Use
a tip shaped screwdriver or similar instrument and press
the valve core at the side port for 1-2 s, then expel the air
between the air supply hose and manifold gauge.
Perform switch operations according to the
following methods
1. Switch the front and rear blower speed control switch
to the highest settings, and rotate the temperature
control switch to the coldest position.
2. Press down the A/C switch, and set inner/outer circula-
tion to inner circulation mode. Open the doors and win-
dows during this procedure.
3. Adjust the engine's speed to the regulated idle speed.
4. Hold up the refrigerant tank or gas cylinder (emptying