8cab & Air Conditioner System PDF

Service Manual of Wheel Loader
Ⅰ
Contents
8 Cab & air conditioner system .................................................................................. 1
81 General cab disassembly and installation steps ....................................................... 1
82 Air conditioner system description .......................................................................... 2
821 Working principle and layout of air conditioner system.................................. 2
822 Air conditioner control principle ...................................................................... 5
823 Considerations of installing and using air conditioner..................................... 8
83Routine check of air conditioner system ................................................................... 9
84 Maintenance instruction of air conditioner system ................................................ 11
841 Basic process .................................................................................................. 11
842 system drains refrigerant ................................................................................ 11
843 dissemble pipeline or pressure switch ............................................................ 11
844 refrigerant oil .................................................................................................. 12
845 Refrigerant charging method .......................................................................... 14
85 Common fault diagnosis and troubleshooting of air conditioner system .............. 16
The system fails in refrigeration ............................................................................ 17
System refrigerating capacity shortage ................................................................. 18
The refrigeration system works discontinuously automatically. .......................... 19

Common fault diagnosis and troubleshooting....................................................... 20
Common troubleshooting flow diagram of the air conditioner system ................ 23

8 Cab & air conditioner system

81 General cab disassembly and installation steps
Lift cab
Disassemble foot brake valve pipeline
Disassemble steering gear pipeline
Disconnect cable accelerator
(two-stage)
Disconnect flexible shaft of
transmission (mechanical control)
Disconnect cab harness
Disconnect flexible shaft of multiway
Disassemble cab
valve (mechanical control)
Disconnect flexible shaft of parking
brake
Disconnect water pipe of fan heater
Disconnect fuel level sensor
Disassemble fixing bolts of cab
Life cab
Assembly steps are basically opposite to disassembly steps, pay attention to hoisting safety.
8-1
82 Air conditioner system description
821 Working principle and layout of air conditioner system

1.1 Heating system
Heating system of loader air conditioner consists of engine, heater valve, heater pipe, evaporator,
connector, etc.
Use circulating coolant of the engine as the heat source, circulating coolant enters heater core of air
conditioner system from the engine and then returns to radiator after circulating in the heater core.
The fan exchanges heat by blowing air to the heater, hot air blows off from the air port and
circulates continuously to supply heat for the cab.
Evaporator
Heater valve
Heater pipe
Engine
Enter cab-hot air

Engine circulating water
Heater core
Back to engine
Cab return air-cold air
Fig.8-1 Heating principle
8-2
1.2 Refrigeration system
The refrigeration system of the loader circulates in the system by using refrigerant, turns into
gaseous state from liquid state when passing through evaporator and absorbs plenty of latent heat in
cab, then it releases the heat in condenser through compressor and blows off the heat to outside air
through the fan to reduce interior temperature of the cab. It can be divided into five processes:
1. Compression process: compress low temperature and low pressure gas refrigerant flowing
through the evaporator into high temperature and high pressure gas refrigerant and covey it to the
condenser.
2. Condensation process: cool the high temperature and high pressure gas refrigerant off to
produce intermediate temperate and high pressure gas refrigerant and convey it to a drying bottle.
3. Drying process: filter intermediate temperate and high pressure gas refrigerant to remove
impurities and water in it, convey it to a throttle valve and store a fraction of refrigerant.
4. Expansion process: transform the filtered intermediate temperate and high pressure gas
refrigerant into low pressure vaporous liquid/gaseous state mixture by taking advantage of throttling
principle, then convey it to the evaporator.
5. Evaporation process: low pressure vaporous liquid/gaseous state mixture flows into the
evaporator, absorbs surrounding heat and vaporizes for the purpose of refrigeration, then draws in
from low pressure intake tube of the compressor to proceed to next cycle and so forth.
Temperature Expansion
controller panel valve
Evaporator
Condenser
Compressor Compr
belt essor Fluid reservoir
Fig.8-2 Refrigeration principle
8-3
1.3 Air conditioner system arrangement
There are two types of system layout in accordance with manufacturers of air conditioner parts:
Fig.8-3 Layout of Xinxiang Yuxin air conditioner
Fig.8-4 Layout of Hangzhou Aolan air conditioner
8-4
822 Air conditioner control principle

2.1 Fan control principle
Air volume switch:
Power air volume switch is a three-grade rotary switch, cut off control supply at “0”, switch on
“control supply” at other positions, air volume of the fan corresponds to low, mid- and high ranges.
Fig.8-5 Air volume switch

Fan high range
Fuse Red Red
Main vehicle power positive
Main vehicle power negative

Power line Fan high range control line
Control line of fan mid-range
Brown
Fan high range Control line of fan low range
Yellow
Fan mid-range
Green Relay coil
Fan low range control
Fan high range Wh Refrigeration control relay Speed control resistance
Sensor positive control line ite Defrost
White Evaporative motor sensor
Sensor ground
Air conditioner
controller Purple
Refrigeration output Diode
Red/black Black Speed
control
Green/bla resistance
ck Black
Fresh air control output Fresh air servo
motor
Refrigeration indicator Grey Purple

lamp input(+)
Black Black
Purple
Blue
High/low pressure switch
of air conditioner Conden
Compressor ser
electromagnetic motor
clutch
Black
Black
GND ground
Fig.8-6 Schematic diagram of high range

Fan mid-range
8-5
Fuse Red Red

Brown
Control line of fan low range
Fan high range
Yellow
Fan mid-range
Green Relay coil
Fan high range Wh Speed control resistance
control line ite
Refrigeration control relay
Sensor positive Defrost
Sensor ground
Air conditioner
controller Purple
control
Fresh air control output ck Black

Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
Fig.8-7 Schematic diagram of mid-range

Fan low range
Fuse
Red Red

Brown
Fan high range
Yellow
Fan mid-range
Green Relay coil
control line ite
Refrigeration control relay
Sensor positive Defrost
Sensor ground
Air conditioner
controller Purple
control

Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
Fig.8-8 Schematic diagram of low range

2.2 Working principle of air conditioner system
Rotate the temperature control switch to a certain position, refrigeration indicator lamp is on,
8-6
indicating start of refrigeration. The temperature sensor detects cab temperature, the indicator lamp
is off and the compressor stops working when the temperature falls to required temperature,
temperature in the cab at present is set temperature. When indoor temperature exceeds this
temperature, the indicator lamp is on, the compressor starts automatically and the system starts
refrigeration; when indoor temperature is lower than this temperature, the indicator lamp is off and
the system stops working;
Fig.8-9 Temperature control switch

Fuse Red Red

Brown
Fan high range
Yellow
Fan mid-range
Green Relay coil
Fan high range Wh Refrigeration control relay Speed control resistance
Sensor positive control line ite Defrost
White
Evaporative motor sensor
Sensor ground
Air conditioner
Purple
controller Refrigeration output Diode

control

Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
Fig.8-10 Schematic diagram of air conditioning

2.3 Fresh air control principle
Change-over switch of fresh air:
controls operation of fresh air actuator as well as internal and external circulating intake. Air inlet of
fresh air and recirculating air is controlled by throttle motor at unit ventilator. Its control panel is on
the right panel inside the cab.
8-7
Fig.8-11 Change-over switch of fresh air
: fresh air
: recirculating air
Fig.8-12 Route diagram of fresh air
Fuse
Red Red

Brown
Fan high range
Yellow
Fan mid-range
Green Relay coil
Sensor positive control line ite Refrigeration control relay
Defrost
Evaporative motor
White sensor
Sensor ground
Air conditioner
controller Purple
Speed
Red/black Black control
ck Black
Fresh air control output Fresh air servo
motor

lamp input(+)
Black Black
Purple
Blue
Compressor ser
clutch
Black
Black
GND ground
Fig.8-13 Schematic diagram of fresh air
823 Considerations of installing and using air conditioner

1. To extend service life of air conditioner system, we recommend you to run the air conditioner 1-2
time (s) for 15-20 minutes monthly when it is not used and run it in winter while using warm air.
8-8
2. Correct steps of starting air conditioner system: turn off air volume switch of evaporator fan and
adjust refrigeration knob to 0 position before starting the engine; first turn on air volume switch of
evaporator fan and then adjust refrigeration knob after starting the engine.
3. Models with air conditioner filter element shall be cleaned on a regular basis according to
operating condition. Clean the filter element when the air volume reduces significantly. Filter
element replacement is recommended when the air volume still reduces significantly after cleaning
filter element.
4. To guarantee refrigeration performance of air conditioner, clean condenser core on a regular basis
to keep the condenser clean and give full play to its heat dissipation performance.
5. Refrigerant charging shall be completed by professionals in accordance with specified process.
6. LG918 and higher level SDLG loaders provide reserved installation interface of air conditioner
and supporting optional air conditioner modules for users.
7. Reserved power interface must be used when installing the air conditioner system, do not alter
original circuit without authorization.
8. Do not remove sealing elements mounted at pipeline joints of the new reservoir before
connecting pipeline to protect service life of the air conditioner system from being affected by dryer
failure.
9. Try not to dissemble pipeline and discharge refrigerant when repairing parts of the air conditioner
system. Repairable parts are not recommended to be replaced. The assembly is not recommended to
be replaced if secondary parts can be replaced. Parts maintenance and replacement should be
operated in strict accordance with technological requirements, otherwise secondary failures may be
caused.
83 Routine check of air conditioner system

Main check methods:
Check if temperature in each part is normal by touching.
Check leaking parts and surface conditions through visual inspection.
Judge system operating condition from sight glass.
Check electrical apparatus elements by disconnecting and connecting circuit.
Check abnormal sound and smell by hearing and smelling.
Check time
Check item Check content
Daily Semi-annually Annually
Pipeline Poor fixation with gap √ √
8-9
assembly
Junction looseness, nut and bolt √ √
looseness
Junction looseness, nut and bolt √ √

Connecting bolt
looseness and detachment
Looseness and bending √ √
Driving belt Degradation: wear, scar, crack √ √
Noise, smell or abnormal heating √
Fins lodging √
Condenser
assembly Impurities blockage (rubbish, dust, √ √ √
worm grass, etc.)
Starting check, air volume, switch √ √

Air volume control
switch of air
conditioner
Switch function √ √
Leakage at pipeline joints √ √
Refrigerant
leakage Internal leakage of components and √
parts (compressor, condenser,
evaporator, receiver-dryer)
Refrigerant Check refrigerant quantity (observe √ √

quantity sight window)
Compressor (including unloaded) √

Noise
Condenser fan, evaporator fan √
Reservoir Temperature difference indicates √

temperature blockage in the dryer
8-10
difference
84 Maintenance instruction of air

conditioner system
841 Basic process

Discharge refrigerant replace parts, charge
refrigerant oilvacuumizecharge refrigerant
commission and operate
842 system drains refrigerant

Low High
pressure pressure 1. Make sure knob switch of the pressure gauge is
end (L) end (H) switched off.
2. Connect the pressure gauge to refrigerant
charging point. Connect red pipeline joints of the
Blue Red pressure gauge to high pressure end (H) and blue to
low pressure end (L).
3. Discharge refrigerant: rotate knobs on high and
low pressure sides of the pressure gauge to discharge
the refrigerant in gas state by yellow pipeline of the
pressure gauge.
Vacuum pump connecting end, refrigerant Note: do not discharge the refrigerant in
charging end, refrigerant discharge end
liquid state. Wear gloves to prevent hand
Fig.8-14 frostbite during operation.
843 dissemble pipeline or pressure switch
4. Make sure there is no refrigerant in the system
before dissembling pipeline or pressure switch,
discharge it if any by using a pressure gauge.
5. Keep the whole process of parts replacement
shall be clean and free from pollution to avoid
system pollution if pipeline or pressure switch shall
be dissembled to replace parts.
8-11
6. When connecting pipeline joints or pressure

switch due to parts replacement, check if the O ring
is intact, replace it with a new one in case of any
damage.
Note: please use special O ring made from

hydrogenated nitrile rubbers (H-NBR) designed
for R134a system.
Special O ring made from hydrogenated

nitrile rubbers (H-NBR)
Fig.8-16
7. Connect pipeline as directed by arrows when

replacing the reservoir.
Connect inlet end of refrigerant to pipeline on the
condenser end and outlet to pipeline on the
evaporator end.
Note: arrow in the left figure indicates flow

direction of refrigerant.
Evaporator Condenser
Fig.8-17
Fluid reservoir
844 refrigerant oil
8. Charge refrigerant oil to the system when
replacing the evaporator, condenser, reservoir and
pipeline.
Note: refrigerant oil shall be PAG100 model

and do not use other models of refrigerant oil.
Pipeline
Refrigerant oil charge
Replaced components
(ml)
Evaporator 30
Condenser 70
Reservoir 30
8-12
Condenser
Autoclaved pipe 30
Pressure cooling pipe,

cold storage pipe and 10
steam storage pipe
Fig.8-18
9. Replace compressor
10. Discharge refrigerant oil in a faulty compressor
and measure refrigerant oil mass.
(Discharge 100ml of refrigerant oil)
Fig.8-19
11. Discharge refrigerant oil in new compressor,

recharge refrigerant oil with mass equivalent to that
in the faulty compressor.
Fig.8-20
8-13
12. Recharge 10ml of refrigerant oil to the new

compressor (100+10=110ml).
Fig.8-21
Low High
pressure pressure 845 Refrigerant charging method
end (L) end (H)
Note: refrigerant charging method for air

Blue Red
conditioner system without refrigerant is as
follows.
1. Vacuumize the system
a) Connect the pressure gauge to refrigerant
charging point. Connect red joints of the pressure
gauge to high pressure end (H) and blue to low
pressure end (L). At present knob switch of the
Connecting pipe of vacuum pump
pressure gauge is switched off.
Fig.8-22 Pressure gauge
b) Connect yellow pipeline of the pressure gauge to
vacuum pump.
c) Switch on the vacuum pump and then turn on
knob switch of the pressure gauge to vacuumize it on
high and low pressure sides simultaneously for 25 to
30 minutes.
d) Maintain pressure. Maintain pressure for 5-10
minutes to check if pressure changes. Check leaking
point in case of obvious change. Otherwise continue
vacuumizing.
Note: first turn off the knob switch of

pressure gauge and then the vacuum pump when
maintaining pressure.
e) Vacuumize it again. The start the vacuum pump
8-14
and turn on the pressure gauge knob. Vacuumize it
on high and low pressure sides simultaneously again
for 15 to 20 minutes. In case of high ambient
humidity (rainy days), extend vacuumizing by 20-30
minutes.
f) Maintain pressure again. Turn off the knob
switch of pressure gauge and then the vacuum pump
to maintain pressure for 5 minutes.
Note: failing to vacuumize it within required

time may produce residual moisture in the system
and further cause such system failures as
reservoir failure and evaporator ice blockage.
2. Charge refrigerant to the system
a) After vacuumizing, dissemble yellow pipeline of
the pressure gauge from the vacuum pump and
connect it to refrigerant tank.
Note: the refrigerant shall be R134a model,

any other models of refrigerant are forbidden.
Unqualified refrigerant may cause deadly damage to
the system.
Recommended brand: Xi’an Jincool.
Fig.8-24
b) Turn on exhaust knob of the yellow pipeline to

Red inject some refrigerant and exhaust air in the yellow
Blue pipeline.
c) Turn on the knob switch on high and low
pressure ends of the pressure gauge to cause the
refrigerant to be drawn in by the air conditioner
system under effect of negative pressure.
Connect refrigerant charging

exhaust button
Fig.8-25
8-15
d) When the pressure gauge shows no change in

pressure display, turn off knob switch on high
pressure end.
Blue Red
e) Start the engine and air conditioner system to
adjust air volume switch and refrigeration knob to
the maximum. Note to see if the compressor clutch
works and the condensate fan runs properly.
Close button of high pressure end

Fig.8-26
f) Turn on knob switch on low pressure end of the

pressure gauge to cause the refrigerant to be drawn
in by the air conditioner system from the low
Blue Red
pressure end.
g) After charging the first tank, turn off knob
switch of the pressure gauge and replace the
refrigerant tank, continue charging refrigerant from
the low pressure end. Repeat b operation each time
when replacing the tank with a new one.
Open button of low pressure end
h) Observe flow of the refrigerant through sight
Fig.8-27 glass during charging, stop charging when many
foams reduce to several (clearly countable).
Note: do not charge refrigerant from high

pressure end after starting the engine.
3. Operation debugging.
Start and run the air conditioner system to keep the
system free from leakage and runs properly.
85 Common fault diagnosis and troubleshooting of air conditioner

system
Note to find out causes of malfunction in accordance with abnormal running phenomenon of the air
conditioner when checking and repairing failures of the air conditioner system, then take measures
to repair the system. Common failures present in air conditioner system are usually system
refrigeration failure, system refrigerating capacity shortage and discontinuous system working.
8-16
The system fails in refrigeration

The diesel engine works in idle state after starting the engine. Adjust change-over switch to
refrigeration position, temperature control switch to maximum refrigeration position and fan switch
to H (high speed) position, cold air shall blow off from air outlet after the air conditioner system
runs steadily for 2min, otherwise check following items
Check if circuit fuse of the air conditioner is subject to fusing, the circuit is subject to short
circuit and all connector clips are in good contact, whether the evaporator fan and compressor
clutch work, temperature switch is turned on and the relay pulls in.
High/low pressure switch fault on fluid reservoir; working range of the switch, high pressure up
to 2.65MPa and low pressure up to 0.20MPa. High pressure switch acts in case of too high
pressure in the system; or low pressure switch acts when there is no refrigerant in the system.
Cut off the clutch to judge whether the high/low pressure switch fails or not. Cut out the
high/low pressure switch if necessary. When the clutch pulls in and system starts working,
replace the faulty high/low pressure switch.
The high/low pressure switch shall not be subject to short circuit to work during check,
otherwise it may damage the whole system
Drive belt of the compressor is too loose. It shall drop by 14-20mm under 110N of pressure.
First tighten and turn the nut when adjusting the belt until appropriate belt tension is achieved.
Considerations of using and maintaining compressor
1. Air intakes and exhaust ports of the compressor must be mounted upward with allowable
deflecting angle ＜45°
2. System connecting hose shall be fixed securely and do not contact with hot parts so as to avoid
damage to the hose.
There is no refrigerant in the refrigerating system. In case of serious refrigerant leakage, detect
it by using integrated high and low pressure gauge. High and low pressure display is very low
and no cold air blows off even if the compressor works.
At a temperature of 32-37°and the compressor rotates at a revolving speed of 1800-2000r/min,
normal pressure of the system is as follows
Pressure of high pressure gauge amounts to 1.27-1.52MPa
Pressure of low pressure gauge amounts to 0.12-0.15MPa
Find out leaking point of the refrigeration system by using a refrigerant air leakage detector and
treat it correspondingly, then vacuumize the refrigeration system and charge refrigerant.
The refrigeration system is blocked by dirt, the refrigerant can not flow and refrigerate any
more. Low pressure of the integrated high and low pressure gauge presents vacuum indication
while high pressure presents higher indication. Such situation is usually present in the fluid
reservoir or expansion valve. Deal with it by replacing fluid reservoir or expansion valve.
Compressor of the system is damaged and fails to discharge high temperature and high pressure
8-17
refrigerant, the integrated high and low pressure gauge indicates almost equal high and low
pressure. Deal with it by replacing the compressor or dissembling it for repairing.
Following items shall be noted when overhauling the refrigeration system
1. Wear protective glasses or face shield as far as possible during overhaul. Wear gloves to
prevent refrigerant from spilling on the skin and causing skin frostbite.
2. First switch off the diesel engine, then connect the integrated high and low pressure gauge to
the compressor for detection.
3. Do not touch hot and moving parts of the diesel engine
4. Ensure that system joints and inner chamber are clean when replacing components for the
system. Paint seal ring of the joints with a layer of refrigerator oil before pipeline mounting.
Use a torque wrench when tightening pipeline joints. Tightening torque is as shown in the table
below. Supplement refrigerator oil when replacing parts and components for the system.
System refrigerating capacity shortage

Condensation effect is poor, oil stain, dirt and debris on the condenser may prevent the
condenser from radiating heat outwards. Detect it by using the integrated high and low pressure
gauge. The detection shows very high indicated value of high and low pressure, clean the
condenser and clear debris. Note not to damage fins of the condenser while cleaning the
condenser.
Evaporating fan of the evaporator blows off low air volume and brings few cold air. It seems
that the cold air is insufficient mainly because impediments inside the air duct have blocked the
air inlet and outlet.
In case of refrigerant shortage in the refrigeration system, detect it by using the integrated high
and low pressure gauge. The detection shows that the indicated values of high and low pressure
are lower. Bubbles roll can be observed from the reservoir sight glass, charge sufficient
refrigerant.
Evaporation temperature increases since excess refrigerant has been charged, discharge some
refrigerant.
If the refrigeration system is mixed with air, detect it by using the integrated high and low
pressure gauge. The detection shows that the indicated values of high and low pressure as well
as the condenser temperature are higher, radiating effect is poor. Hence discharge the
refrigerant, vacuumize it and recharge it.
Warm water solenoid valve is damaged and should be turned off when not electrified, the water
pipe is relatively warm and outlet pipe is under normal temperature by touching. After the
warm water solenoid valve is damaged, touch the inlet pipe and outlet pipe and find that both
are hot. Poor refrigeration effect will be made while refrigeration and heating elements of the
evaporator work simultaneously. The warm water solenoid valve must be replaced.
8-18
The refrigeration system works discontinuously automatically.

The refrigeration system works discontinuously automatically because the system is mixed with
moisture, few moisture freezes and blocks the expansion valve, causing the system to stop
working and recover working after the ice melts. The moisture freezes at the expansion valve
after refrigeration and so forth, causing the system to work discontinuously automatically.
Troubleshooting: discharge the refrigerant, replace the fluid reservoir, vacuumize the
refrigeration system in dry environment for a relatively long period, vacuumize it for 30min
and maintain pressure for 30min, then vacuumize it for 30min again and finally charge
refrigerant.
Circuit contact is poor. The power is connected and disconnected now and then, check the
circuit carefully.
Considerations of overhauling air conditioner system
1. Do not close all air outlets when the air conditioner system works so that the system can
exhaust air.
2. Do not put cotton yarn, waste paper, plastic film and other debris which may easily block the
air inlet in the cab. Serious blockage and poor ventilation may lead to electrical faults of the
system and even cause fire.
3. Discharge the refrigerant from the low pressure side and keep the workplace in good ventilation
conditions to protect personnel from suffocation accidents.
4. Liquid inlet and outlet of the fluid reservoir shall be connected properly, otherwise the system
may fail in refrigeration.
8-19
Common fault diagnosis and troubleshooting
S/N Fault phenomenon Failure causes Troubleshooting
Poor connector clip

contact
Blowing rate switch,
1 Fan does not rotate relay and cold hot Repair or replace it
switch damage
Fuse break or battery
undervoltage
Obstacles on suction
side, rib plate of
2 Fan runs properly evaporator and Clear
condenser blocked by
dust
Compressor clutch does

not pull in as a results of
circuit disconnection
and poor contact
Repair
Loose stretching device
of the compressor belt
falls off and the belt is
Repair
Compressor does not run or runs with too loose
3
difficulty Coils of the compressor
clutch is broken and Replace pull-in coil
faulty
Discharge or charge
High/low pressure refrigerant
switch of the fluid
reservoir works, there is
excess or few
refrigerant
Refrigerant leakage
Eliminate air leakage,
4 Refrigerant supply Insufficient refrigerant supply refrigerant
charge
8-20
At a temperature of 32-37°and the compressor

rotates at a revolving speed of 1800-2000r/min,
normal pressure of the system is as follows
Measure spot high pressure and low
pressure according to readings of Pressure of high pressure gauge amounts to
high/low pressure gauge 1.27-1.52MPa
Pressure of low pressure gauge amounts to
0.12-0.15MPa
Excess expansion valve

Replace expansion
opening
valve
Poor thermal bulb
Higher low Frost on low pressure Install thermal bulb
contact of expansion
pressure pipe surface properly
valve
Discharge part of
Excess refrigerant in
refrigerant
system
Find out leak points

Displayed value on Pipeline joint looseness by using leak
low pressure gauge due to vibration leads to detector, tighten the
lower than normal leakage and refrigerant loose parts carefully
5
value shortage as charge refrigerant
as specified
The low pressure Low pressure rubber Evacuate the system,

gauge indicates hose is blocked or replace fluid reservoir
negative pressure expansion valve blocked and recharge
sometimes by ice refrigerant
Lower low Temperature controller Replace temperature

Evaporator freeze
pressure failure controller
Inlet side of the

expansion valve is Expansion valve Clean or replace
cool and covered by blockage expansion valve
frost
Outlet side of the

expansion valve is not Air leakage at
cool, the low pressure temperature sensitive Replace expansion
gauge indicates pipe and thermal bulb of valve
negative pressure the expansion valve
sometimes
8-21
Evacuate and
vacuumize the
Air conditioner Air in air conditioner
system again,
system system
maintain pressure and
charge refrigerant
Discharge a given
mass of refrigerant to
Higher high Excess refrigerant Excess refrigerant
keep appropriate
pressure charge charge
mass of refrigerant in
the system
Clean condenser and

clear debris
Poor condensation Poor condensation
effect of condenser effect of condenser Check and replace
broken condensate
6 fan
Find out leak points

Pipeline joint looseness by using leak
due to vibration leads to detector, tighten the
Pipeline
leakage and refrigerant loose parts carefully
shortage as charge refrigerant
as specified
Lower high
Low pressure
pressure
indicates negative Low pressure pipeline is Clean or replace
pressure state blocked and damaged pipeline
sometimes
Not hot compressor

and high pressure Compressor failure Replace compressor
pipeline
7 Poor refrigeration effect Block valve damage Replace block valve
8-22
Common troubleshooting flow diagram of the air conditioner system

Abnormal refrigeration
system
Check air outlet of the evaporator
Low or none air volume at air outlet Normal blowing rate at air outlet
Check fan motor of the evaporator Check compressor rotation
Fan motor does not rotate Fan motor rotates, few blowing rate Compressor rotates normally Compressor does not rotate or rotates
abnormally
In accordance Check refrigerant charge

In accordance with In accordance with
the table with the table
Second check the table
First check item Third check item
item
Normal or excess refrigerant Refrigerant shortage

charge
In accordance with
Check system pressure the table
Forth check item
Abnormal system pressure Normal system pressure
In accordance In accordance
with the table with the table
Fifth check item Sixth check item
8-23

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Service Manual of Wheel Loader

81 General cab disassembly and installation steps ....................................................... 1

82 Air conditioner system description .......................................................................... 2

821 Working principle and layout of air conditioner system.................................. 2

822 Air conditioner control principle ...................................................................... 5

823 Considerations of installing and using air conditioner..................................... 8

83Routine check of air conditioner system ................................................................... 9

84 Maintenance instruction of air conditioner system ................................................ 11

841 Basic process .................................................................................................. 11

842 system drains refrigerant ................................................................................ 11

843 dissemble pipeline or pressure switch ............................................................ 11

844 refrigerant oil .................................................................................................. 12

845 Refrigerant charging method .......................................................................... 14

85 Common fault diagnosis and troubleshooting of air conditioner system .............. 16

The system fails in refrigeration ............................................................................ 17

System refrigerating capacity shortage ................................................................. 18

The refrigeration system works discontinuously automatically. .......................... 19

Common fault diagnosis and troubleshooting....................................................... 20

Common troubleshooting flow diagram of the air conditioner system ................ 23

8 Cab & air conditioner system

82 Air conditioner system description

821 Working principle and layout of air conditioner system

Enter cab-hot air

Cab return air-cold air

Fig.8-1 Heating principle

Fig.8-2 Refrigeration principle

Fig.8-3 Layout of Xinxiang Yuxin air conditioner

Fig.8-4 Layout of Hangzhou Aolan air conditioner

822 Air conditioner control principle

Fig.8-5 Air volume switch

Fuse Red Red

Main vehicle power positive

Main vehicle power negative

Control line of fan mid-range

Refrigeration indicator Grey Purple

Fig.8-6 Schematic diagram of high range

Fuse Red Red

Main vehicle power positive

Main vehicle power negative

Fresh air control output ck Black

Refrigeration indicator Grey Purple

Fig.8-7 Schematic diagram of mid-range

Main vehicle power positive

Main vehicle power negative

Fresh air control output ck Black

Refrigeration indicator Grey Purple

Fig.8-8 Schematic diagram of low range

Fig.8-9 Temperature control switch

Main vehicle power positive

Main vehicle power negative

Red/black Black Speed

Fresh air control output ck Black

Refrigeration indicator Grey Purple

Fig.8-10 Schematic diagram of air conditioning

Fig.8-11 Change-over switch of fresh air

Fig.8-12 Route diagram of fresh air

Main vehicle power positive

Main vehicle power negative

Refrigeration indicator Grey Purple

Fig.8-13 Schematic diagram of fresh air

823 Considerations of installing and using air conditioner

83 Routine check of air conditioner system

Pipeline Poor fixation with gap √ √