25.

AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3

25.1.1 AIR CYCLE.............................................................................................................25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1 COMPONENT ........................................................................................................25-5
25.2.2 CONSTRUCTION...................................................................................................25-6
25.3 PIPING.............................................................................................................................25-9
25.3.1 AIR CONDITIONER................................................................................................25-9
25.3.2 AIR DRYER ASSY..................................................................................................25-11 25
25.4 FUNCTION ......................................................................................................................25-12
25.4.1 MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.2 COOLING CIRCUIT................................................................................................25-14
25.4.3 COMPONENT PARTS ...........................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.2 OPERATING PROCEDURE...................................................................................25-25
25.6.3 CHARGING PROCEDURE ....................................................................................25-26
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION ...25-34

25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE...................................................................25-46

Book Code No. S5YN2518E01

25-1
25. AIR-CONDITIONER SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK200–8 : YN11-45001~ S5YN2518E01
First edition August, 2006 K
SK210LC–8 : YQ11-06001~ (ASIA, OCE)

25-2
 25. AIR-CONDITIONER SYSTEM

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside /
outside air switching unit. And this unit changes hot air to cool air.

25.1.1 AIR CYCLE

• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.

• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.

• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab. 
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.

25-3
25. AIR-CONDITIONER SYSTEM

25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

AIR CONDITIONER CONTROL PANEL

COMPRESSOR

SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE

REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH

AIR-CON BLOWER REVOLUTION SIGNAL

AIR OUTLET SWITCHING SIGNAL CONTROLLER

INNER AIR SENSOR

EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL

OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR

AIR CONDITIONER UNIT FACE

FOOT MOTOR BLOWER

ACTUATOR CONTROLLER

25-4
 25. AIR-CONDITIONER SYSTEM

25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT

27

33 30
27-1

40

32

39
27-6
27-3 27-5

27-2
35

35-7 35-6

35-1

35-2 35-5

34 35-8

35-10 35-9

Fig. 25-1 Air-conditioner group

A/C ASSY YN20M00104F1

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
27 Air-conditioner assy 1 32 Compressor 1 35–6 D hose 1
27–1 Air-conditioner unit 1 33 Pulley 1 35–7 L hose 1
27–2 Hose 2 34 Condenser 1 35–8 L hose : Ø 15.5 1
27–3 Clamp 2 35 Air dryer assy 1 35–9 S tube : Ø 16 1
27–5 Filter 1 35–1 Receiver dryer 1 35–10 L tube : Ø 8.5 1
27–6 Tube assy 1 35–2 Bracket 1 39 Filter 1
30 Panel assy 1 35–5 S hose : Ø 24.5 1 40 Solar radiation sensor 1

25-5
25. AIR-CONDITIONER SYSTEM

25.2.2 CONSTRUCTION
(1) Air conditioner unit

49
48
6
47
46
44

31
42 31
41 F
50
3 1

45 1

43 G

1 32

1
28 1
39

37
38
B
36
27
H

9
40

A
I

2
33

Fig. 25-2 Air conditioner unit (1/2)

25-6
 25. AIR-CONDITIONER SYSTEM

14
1 1 31 16

1 5
15
31
1
3
1 61

F 1
C 1
D
4
7
G

1 1
1

26 20 13

59

29
11

21 23
22

H
24 1

B
1
8 60

D
17
18 A
I
C
10
31
19
12
1
3
31 25

52

Fig. 25-3 Air conditioner unit (2/2)

25-7
25. AIR-CONDITIONER SYSTEM

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Screw M5u16 23 19 Relay 2 40 KK-box lower packing 1
2 Main harness 1 20 Evaporator 1 41 Vent lever 1
3 MA air mix 3 21 Expansion valve 1 42 Face lever 1
4 Blower controller 1 22 O-ring 1 43 Foot joint lever 1
5 Upper casing 1 23 O-ring 1 44 MA mode lever 1
6 Air mix door 1 24 Screw M5u40 2 45 Foot lever 1
7 Air mix lever 1 25 Thermistor 1 46 Face lever cam 1
8 Lower casing 1 26 Thermistor holder 1 47 Vent lever cam 1
9 Air mix door sub 1 27 Heater core 1 48 Face rod 1
10 Air mix lever sub 1 28 Pipe holder 1 49 Vent rod 1
11 Blower 1 29 Thermistor 1 50 Foot rod 1
12 Lever MA air mix 1 31 Screw M4u30 9 52 Inner air filter 1
13 Intake door 1 32 Upper casing 1 55 Screw M6u25 10
14 MA intake lever 1 33 Lower casing 1 56 Screw M8u25 10
15 Intake lever 1 36 Foot door 1 59 Evaporator packing 1
16 Intake rod 1 37 Vent door 1 60 Casing packing A 1
17 Air mix rod 1 38 Face door 1 61 Casing packing B 1
18 Air mix rod sub 1 39 KK box upper packing 1

(2) Receiver dryer

REFRIGERANT 2
INLET
REFRIGERANT
OUTLET

2-M6
1

No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1

Fig. 25-4 Receiver dryer

25-8
 25. AIR-CONDITIONER SYSTEM

25.3 PIPING
25.3.1 AIR CONDITIONER

30
40

NOTE
1. Apply oil for refrigerant R134a to the
27 8 O-rings of all air-conditioner hose fittings.
8 2. Refrigerant volume : 900 50g
3. T : Tightening torque N.m(lbf.ft)

8 58
25 6
24
8
6
24

5
8

A
12
55
2
13
6 INITIAL BELT TENSION
24 When the belt is pushed by the
54 force of 28N, adjust the 25
deflection of L part to be 6mm.
39 4
8 22
51
JAM NUT FOR 18
TENSION PULLEY 20
T=46.1(33) 25
5
2 10
11 21
16
3
6 L

59
9
25 10
25 33
49 23
A 25
9 1
32 10
15
35 52 50
53
5
7 13
25
25
8 25

17 25
3 12
6

56 14
57

23

34 56
57

Fig. 25-5

25-9
25. AIR-CONDITIONER SYSTEM

Air conditioner YN20M00104F1

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Hose : L = 3550 1 24 Clip 3
2 Hose : L = 2950 1 25 Clip 15
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
6 Sems bolt : M10u25 5 33 Pulley assy 1
7 Sems bolt : M6u20 2 34 Condenser 1
8 Sems bolt : M8u20 9 35 Air dryer assy 1
9 Capscrew : M8u100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
23.5 (17.3) 11 Capscrew : M8u25 2 49 Clip 1
12 Tube for heater : L = 2400 1 50 Connector 1
13 Tube for heater : L = 1500 1 51 Bracket 1
14 Tube for D hose : L = 2350 1 52 Clip 1
15 Tube for S hose : L = 2050 1 53 Sems bolt : M10u20 1
16 Bracket 1 54 Grommet 1
17 Tube for L hose : L = 1800 1 55 Grommet 1
18 hose : L = 90 1 4.4 (3.2) 56 Capscrew : M6u50 4
20 Clip 2 57 Washer 4
21 Bracket 1 58 Tube for L hose 1
46.1 (34.0) 22 Sems bolt : M10u40 2 59 Clip 1
23.5 (17.3) 23 Sems bolt : M8u25 4

UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT

S TUBE (9)

27 AIR CONDITIONER ASSY D HOSE (6)

S

32 COMPRESSOR ASSY

RECEIVER CONNECTION BOLT

S HOSE (5)

L TUBE (10)

L HOSE (8) L HOSE (7) 34 CONDENSER

Note : 35 RECEIVER DRYER
Numbers in ( ) shows the number in Fig. 25-6. RECEIVER DRYER MOUNTING BRACKET

25-10
 25. AIR-CONDITIONER SYSTEM

25.3.2 AIR DRYER ASSY

&

#
! )
" 
'
"

!
%

) ,
#

, *
+ $

 +
*

Fig. 25-6

Air dryer assy YN96V00024F1

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Receiver dryer 1 6 D hose 1
2 Bracket 1 7 L hose 1
3 Capscrew 2 8 L hose 1
4 Capscrew 2 9 S tube 1
5 S hose 1 10 L tube 1

25-11
25. AIR-CONDITIONER SYSTEM

25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient
0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.

25-12
 25. AIR-CONDITIONER SYSTEM

(3) Characteristics of Refrigerant (Fig. 25-7) PRESSURE

In general, the fluid (general term of gas and liquid) MPa(psi)
R134a
has the following qualities: 4(580)

1) As a gas under certain pressure is cooled down,

3(435)
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
2(290)
condensation begins is unique to each
substance (fluid) at a given pressure. The 1(145) GAS
temperature determined by a given pressure is 0.5(75)
TEMPERATURE
called saturation temperature. [ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-7 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-7 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-7 the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to
cool the inside of the compartment down to 25°C
(77°F), the refrigerant must transform
(evaporate) from a liquid to a gaseous state at a
lower temperature. It can be seen from Fig. 25-7
that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the circuits,
thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 MPa
(145psi), as seen from Fig. 25-7.

25-13
25. AIR-CONDITIONER SYSTEM

25.4.2 COOLING CIRCUIT

Fig. 25-8 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
heat off the surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the part at which EVAPORATOR EXPANSION
VALVE
vaporization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
refrigerant) is fed into the evaporator, when "cooling" COMPRESSOR COOLING FAN

effect is attained. 
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi).  Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.

25-14
 25. AIR-CONDITIONER SYSTEM

25.4.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-9.)
The evaporator is an important heat exchanger that
EVAPORATOR
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air.
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator EXPANSION VALVE
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to
discharge water is an important point. SOCKET BOLT M5X40(2 PCS.)
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve Fig. 25-9
which is described in the following. In order to attain
proper control, it is necessary to reduce the
pressure drop of the refrigerant of the evaporator.
Accordingly, reducing the pressure drop is one
element that makes the evaporator attain its full
performances.
(2) Expansion Valve
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is
too high, unvaporized liquid refrigerant returns to
the compressor (liquid back). This not only
deteriorates the cooling effect, but also damages
the compressor valves.
The expansion valve feeds the flowing high-
pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.

25-15
25. AIR-CONDITIONER SYSTEM

Fig. 25-10 shows how the block type expansion

valve is constructed. The temperature sensing
DIAPHRAGM
part is provided in the shaft of the expansion
valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
state. The pressure in the diaphragm changes EVAPORATOR OUTLET
SIDE
according to the temperature detected by the
sensor. The change in the pressure causes the SHAFT
force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side REFRIGERANT
INLET
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
BALL
occasion, part of the refrigerant evaporates by VALVE
the very heat of the refrigerant and cooled off. SPRING
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator. Fig. 25-10 Block type expansion valve
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that
under the pressure in the evaporator, the
refrigerant is properly overheated (3~8 degrees
C) and goes out of the evaporator. This action is
carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure drop
in the evaporator is excessive, it is difficult to
control the overheating or the feed rate of the
refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
and the refrigerant supply to the evaporator more
Fig. 25-11 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.

25-16
 25. AIR-CONDITIONER SYSTEM

(3) Compressor (See Fig. 25-12.)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-12
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35°C (95°F) and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
(4) Condenser ( See Fig. 25-13.)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the
refrigerant. The direction in which heat moves is
from the refrigerant to air, the opposite to the case
of the evaporator. Fins are equipped on the outer
air side to improve thermal transfer. If the
refrigerant is not cooled well by the condenser, the
air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the
cooling of the refrigerant.

Fig. 25-13 Condenser

25-17
25. AIR-CONDITIONER SYSTEM

(5) Receiver dryer ( See Fig. 25-14.)

REFRIGERANT SIGHT GLASS
1) Receiver Tank INLET
On the air-conditioner, the revolution of the REFRIGERANT
compressor varies greatly which causes the OUTLET
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
PRESSURE SWITCH
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil, DESICCANT
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion SUCTION
valve. It is desirable that the amount of water PIPE
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for FILTER
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the RECEIVER
TANK
only means of confirming the inside of the circuit
visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by Fig. 25-14
cutting off the power supply to the compressor
when high pressure increases abnormally high
[more than 3.14MPa (460psi) ].
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.2MPa (28psi).

25-18
 25. AIR-CONDITIONER SYSTEM

25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Unit : N.m (lbf.ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils other PIPE FASTENING PART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)

1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)

2) Use care so SP20 does not adhere to the

painted surface and resin parts. In case SP20 Unit : N.m (lbf.ft)
has adhered to such surfaces, wipe it off SCREW SIZE TIGHTENING TORQUE
immediately.
N4,T4 machine screw, M4 0.78~1.18 (0.58~0.87)
(2) The receiver dryer is filled with desiccant to absorb
moisture in the circuit. Therefore, remove the valve N5,T5 machine screw, M5 1.96~2.45 (1.4~1.8)
at the pipe port immediately before connecting M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7)
pipes.
M6 (except mounting part of L hose joint) 9.8~11.8 (7.2~8.7)
(3) Tightening Torque
M8 (mounting part of S,D hose joints) 19.6~24.5 (14~18)
1) Pipe Joints
When connecting pipe joints, coat the O-ring with M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
special oil (SP20) and fasten to the tightening
M8 (other than those mentioned above) 11.8~15.7 (8.7~12)
torque indicated in the table, using a double
spanner. M10 39.2~53.9 (29~40))

2) Screws and Bolts

Fasten to the tightening torque indicated in the
table REPLACED PARTS AMOUNT TO BE FILLED IN
(4) Amount of Oil for Compressor
EVAPORATOR 40 cc (2.4cu.in)
The compressor SD7H (HD type) is filled with
135cc (8.2cu•in) of oil. If the oil volume is small, CONDENSER 40 cc (2.4cu.in)
seizure at high revolution and shortening of service
Drain out the volume of oil left in
life will occur. If the oil volume is large, the cooling
COMPRESSOR the compressor to be replaced,
ability will be deteriorated.
from the new compressor.
Once the air-conditioner is operated, part of the oil
is dispersed in the refrigeration circuit. Therefore,
RECEIVER DRYER 20 cc (1.2cu.in)
when replacing the parts in right Table, adjust the oil
level to that of table. HOSES 20 cc (1.2cu.in)
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
(6) After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.

25-19
25. AIR-CONDITIONER SYSTEM

25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter
HARNESS CLAMP UNIT
Slide the inner air filter leftward and remove it from
the unit.

INNER AIR FILTER

Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.

CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING

AIR MIX
ROD SUB
AIR MIX
ROD SUB

LOWER UNIT CASING

Fig. 25-17

25-20
 25. AIR-CONDITIONER SYSTEM

(5) Replacing blower controller UPPER UNIT CASING

1) Remove 2 plus screws and remove the blower
controller from the upper unit casing.
2) Install new blower controller by the reverse
procedure of removal.

* Do not disassemble the blower controller.

PLUS SCREW BLOWER CONTROLLER

Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.

(7) Replacing blower motor

1) Disconnect connector which is connected to the
blower motor and remove the blower motor from
the lower unit casing.

* Do not remove the fan from the blower motor.

LOWER UNIT CASING

2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-20 and install the (4.1 inch)
evaporator sensor again.

11TH ROWS OF FIN

EVAPORATION SENSOR

Fig. 25-20

25-21
25. AIR-CONDITIONER SYSTEM

4) Remove 2 socket bolts M5u40 with Allen wrench

(4mm) and remove the expansion valve from the
EVAPORATOR
evaporator.
5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to
A
new evaporator.

* When assembling again, fit O-ring paying
attention so as not to be caught with others. O-RING
(Socket bolt M5u40 (2 pcs.) Tightening torque :
6.9N•m (5.1lbf•ft)

* Do not apply undue force to pipe of evaporator
outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator. EXPANSION VALVE
Moreover, when tube assembly (27-6) (see Fig.
25-1) connected with expansion valve is
SOCKET BOLT M5X40(2 PCS.)
disconnected from expansion valve, similar
careful work is necessary.
Fig. 25-21

(9) Replacing motor actuator

VENT ROD
1) Replacing mode actuator
FACE ROD
a) Remove connector connected to the motor
MA MODE
actuator. LEVER
CONNECTOR
b) Remove FACE rod and VENT rod which is PLUS SCREW
3PCS.
used to connect MA mode lever and mode
MODE
cam from the holder. ACTUATOR
c) Remove 3 plus screws and remove the
motor actuator with lever MA mode from the
unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on new Fig. 25-22
motor actuator by the reverse procedure of
removal.
2) Replacing air mixing actuator
AIR MIX ROD
a) Remove connector connected to the motor
MA AIR MIX LEVER
actuator.
b) Remove rod air MIX which is used to connect
the motor actuator and the lever MA air MIX. CONNECTOR

c) Remove 3 plus screws and remove the

motor actuator with MA lever air MIX from the
unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal. PLUS SCREW 3PCS.
AIR MIX ACTUATOR

Fig. 25-23

25-22
 25. AIR-CONDITIONER SYSTEM

3) Replacing inner and outer air switching actuator

MA INTAKE LEVER

a) Disconnect connector connected to the

motor actuator. INTAKE ROD
PLUS SCREW
b) Remove intake rod from MA intake lever. (3PCS.)

c) Remove 3 plus screws and remove the

motor actuator with MA intake lever from the
CONNECTOR
unit.
d) Remove the MA intake lever from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal.

INNER AND OUTER AIR SWITCHING ACTUATOR

Fig. 25-24

25-23
25. AIR-CONDITIONER SYSTEM

25.6 CHARGING REFRIGERANT

25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar
with how work is done for handling refrigerant.

• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)

(2) Storage and Transportation

1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is
filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises.
The can may blast as the result.
It is for this reason why the can temperature must be kept below 40°C (104°F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous
temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to
a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into
account.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
(3) Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent
that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a
direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge
manifold in any case.
(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-
conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-
conditioner correctly and speedily. Pay full attention to the entry of water and dust.

• Be careful about overcharge of gas.

• Fasten pipes to a specified torque.

25-24
 25. AIR-CONDITIONER SYSTEM

25.6.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge
operation".
1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water
remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the
circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before filling refrigerant in the
circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus
eliminated.
2) The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not
only depends upon the cooling performances of the air-conditioner, but also affects the service life of the
component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes
the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the
lubricating oil of the compressor and causes seizure of the moving parts of the compressor.
The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation
procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in
this manual.
(2) Operation Chart

Vacuum making operation Refrigerant filling operation

More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)

(3) Tools

No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red : 
high pressure side
Charging Blue :  Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow : 
vacuum pump side

Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter

25-25
25. AIR-CONDITIONER SYSTEM

25.6.3 CHARGING PROCEDURE

25.6.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See Fig. 25-25)
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
(CLOSED)LOW HIGH PRESSURE
2) Connect the charging hoses (red and blue) with PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
BLUE
Red hose : 
High pressure side (HI) of the gauge HIGH
PRESSURE YELLOW
manifoldohigh pressure side (DIS) of SIDE
compressor DIS
LOW
Blue hose :  PRESSURE
Low pressure side (LO) of gauge manifoldolow SIDE
SUC
pressure side (SUC) of compressor
COMPRESSOR VACUUM PUMP(STOP)

Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when BLUE

connecting them. Put the hose in firmly till a clicking RED

sound is heard.

CHARGING
3) Connect the center valve of the gauge manifold
HOSE
with the charging hose of the vacuum pump. (GAS VALVE)

Fig. 25-26 Connecting gauge manifold

Some kinds of gauge manifolds are not equipped with

an open/close valve in the center.

25-26
 25. AIR-CONDITIONER SYSTEM

(2) Vacuum making (See Fig. 25-27)

LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. GAUGE MANIFOLD
3) When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
(3) Air-tightness Check
Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for more SUC
than five minutes and make sure that the gauge
indication does not return toward 0.
Fig. 25-27 Vacuum making operation

If the gauge indication swings toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.

25-27
25. AIR-CONDITIONER SYSTEM

25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See Fig. 25-28.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge AIR PURGE
manifold.) Then push the gas valve of the side CLOSE
service port on the low pressure side of the
SCREW DRIVER OPEN SERVICE
gauge manifold, using a screw driver, in order to CAN VALVE
YELLOW
let out the air in the charging hose by the
pressure of the refrigerant. (See Fig. 25-28.)
BLUE RED
(The operation ends when a hissing sound is
heard.)

Fig. 25-28 Gas charging operation

3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).] LOW PRESSURE HIGH PRESSURE VALVE
After charging, close the high pressure valve of VALVE(CLOSE) (OPEN) (CLOSE)
RED FILL IN 1~1.5 CANS
the gauge manifold and the service and valve. BLUE OF REFRIGERANT
(See Fig. 25-29.)
DIS
YELLOW
SERVICE CAN
VALVE
• Do not run the compressor during this work, (OPEN) (CLOSE)
CHARGE
(Otherwise the refrigerant flow in reverse
direction which causes the service can and the SUC
hoses to rupture. This is very dangerous.)
Fig. 25-29 Gas charging operation
(2) Checking for gas leak (High pressure side)
Check for gas leak in the cycle, using a gas leak
detector (electric type). Retighten and correct
leaking points.

• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)

25-28
 25. AIR-CONDITIONER SYSTEM

(3) Charging from low pressure side (See Fig. 25-30)

1) Make sure that the high-pressure and low-
pressure valves of the gauge manifold and the
service can valve are closed. LOW PRESSURE HIGH PRESSURE
VALVE VALVE(CLOSE)
2) Start the engine and run the revolution to OPEN CLOSE
RED
(CLOSE SECURELY)
WHEN AIR
1500±100rpm and fully close the cab door and BUBBLES IN THE
SIGHT GLASS
the windows. DISAPPEAR
YELLOW
DIS
3) Turn on the air-conditioner switch, set the fan BLUE
switch to Max and the temperature control switch
to cool Max. SERVICE CAN
VALVE(OPEN)
4) When charging gas, set the discharge pressure
SUC
of the compressor to 1.4~1.6 MPa (200~230psi).

COMPRESSOR SERVICE CAN
 OPERATION (DO NOT TURN IT OVER)

Fig. 25-30 Gas charging operation
(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-30)
[Total amount of gas to be charged : 
900g±50g (2.0±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER

• Do not open the high pressure valve of the

gauge manifold in any circumstances. Fig. 25-31 Receiver dryer
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)








25-29
25. AIR-CONDITIONER SYSTEM

(4) Criterion for checking the amount of refrigerant

filled in

JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER

After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.

After A/C is turned on,

OVERCHARGE no air bubbles are seen.

After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.

• If the air-conditioner is run with poor refrigerant

R134a, it has adverse effect on the compressor.
• If the refrigerant is charged too much
(overcharged), the cooling performance is
deteriorated. Moreover, the circuit pressure
gets abnormally high : Always keep a proper
level.

(5) Removing Gauge Manifold

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1. Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the
service valve of the compressor so the
refrigerant does not leak out and loosen the nut.
As soon as the nut has been removed,
disconnect the charging hose from the service
valve.
2. Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.

25-30
 25. AIR-CONDITIONER SYSTEM

This page is blank for editing convenience.

25-31
25. AIR-CONDITIONER SYSTEM

25.7 ELECTRIC CIRCUIT

25.7.1 WIRING DIAGRAM AND CONNECTORS
JAE : JAPAN AVIATION ELECTRONICS
JAE JAE INDUSTRY, LTD.
HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000

MAKER : YAZAKI CORP.

MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40 REAR HOLDER : 7157-6260-30
TERMINAL : 7116-2871 TERMINAL : 7114-2871

NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)

MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING

MAKER : YAZAKI CORP. MAKER : YAZAKI CORP. A/C MAIN POWER

HOUSING No. : 7123-2249 FUSE 5A
HOUSING No. : 7123-6020 MAIN KEY SW POWER SUPPLY FOR
TERMINAL : 17111 TERMINAL : 7116-2871 COMPRESSOR CLUTCH
FUSE 15A

FUSE 5A

MAKER : YAZAKI CORP. MAKER : YAZAKI CORP.

HOUSING No. : 7123-2237 HOUSING No. : 7123-2228
TERMINAL : 17111 TERMINAL : 17111 FUSE BOX

MAKER : YAZAKI CORP.

JAE IL-AG5-7S-S3C1 HOUSING No. : 7123-2228
TERMINAL : AG5-C1-5000 TERMINAL : 17111

COMPRESSOR

NIPPON AMP KK 174056-2 JAE IL-AG5-7S-S3C1

TERMINAL : 175062-1 TERMINAL : AG5-C1-5000

JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111

NOTE) 1. THe double chain lines indicate the wiring

on the excavator side. MACHINE SIDE WIRING (PARTS)
2. The connector colors indicate the cord colors seen
from the connecting part.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

Fig. 25-32 Electric diagram (1/2)

25-32
 25. AIR-CONDITIONER SYSTEM

CCU (OPERATION PANEL + CONTROLLER)

EVA SENSOR

AIR INLET SENSOR

SUN SENSOR

MOTOR ACTUATER
(FOR AIR MIX)

MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)

BLOWER MOTOR

BLOWER AMP

MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY

AIR CONDITIONER SIDE

WIRING (PARTS) IN THE CAB

Fig. 25-33 Electric diagram (2/2)

25-33
25. AIR-CONDITIONER SYSTEM

25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-34
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.

(2) Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the control B
unit.

TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)

In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
 Fig. 25-35
* The installing position is provided on the left side
of air-con unit.

25-34
 25. AIR-CONDITIONER SYSTEM

(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320 
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.

When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR

through the temperature control switch, the control LIMITER

COOL
unit reads the level of potentiometer of the actuator, POTENTIO 5V

and determines the rotating direction of motor in

POTENTIO
POTENTIO GND

either normal rotation or reverse rotation. Then as

the motor rotates, the contact point is moved, and HOT

when the contact point is detached or the output

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-37

25-35
25. AIR-CONDITIONER SYSTEM

(5) The actuator for inner and outer

The actuator for inner and outer air flow select is
installed on the blower intake unit, and opens and
closes inner and outer air damper through the link.

The actuator for inner and outer air flow select
contains position detection switch which is
switched with the movement of shaft of the
actuator.  AMPLIFIER MOTOR ACTUATOR

When the inner and outer damper position is set by

the inner and outer switch on the control panel, the
control unit reads the signal of the position
detection switch in the actuator and determines the INNER AIR SIDE

rotation direction of motor in either normal rotation OUTER AIR SIDE

or reverse rotation. Then as the motor rotates, the LIMITER

position detection switch also rotates and makes it

stop at the set position of the inner and outer air Fig. 25-38
damper.
(6) Evaporator sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to
protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
• Evaporator sensor inspecting items
(Specification)
Terminal resistance : Fig. 25-39
at 0 degree C : 7.2 k 
at 25 degree C : 2.2k
(7) Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was
generated on the high pressure side.
Fig. 25-40
SPECIFICATION OF DUAL PRESSURE SWITCH

0.02MPa(2.9psi) 0.59MPa(86psi)

ON

OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)

(8) Solar radiation sensor

This solar radiation sensor, which is used to correct
the solar radiation to the auto air conditioner
detects the strength and solar orientation of
sunbeam after transforming them into current by
means of photo diode.
Inspection : Check for the continuity between
Fig. 25-41
terminals.

25-36
 25. AIR-CONDITIONER SYSTEM

25.8 TROUBLESHOOTING

Air temperature does not fall. Note : M/A is motor

actuator
* is any of the
numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed,
"HL.E" is indicated on the set temp. display of the panel.
NO YES

"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air
NO YES . Mainmixharness
M/A is failed.
shows poor continuity.

A snow mark ( ) on A snow mark ( )

the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES

. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.

See section monitor mode.

Inspect and correct or replace parts.

A
NO YES

Blowout temp. falls if temp. is set . Evaporation sensor connector

at 18.0 (64.4 ) (COOLMAX) and the is disconnected or in poor contact.
blowout mode is changed to vent mode. . Evaporation sensor is disconnected or shorted.
NO YES Inspect and correct or replace parts.

Air mix damper is Cool air flowing

in COOLMAX. into inner air sensor Inspect and correct or replace parts.

NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.

NO YES

. Inspect, correct or replace M/A failed or controller

M/A lever link. is out of order.
. After cleaning lever link,
apply grease.
Replace.

25-37
25. AIR-CONDITIONER SYSTEM

Air temperature does not rise. Note : * is any of

the numbers 0 ~ 9.

HL.E is shown on the set temp. display of the panel.

NO YES

"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air
NO YES . Mainmixharness
M/A is failed.
shows poor continuity.

. Inner air sensor or harness is disconnected or shorted.

. Inner air sensor connector is disconnected or in poor contact. Inspect and correct or replace parts.
See section monitor mode.
NO YES
Inspect and correct or replace parts.

NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES

Air mix damper is Warm air is flowing into

in HOT MAX. inner air sensor.
NO YES
NO YES
If M/A action is at stop, Inspect warm water piping.
eliminate cause, correct
Controller or Inspect duct or
and measure operating
inner air sensor eliminate causes
force. (less than 14.7N : OK)
is out of order. for warm air entry.

NO YES
Inspect and replace.

. Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
. Clean lever link and apply grease.

Replace.

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 25. AIR-CONDITIONER SYSTEM

Blower motor does not run.

At air flow HI, battery voltage acts across

Note 1) both terminals (+) and (-) of blower motor.

NO YES

Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.

Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES

Controller is out of order. Remove blower amplifier and check for

Wire harness is Replace continuity across light green wire
faulty. Inspect and black wires ; you get continuity.
and correct or replace.
NO YES

Battery voltage acts across white /

red wire and body of blower motor relay. Eliminate cause Inspect and
and replace repair harness.
NO YES blower amplifier.

Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES

Replace relay. Inspect and correct harness

or replace controller.

Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.

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25. AIR-CONDITIONER SYSTEM

Blower motor speed does not change.

CASE (1)
Note) is any of the
"HL.*" is shown on the set temp. display of the panel. *
numbers 0 ~ 9.
NO YES

Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier controller. . Inner air sensor connector is disconnected or in poor contact.
See section monitor mode.

Inspect and correct or replace parts.

CASE (2)

Does not blower motor speed

change because the setting mode
is other face mode?
YES NO

Is door or front window open? See CASE (1).

YES NO

The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch.

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 25. AIR-CONDITIONER SYSTEM

Magnet clutch does not engage.

Snow mark ( ) lights

if A/C switch is pressed.
No Yes

Snow mark ( ) flickers and E is Voltage acts upon clutch.

shown on panel display.
No Yes

To A On page 25-37. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes

Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.

No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes

Replace harness. Replace controller.

Inner air and outer air do not change over.

Inner / outer air mode display on

operation panel is flickering.
No Yes

M/A lever includes foreign matter Connector of inner/outer air

or is broken. M/A is disconnected or in poor
No Yes contact.
Or M/A failed or main harness failed.

M/A failed Remove foreign matter

and replace parts. Inspect or replace.

Replace

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25. AIR-CONDITIONER SYSTEM

Modes do not change.

Mode display (Mark of person)

on operating panel is flickering.
No Yes

M/A rod does not disengage. Mode M/A connector is

disconnected or in poor
No Yes
contact or M/A failed or main
harness is faulty.
Repair. Each damper lever does not disengage.
No Yes Inspect or replace.

Repair. When rod is removed and cam is operated

by hand, it is heavy. (more than 19.6N.)
No Yes

M/A or controller is out of order. . Cam or damper shaft includes

foreign matter or is broken
. Erroneous motion occurs due to
Replace. dirty grease.

. Remove foreign matter or replace parts.

. Clean cam and apply new grease.

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 25. AIR-CONDITIONER SYSTEM

Trouble with refrigeration cycle.

Both high and low pressures are lower.

Low pressure is higher.

NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES

Cooling does not work Oil comes out from

if run at high speed. piping and parts. Compressor cylinder Compressor cylinder
does not get hot. gets very hot.
NO YES NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged or is frozen or leak from from pipe
maladjusted. intruded by water. hose. joints and
Expansion valve is Compressor does
parts.
maladjusted. not discharge well.
(too much open)
Adjust or replace After making
expansion valve. vacuum, refill Retighten
refrigerant Charge gas. or replace
and replace parts.
receiver. Replace Replace compres
expansion valve.

High pressure
is lower.

Air bubbles are seen in sight glass.

NO YES

High pressure gets Condenser is

lower slowly. fouled or clogged.

High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.

Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.

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25. AIR-CONDITIONER SYSTEM

25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.

25.9.1 POSITION OF INDICATION FOR FAILURE.

The error is indicated on 3 digits segment.

25.9.2 EXPLANATION OF INDICATION FOR FAILURE.

(1) Failure of Motor Actuator
1) HL.E is indicated on 3 digits segment.

Check harness or connector to motor actuator

for the air mix damper for disconnection.

2) MODE is flickering.

Check harness or connector to motor actuator

for the air outlet damper for disconnection.

3) R/F is flickering.

Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.

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 25. AIR-CONDITIONER SYSTEM

(2) Failures of sensors

1) HL.* is indicated on 3 digits segment.

Check the inner air sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

(* is any of the numbers 0 to 9.)

2) **E and mark are flickering.

(** is displayed leaving the present set temperature value.)

Check evaporator sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.

(3) Communication error of control amplifier and panel

1) E is indicated on the only use segment of display.

Check the harness of control amplifier and panel for disconnection,

and connectors for poor connection.

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25. AIR-CONDITIONER SYSTEM

25.9.3 EXPLANATION OF MONITOR MODE

When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
(1) Position of monitor mode indication

SEGMENT FOR ONLY MONITOR INDICATION

3 DIGITS SEGMENT

(2) Operation of monitor mode

SPEED UP AND DOWN

INNER OR OUTER
SWITCH FOR BLOWER
AIR INLET SELECT
SWITCH (R/F)

ON/OFF SW

1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd
digit of segment in three digits. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing
UP or DOWN of blower switch, and the required sensor is selected from the list below.

SEGMENT ASSIGNMENT LIST

0 INNER AIR SENSOR

1 EVAPORATOR SENSOR

2 SOLAR RADIATION SENSOR

(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)

5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.

Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.

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 25. AIR-CONDITIONER SYSTEM

(3) Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1) Example 1

When the segment exclusively used for monitor indicates 0

(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.

2) Example 2

When the segment exclusively used for monitor indicates 1

(displays the evaporator sensor condition),
since the segment indicates 00, the sensor is
in disconnection condition according to the list of 3 segments
--> The evaporator sensor is in disconnection condition.

3) Example 3

When the segment exclusively used for monitor indicates 2

(displays the solar radiation sensor condition), since the
segment indicates FF,the sensor is in short-circuiting condition
according to the list of 3 segments.
-->The solar radiation sensor is in short-circuiting condition.

4) List of 3 segments

SECOND SEGMENT

INNER AIR SENSOR DISCONNECTION

EVAPORATOR SENSOR DISCONNECTION
SOLAR RADIATION SHORT-CIRCUITING
THIRD SEGMENT

EACH SENSOR IS NORMAL

SOLAR SENSOR 5V SIDE SHORT-CIRCUITING

INNER AIR SENSOR SHORT-CIRCUITING

EVAPORATOR SENSOR SHORT-CIRCUITING

25-47
25. AIR-CONDITIONER SYSTEM

[MEMO]

25-48