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Rearmount

68RM35-604-20 R-134a NYCDOT

T-288

OPERATION AND SERVICE MANUAL


BUS AIR CONDITIONING UNIT

Rearmount 68RM35-604-20 R-134a

Carrier Transicold Division, Carrier Corporation, P .O. Box 4805, Syracuse, N.Y. 13221 Carrier Corporation 1999 D Printed in U. S. A. 0699

SAFETY SUMMARY
GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing elsewhere in the manual follows the general safety notices. FIRST AID An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately. OPERATING PRECAUTIONS Always wear safety glasses. Keep hands, clothing and tools clear of the evaporator and condenser fans. No work should be performed on the unit until all circuit breakers and start-stop switches are turned off, and power supply is disconnected. Always work in pairs. Never work on the equipment alone. In case of severe vibration or unusual noise, stop the unit and investigate. MAINTENANCE PRECAUTIONS Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan grille or evaporator access panels before turning power off, and disconnecting and securing the power plug. Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag circuit breaker and power supply to prevent accidental energizing of circuit. Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel. When performing any arc welding on the unit, disconnect all wire harness connectors from the modules in the control box. Do not remove wire harness from the modules unless you are grounded to the unit frame with a static-safe wrist strap. In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).

SAFETY SUMMARY
SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the Unit and explain the level of awareness each one carries, an explanation is given with the appropriate consequences: DANGER --- means an immediate hazard which WILL result in severe personal injury or death. WARNING --- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or death. CAUTION --- means to warn against potential hazard or unsafe practice which COULD result in minor personal injury, product or property damage.

The statements listed below are applicable to the refrigeration unit and may appear elsewhere in this manual. These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein. WARNING When servicing the unit, use caution when handling R-134a. This refrigerant when in contact with high temperatures (about 1000_F) will decompose into highly corrosive and toxic compounds. WARNING Be sure to avoid refrigerant coming in contact with the eyes. Should refrigerant come in contact with the eyes, wash eyes for minimum of 15 minutes with potable water only. THE USE OF MINERAL OIL OR REFRIGERANT OILS IS NOT RECOMMENDED. WARNING Be sure to avoid refrigerant coming in contact with the skin. Should refrigerant come in contact with the skin, it should be treated as if the skin had been frostbitten or frozen. WARNING Be sure ventilation in the workspace is adequate to keep the concentration of refrigerant below 1000 parts per million. If necessary, use portable blowers. WARNING Beware of rotating fan blades and unannounced starting of fans. WARNING Do not use a nitrogen cylinder without a pressure regulator and do not use oxygen in a refrigeration system, as an explosion could occur. WARNING Never fill a refrigerant cylinder beyond its rated capacity. Cylinder may rupture due to excessive pressure when exposed to high temperatures. WARNING When starting the unit, be sure that all manual refrigerant valves in the discharge line are open. Severe damage could occur from extremely high refrigerant pressures.

ii

TABLE OF CONTENTS

Section
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page
i 1-1

1.1 1.2 1.3 1.4 1.5 1.6 1.7


2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERATION SYSTEM COMPONENT SPECIFICATIONS . . . . . . . . . . . ELECTRICAL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . MOISTURE/LIQUID INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONING REFRIGERANT CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-5 1-5 1-5 1-7 1-9 1-10


2-1

2.1 2.2 2.3

STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . PRE-TRIP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Air Conditioning Auto/Reheat Mode of Operation . . . . . . . . . . . . . . .

2-1 2-1 2-1 2-1


3-1

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8


4

UNIT WILL NOT COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM RUNS BUT HAS INSUFFICIENT COOLING . . . . . . . . . . . . . . . . . . . ABNORMAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ABNORMAL NOISES OR VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEMPERATURE CONTROLLER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . . EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NO OR INSUFFICIENT HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-2


4-1

4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUCTION AND DISCHARGE SERVICE VALVES . . . . . . . . . . . . . . . . . . . . . . . INSTALLING MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SYSTEM PUMPDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT LEAK CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADDING REFRIGERANT TO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . FILTER-DRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii

4-1 4-1 4-1 4-3 4-3 4-4 4-4 4-6 4-6 4-6

TABLE OF CONTENTS (CONTD)

Section 4.11 4.12 4.13 4.14 4.15 4.16 CHECKING PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICING THE REHEAT COOLANT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONDENSER FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . SERVICING THE EVAPORATOR FAN BLOWER MOTOR ASSEMBLY . . . . 4.16.1 4.16.2 4.17 4.18 Routine Examination and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brush Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4-7 4-8 4-9 4-9 4-10 4-10 4-10 4-11 4-11 4-11 4-11 4-12 4-12 4-13 4-13
5-1

REPLACING THE RETURN AIR FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18.1 4.18.2 4.18.3 4.18.4 4.18.5 Replacing the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . Adding Oil to the Installed Compressor . . . . . . . . . . . . . . . . . . . . . . . . Adding Oil to Service Replacement Compressor . . . . . . . . . . . . . . . . Removing Oil from the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 ELECTRICAL SCHEMATIC WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF ILLUSTRATIONS

5-1 Page

Figure 1-1. 1-2. 1-3. 1-4. 1-5. 2-1. 2-2. 2-3. 2-4. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. Unit Assembly -- Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Assembly -- Inside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 05G Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Refrigerant Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat Control Sequence Auto Cool Mode with Reheat . . . . . . . . . . . . . Automatic Low Speed Cool/Heat Mode Operation - with Reheat . . . . . . . . . . Automatic High Speed Cool/Heat Mode Operation - with Reheat . . . . . . . . . Automatic High Speed Cool Mode Operation - No Reheat . . . . . . . . . . . . . . . Suction or Discharge Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-134a Manifold Gauge Set Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evacuation Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evacuation Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Drier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv

1-2 1-3 1-4 1-4 1-11 2-2 2-3 2-4 2-5 4-1 4-2 4-4 4-5 4-7 4-7 4-8

LIST OF ILLUSTRATIONS (CONTD)

Figure 4-8. 4-9. 4-11. Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . Condenser Fan Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model 05G Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 4-9 4-10 4-10 4-12 4-13

4-10. Evaporator Fan Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12. Compressor Oil Charge Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. 5-2.

Electrical Schematic Diagram Legend and Symbols . . . . . . . . . . . . . . . . . . . . . Electrical Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


LIST OF TABLES

5-2 5-3

Table 1-1. 1-2. 1-3. 3-1. 4-1. 4-2. Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unloader Pressure Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch Continuity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-134a Temperature - Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 1-1 1-6 1-6 3-1 4-8 4-14

SECTION 1 DESCRIPTION
1.1 INTRODUCTION

This manual contains operating and electrical Data, and service instructions for the 68RM35 bus air conditioning system shown in Table 1-1. The 68RM35 unit is a one-piece system consisting of a compressor, condenser, evaporator and electrical control panel sections. The units are installed in the rear A/C compartment of the bus. These units interface with the bus driver switches and pump to provide a complete air conditioning system.

All control systems are powered by 24 vdc supplied by the bus battery and alternator or alternate source. Operation of the 68RM35 units is controlled automatically by the electronic thermostat, which maintains the vehicles interior temperature at the desired set point.

Table 1-1. Model Chart Model Number 68RM35-604-20 Refrigerant R-134a Electronic Thermostat Adjustable Description Heat/Cool Relay Board Configuration Reheat Fan Motors Wound Field

1-1

T-288

ROADSIDE (RS)

CURBSIDE (CS)

10 11

12 13 14 15 16

25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

24

23

22 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

21

20

19

18

17

Condenser Fan Motor (CM1) Filter-Drier Inlet Valve Filter-Drier Low Ambient Thermostat (LATH) Filter-Drier Outlet Valve Condenser Fan Motor (CM2) Receiver Fusible Plug Condenser Coil Discharge Line Check Valve Discharge Line Isolation Valve Receiver Sight Glass (Upper) Moisture/Liquid Indicator Unloader Pressure Switch (UPS3), Upper

Condenser Fan Switch (CFS), Lower Evaporator Fan Housing, Curbside Discharge Line Connection Suction Line Connection Unloader Pressure Switch (UPS1), Lower Unloader Pressure Switch (UPS2), Upper Evaporator Fan Motor (EFM1) Liquid-Suction Heat Exchanger Heater Coil Assembly Evaporator Fan Motor (EFM2) Evaporator Fan Housing, Roadside

Figure 1-1. Unit Assembly - Back View

T-288

1-2

CURBSIDE (CS)

ROADSIDE (RS) 1

CDR

6 1. 2. 3. 4. 5. 6. 7. Electrical Control Panel (See Figure 1-3.) Liquid Line Solenoid Valve Thermostatic Expansion Valve (TXV) Roadside Blower Housing Air Filter Evaporator Coil Curbside Blower Housing

Figure 1-2. Unit Assembly - Inside View

1-3

T-288

10

11

12 13

14

CDR

26 24 28 27 25 1. Circuit Breaker (CB5)-60 Amp 12. 2. Circuit Breaker (CB4)-60 Amp 13. 3. Circuit Breaker (CB3)-60 Amp 14. 4. Circuit Breaker (CB2)-60 Amp 15. 5. Relay Board 16. 6. Clutch Relay (CR) 17. 7. Air Conditioning Relay (ACR) 18. 8. Evaporator Overload Relay No. 2 (OR2) 19. 9. Evaporator Overload Relay 20. No. 1 (OR1) 10. Temperature Selector 21. 11. Electronic Thermostat (4-Relay Controller)

23 22 21 20 19 18 17 Circuit Breaker (CB6)-10 Amp Circuit Breaker (CB1)-15 Amp Cool Disable Relay (CDR) Evaporator Speed Relay (ESR) Power Terminal Block (PTB) Return Air Probe Air Conditioning Stop Relay No. 2 (ACSR2) Heat Relay (HR) Air Conditioning Stop Relay No. 1 (ACSR1) Fault Relay (FR)

15 16 22. Heat Relay No. 2 (HR2) 23. Boost Pump Relay (BPR) 24. Condenser Speed Relay No. 1 (CSR1) 25. Condenser Fan Relay No. 1 (CFR1) 26. Condenser Fan Relay No. 2 (CFR2) 27. Evaporator Fan Relay No. 1 (EFR1) 28. Evaporator Fan Relay No. 2 (EFR2)

Figure 1-3. Electrical Control Panel 1 2 3 4 5 4

1. Model 05G Compressor 2. High Pressure Switch (HPS) 3. Clutch

4. Unloader Coil 5. Low Pressure Switch (LPS)

Figure 1-4. Model 05G Compressor

T-288

1-4

1.2

REFRIGERATION SYSTEM COMPONENT SPECIFICATIONS

i. Water Temperature Switch

Closes at 105_F (41_C) on temperature rise


j. Reheat Coolant Valve

a. Refrigerant Charge

R-134a: 16 to 17 lb (7.3 to 7.7 kg)


b. Compressor

(Customer Supplied)
k. 05G Compressor Electric Unloader Pressure Switches UPS1, UPS2 & UPS3 (See Table 1-2 for settings.) 1.3 ELECTRICAL SPECIFICATIONS a. Evaporator Blower Motor

Model: 05G No. of Cylinder: 6 Weight (Dry): 145 lbs. (66 kg) including clutch Oil Level: Oil Charge: 6.75 pints (3.2 liters) Oil Level: Between Min--Max marks on crankcase Approved Compressor Oils - R-134a: Castrol: Icematic SW68C Mobil: EAL Artic 68 ICI: Emkarate RL68H
c. Thermostatic Expansion Valve R-134a Units

Bearing Lubrication: Factory Lubricated (additional grease not required) Horsepower: 0.8 (0.6 kw) Full Load Amps (FLA): 32 amps Operating Speed: Low: 1400 rpm High: 1800 rpm Voltage: 24 vdc
b. Condenser Fan Motor

Superheat Setting: 10_F (5.6_C) MOP Setting: 53.9 4 psig (3.8 kg/cm@)
d. Low Pressure Switch (LPS)

0.28

Opens at: 6 3 psig (0.42 0.21 kg/cm@) Closes at: 25 5 psig (1.8 0.35 kg/cm@)
e. High Pressure Switch (HPS) R-134a Units

Bearing Lubrication: Factory (additional required) Horsepower: 0.8 hp (0.6 kw) Full Load Amps (FLA): 32 amps Operating Speed: Low: 1400 rpm High: 1800 rpm Voltage: 24 vdc
1.4 SAFETY DEVICES

Lubricated grease not

Opens at: 300 Closes at: 200


R-134a Units

10 psig (21 10 psig (14

0.7 kg/cm@) 0.7 kg/cm@)

f. Condenser Fan Switch (CFS)

System components are protected from damage caused by unsafe operating conditions with safety devices listed in Table 1-3. If the high pressure switch (HPS) or low pressure switch (LPS) opens due to unsafe operating conditions, the A/C operation will automatically stop. The A/C stop light will illuminate to indicate an unsafe condition. The evaporator blower motors will continue to operate to circulate air throughout the bus. During any mode of operation, the evaporator or condenser fan motors will stop if excessive current draw is sensed by circuit breakers. All breakers must be manually reset by depressing the breaker button when opened. When the high pressure switch (HPS) or low pressure switch (LPS) opens and unit operation stops, place the drivers A/C switch to the OFF position and back to the ON position to reset the A/C stop relay and de-energize the A/C stop light.

Opens for high speed: 250 10 psig (18 0.7 kg/cm@) Closes for Low Speed: 190 15 psig (13 0.7 kg/cm@)
g. Condenser Fan Motor

Bearing Lubrication: Factory Lubricated (additional grease not required) Horsepower: 0.8 hp (0.6 kw) Full Load Amps (FLA): 32 amps Operating Speed: Low: 1400 rpm High: 1800 rpm Voltage: 24 vdc
h. Low Ambient Switch (LATH)

Opens at: 45 Closes at: 55

5_F ( 7.3 5_F (12.9

2.8 _C) 2.8 _C)

1-5

T-288

Table 1-2. Unloader Pressure Switch Settings UNLOADER PRESSURE SWITCH-Contacts Open/Close Settings [psig(kg/cm@)] UPS1 UPS2 UPS3 Refrigerant Load Up Unload Load Up Unload Load Up (Opens) (Closes) (Opens) (Closes) (Opens) R-134a 35 2 26 2 31 2 23 2 220 15 (2.5 0.14) (1.8 0.14) (2.2 0.14) (1.6 0.14) (19 1) Table 1-3. Safety Devices UNSAFE CONDITION Excessive current draw by the boost pump motor. Excessive current draw by evaporator fan motor no. 2. Excessive current draw by evaporator fan motor no. 1. Excessive current draw by condenser fan motor no. 2. Excessive current draw by condenser fan motor no. 1. Excessive current draw by clutch High system pressure SAFETY DEVICE Circuit Breaker -- CB1 Manual Reset Circuit Breaker -- CB2 Manual Reset Circuit Breaker -- CB3 Manual Reset Circuit Breaker -- CB4 Manual Reset Circuit Breaker -- CB5 Manual Reset Circuit Breaker -- CB6 Manual Reset High Pressure Switch (HPS) Automatic Reset Low Pressure Switch (LPS) Automatic Reset DEVICE SETTING Opens at 15 amps Opens at 60 amps Opens at 60 amps Opens at 60 amps Opens at 60 amps Opens at 10 amps R-134a Units: Opens at: 300 10 psig (21 0.7 kg/cm@) Closes at: 200 10 psig (14 0.7 kg/cm@) R-134a Units: Opens at: 6 3 psig (0.42 0.21 kg/cm@) Closes at: 25 5 psig (1.8 0.35 kg/cm@)

Unload (Closes) 270 15 (19 1)

Low system pressure

T-288

1-6

1.5

SYSTEM OPERATING CONTROLS AND COMPONENTS

Condenser Motor Overload (COL1 and COL2) Each condenser fan motor is equipped with an internal thermal protector switch. If excessively high motor temperature exists, the COL switch will open to de-energize the corresponding condenser fan relay (CFR1 or CFR2); this will stop the corresponding condenser fan motor. Evaporator Motor Overload (EOL1 and EOL2) Each evaporator fan motor is equipped with an internal thermal protector switch embedded in the motor windings. If excessively high motor temperature exists, the EOL switch will open to de-energize the corresponding evaporator fan relay (EFR1 or EFR2); this will stop the corresponding evaporator fan motor. Low Ambient Thermostat (LATH) The low ambient thermostat (LATH) monitors temperature outside the vehicle. The switch opens at 45 5_F (7.3 2.8 _C) and closes at 55 5_F (12.9 2.8 _C). When the outside temperature is below the open setting of the switch, the switch opens to stop the compressor clutch and condenser fans. The low ambient thermostat is mounted on the condenser coil.
d. Pressure Switches

a. Electronic Thermostat (TH)

The electronic thermostat senses and controls the vehicle interior air temperature. The desired interior temperature set point of the controller is manually set with the temperature selector located on the electrical control panel. (See Figure 1-3.) The thermostats temperature sensor monitors the bus interior temperature at the return air section of the unit and controls the operation function of the system to maintain temperature at the desired set point. The thermostat regulates the operation of the unit with three interior switches (LOAD/UNLOAD, LOW/HIGH and HEAT/COOL). The LOAD/UNLOAD switch controls the compressor unloaders; the LOW/HIGH switch controls the evaporator fan speed; the HEAT/COOL switch establishes heating or cooling operating mode.
b. Manual Switches

A/C Mode Switch (ACMS)-Supplied by OEM When the A/C Mode Switch (ACMS) is placed in the ON position, the climate control system responds to the mode (HEAT, COOL or VENT) determined by the electronic thermostat. Evaporator Speed Switch (ESS) - Optional The evaporator speed switch (ESS), if installed, is located on the drivers control panel. The ESS, when in the LOW or HIGH position, overrides the thermostat. When the switch is in the HIGH position, the evaporator fans are operated at high speed at all times. When in the LOW position, the fans are operated at low speed at all times. When in the AUTO position, evaporator fan speed is controlled by the thermostat.
c. Thermal Switches

Condenser Fan Switch (CFS) The condenser fan switch (CFS) senses refrigerant discharge line pressure to control condenser fan speed. If the condenser coil discharge pressure rises to the CFS cutout setting, the switch will open to de-energize the condenser speed relay (CRS1); this will cause the condenser fan motors (CM1 and CM2) to run at high speed. When the pressure drops to the CFS cut-in setting, the switch will close, energizing CSR1 to run the condenser fan motors at low speed. Refer to section 1.2 for switch settings. Unloader Pressure Switches (UPS1, UPS2 and UPS3) The unloader pressure switches UPS1, UPS2 and UPS3 control unloader operation during A/C mode of operation. Unloader pressure switches UPS1 and UPS2 close on pressure drop to energize unloader valves (UV1 and UV2, respectively). Energizing UV2 will place the compressor in four cylinder operation. Energizing UV1 will place the compressor in 2 cylinder operation. As pressure

Water Temperature Switch (WTS)-Supplied by OEM The water temperature switch (WTS) is located on the engine block of the vehicle and senses the engine coolant temperature. The ECS is a normally open switch which closes on a temperature rise to complete a path to energize the control circuits. If this switch is used, and the water temperature is below the switch set point, then the evaporator fan motors will not operate when the thermostat is calling for heat. 1-7

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rises, the switch will re-open. Refer to Table 1-2 for switch settings. Unloader pressure switch UPS3 closes on pressure rise to energize unloader valve UV2. Energizing UV2 will place the compressor in four cylinder operation. As pressure drops, the switch will re-open. Refer to Table 1-2 for switch settings. Energizing of unloader valve UV1 can also be accomplished through the controller LOAD/UNLOAD switch.
e. Relays

the ON position, EFR1 and EFR2 relays are energized. When energized, a set of internal EFR1 and EFR2 contacts are closed to start the evaporator fan motors. Evaporator Overload Relays (OR1 and OR2) Evaporator overload relays (OR1 and OR2) are plugged into the relay board on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) These relays are energized at the same moment the evaporator fan relays are. The OR1 and OR2 relays, when energized, will close a set of internal contacts to energize the evaporator speed relay (ESR). Evaporator Speed Relay (ESR) The evaporator speed relay (ESR) is installed on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) This relay will energize when the thermostat calls for low speed evaporator fan operation. When energized, the internal contacts will open removing a third ground path, which puts the fans in low speed operation. When the ESR coil is de-energized, the internal contacts close, which adds the third ground path and puts the fans in high speed operation. Condenser Fan Relays (CFR1 and CFR2) The condenser fan relays (CFR1 and CFR2) are installed on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) When the A/C Mode Switch (ACMS) is placed in the ON position and the thermostat is calling for cooling, CFR1 and CFR2 are energized. When energized, a set of internal CFR1 and CFR2 contacts are closed to start the condenser fan motors. The low ambient thermostat (LATH) must be closed to energize the condenser fan relays. Condenser Speed Relay (CSR1) The condenser speed relay (CSR1) is installed on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) This relay is energized at the same moment that the A/C Mode Switch (ACMS) is placed in the ON position, provided that the condenser fan switch (CFS) is in the closed position and the thermostat is calling for cooling. If the condenser coil pressure reaches the CFS switch cutout setting, the CFS switch will open to de-energize condenser speed relay CSR1. (Refer to section 1.2 for switch settings.); this will cause the condenser fan motors (CM1 and CM2) to run at high speed. 1-8

Fault Relay (FR) The fault relay (FR) is plugged into the relay board on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) The FR relay is energized during initial start-up of the unit. If the high or low pressure switch (HPS or LPS) opens due to unsafe operating conditions, the fault relay (FR) de-energizes and closes an internal set of FR contacts to energize the ACSR. A/C Stop Relays (ACSR1 and ACSR2) The A/C stop relays (ACSR1 and ACSR2) are plugged into the relay board on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.). The ACSR relay energizes the A/C stop light when activated by the fault relay (FR). To restart the unit and turn the A/C stop light off, the A/C switch must be toggled off and on. Clutch Relay (CR) The clutch relay (CR) is plugged into the relay board on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) When the CR relay is energized, a set of internal contacts will close to activate the compressor clutch (CL) to start the refrigerant cycle. Cool Disable Relay (CDR) The cool disable relay (CDR) coil is de-energized opening a set of normally open CR contacts in the clutch relay circuit whenever the evaporator fans are shut down; this prevents the compressor from operating when the fans are not operating. Evaporator Fan Relays (EFR1 and EFR2) Evaporator fan relays (EFR1 and EFR2) are installed on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) When the A/C Mode Switch (ACMS) is placed in

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Boost Pump Relay (BPR) The boost pump relay (BPR) is plugged into the relay board on the electrical control panel located in the rear compartment of the unit. (See Figure 1-3.) This relay is energized during the reheat and heating modes. When the Boost Pump Relay (BPR) is energized, a set of internal contacts will close to activate the Water Pump Relay (WPR), which is O.E.M. supplied.
1.6 MOISTURE/LIQUID INDICATOR

a storage space when pumping down the system. The receiver is equipped with a sight glass, to observe correct charge level, and a moisture/liquid indicator. The liquid refrigerant leaves the receiver and flows through the subcooler where it is subcooled before entering the liquid-suction heat exchanger. The liquid-suction heat exchanger (LSHX), used on R-134a systems only, increases system operating efficiency by subcooling liquid refrigerant before it enters the thermostatic expansion valve; this reduces flash gas. It also serves to ensure there is no liquid refrigerant in the suction gas returning to the compressor. If there is low temperature liquid refrigerant present in the suction line returning to the compressor, it will evaporate in the heat exchanger from heat absorbed from the liquid line. The refrigerant leaves the LSHX and flows through the filter-drier inlet valve and through a filter-drier where an absorbent keeps the refrigerant clean and dry. It then flows out of the filter-drier and through the filter-drier outlet valve and liquid line solenoid valve. The liquid then flows to an externally equalized thermostatic expansion valve which reduces pressure and temperature of the liquid and meters the flow of liquid refrigerant to the evaporator coil to obtain maximum use of the evaporator coil heat transfer surface. The low pressure, low temperature mixture of liquid and vapor refrigerant that flows into the evaporator coil tubes is colder than the air that is circulated over the evaporator coil tubes by the evaporator blower. Heat transfer is established from the evaporator air (flowing over the tubes) to the refrigerant (inside the tubes). The evaporator coil tubes have aluminum fins to increase heat transfer from the air to the refrigerant. The cooler air is then circulated to the interior of the bus by the evaporator blowers. The transfer of heat from the air to the low temperature liquid refrigerant in the evaporator coil causes the liquid to vaporize. This low temperature, low pressure vapor passes through the liquid-suction heat exchanger and the suction line back to the compressor. The low pressure refrigerant vapor is now drawn into the compressor where the cycle repeats.

The moisture/liquid indicator is located on the receiver. The element in the indicator is highly sensitive to moisture and will gradually change color in direct relation to an increase or decrease in the moisture content of the system. The dry-caution-wet system operating conditions are then easily determined by matching the element color with the two colors displayed on the reference label. Colors change as often as the system moisture content changes.
1.7 AIR CONDITIONING REFRIGERANT CYCLE

The refrigerant cycle is off during the vent mode and only the evaporator blowers operate to circulate air throughout the bus. When thermostat is calling for cooling, the unit operates as a vapor compression system using R-134a as a refrigerant. The main components of the system are the reciprocating compressor, air-cooled condenser coil, thermostatic expansion valve, and evaporator coil. (See Figure 1-5.) The refrigeration cycle begins when the compressor clutch is engaged. The compressor raises the pressure and the temperature of the refrigerant and forces it into the condenser coil tubes. The condenser fan circulates surrounding air (which is at a temperature lower than the refrigerant) over the outside of the condenser coil tubes. Heat transfer is established from the refrigerant (inside the tubes) to the condenser air (flowing over the outside of the tubes). The condenser coil tubes have fins designed to improve the transfer of heat from the refrigerant gas to the air. This removal of heat causes the refrigerant to liquefy; thus liquid refrigerant leaves the condenser coil and flows to the receiver. The receiver serves as a liquid refrigerant reservoir so that a constant supply of liquid is available to the evaporator coil as needed and as

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12 9 10

13 6 7 8 19 5 21 11 15
UPS3 CFS

UPS2 UPS1

16 2 17

20

1. Compressor 2. Discharge Line 18 3. Discharge Line Check Valve 4. Condenser Coil 5. Receiver 6. Filter-Drier Inlet Valve 7. Filter-Drier 8. Filter-Drier Outlet Valve 9. Thermostatic Expansion Valve 10. Evaporator Coil 11. Suction Line 12. Subcooler 13. Liquid-Suction Heat Exchanger 14. Condenser Fan Switch (CFS) 15. Unloader Pressure Switch (UPS3) 16. Charge Isolation Valve 17. Discharge Service Port 18. Suction Service Port 19. Unloader Pressure Switch (UPS2) 20. Unloader Pressure Switch (UPS1) 21. Liquid Line Solenoid Valve

14

Figure 1-5. Air Conditioning Refrigerant Cycle

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SECTION 2 OPERATION
2.1 STARTING AND STOPPING INSTRUCTIONS

a. Starting 1. Start the vehicle engine. 2. Place the ACMS switch in the AUTO position. NOTE The engine coolant must be warm enough to close the engine coolant switch (if installed) for unit operation to start. b. Stopping 1. Place the ACMS switch in the OFF position. NOTE Be sure air conditioning unit is turned off before stopping the vehicle engine.
2.2 PRE-TRIP INSPECTION

During Auto/Reheat mode of operation, the compressor runs continuously. Compressor operation is only stopped when the outside ambient temperature falls to 45_F (7.2C). The Low Ambient Thermostat (LATH) senses ambient temperature outside the bus and opens a set of contacts to interrupt the compressor clutch circuit when the ambient temperature falls to 45_F (7.2_C). Heat is then accomplished by cycling Boost Pump Motor (BPM) and Reheat Coolant Valve (RCV) to supply engine coolant to the heater coil. When the vehicle interior temperature falls to 3_F (1.7_C) above the electronic thermostat setpoint, the HEAT/COOL switch remains in the COOL position. The HIGH/LOW switch remains in the HIGH position. A signal from the thermostat unloads the compressor down to semi-unloaded (4-cylinder) operation. The system is now operating in the COOL mode with high speed evaporator fans and semi-unloaded compressor. When the vehicle interior temperature falls to 1_F (0.56_C) above the thermostat set point, the unit remains in the COOL mode but the HIGH/LOW switch switches to LOW position. The signal from the thermostat continues to keep the compressor in semi-unloaded (4-cylinder) operation. The system is now operating in the semi-unloaded COOL mode with low speed evaporator fan operation. When the vehicle interior temperature falls to 2_F (1.12_C) below the thermostat set point, the HEAT/COOL switch switches to the HEAT position, which energizes Boost Pump Relay (BPR), Water Pump Relay (WPR) and Reheat Coolant Valve (RCV). The signal from the thermostat continues to keep the compressor in semi-unloaded (4-cylinder) operation. The system is now operating in the semi-unloaded HEAT mode with low speed evaporator fan operation and engine coolant flowing through the heater coil to maintain temperature inside the bus. When the vehicle interior temperature rises to the thermostat set point, the HEAT/COOL switch switches to the COOL position and the HIGH/LOW switch remains in LOW. The signal from the thermostat continues to keep the compressor in semi-unloaded (4-cylinder) operation. Switching to COOL, de-energizes the Boost Pump Relay 2-1
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After starting unit, allow system to stabilize (10 to 15 minutes) and proceed as follows: 1. Listen for abnormal noises. 2. Check compressor oil level. 3. Check refrigerant level. 4. Check moisture/liquid indicator.
2.3 UNIT OPERATION

When the ACMS switch is put in the AUTO position, the control thermostat senses the vehicles interior temperature and automatically controls the system to maintain the desired temperature set point. The unit control circuits and components operate on 24-volt power supplied by the bus battery or alternator.
2.3.1 Air Conditioning Auto/Reheat Mode of Operation (See NO TAG.)

To operate in the Auto mode of operation, place the ACMS switch in the AUTO position. The thermostat will then determine at which points cooling or heating are required to regulate vehicle interior temperature. With the ACMS switch in the AUTO position, 24 vdc is supplied to Evaporator Fan Relays (EFR1 and EFR2) and Electronic Thermostat (TH).

(BPR), Water Pump Relay (WPR) and Reheat Coolant Valve (RCV) stopping the flow of engine coolant through the heater coil. The system is now operating in semi-unloaded COOL mode with low speed evaporator fan operation. When the vehicles interior temperature rises to 3_F (1.7_C)above the thermostat set point, the HEAT/COOL switch remains in the COOL position but the HIGH/LOW switch switches to HIGH. The signal from the thermostat continues to keep the compressor in semi-unloaded (4-cylinder) operation. The system is now operating in semi-unloaded COOL mode with high speed evaporator fan operation. When the vehicle interior temperature rises to 5_F (2.8 _C) above the thermostat set point, the HEAT/COOL switch remains in COOL and the HIGH/LOW switch remains in the HIGH position. The thermostat discontinues supplying the signal to semi-unload the compressor and the compressor becomes fully loaded. The system now operates in the fully loaded (6-cylinder) COOL mode with high speed fan operation.

RISING TEMPERATURE HIGH SPEED, FULLY LOADED (6-CYL) COOL 5F ABOVE SETPOINT

3F ABOVE SETPOINT

HIGH SPEED, SEMI-UNLOADED (4-CYL) COOL

3F ABOVE SETPOINT

1F ABOVE SETPOINT SETPOINT

LOW SPEED, SEMI-UNLOADED (4-CYL) COOL

SETPOINT

2F BELOW SETPOINT

LOW SPEED, SEMI-UNLOADED (4-CYL) COOL WITH REHEAT

3F BELOW SETPOINT

5F BELOW SETPOINT

HIGH SPEED, SEMI-UNLOADED (4-CYL) COOL WITH REHEAT 55F AMBIENT

45F AMBIENT

HIGH SPEED, COMPRESSOR OFF FULL HEAT

FALLING TEMPERATURE

Figure 2-1. Thermostat Control Sequence Auto Cool Mode with Reheat

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2-2

TDR 10 SEC

Figure 2-2. Automatic High Speed Cool Mode Operation - with Reheat

2-3

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TDR 10 SEC

Figure 2-3. Automatic High Speed Cool Mode Operation - No Reheat T-288

2-4

TDR 10 SEC

Figure 2-4. Automatic High Speed Heat Mode Operation (Below 45_F Ambient)

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SECTION 3 TROUBLESHOOTING
Table 3-1. Troubleshooting Procedures INDICATION/ TROUBLE 3.1 UNIT WILL NOT COOL Compressor will not run POSSIBLE CAUSES REFERENCE SECTION Check Check/Replace Check/Replace See Note. 1.4 Check/Repair Check/Replace 1.5 Check/Reset 3.5 1.5 Check See Note. 3.3 3.6 3.7 3.7 and 4.12 4.9 Open 1.4 Check 4.9 Check Pressure Check Clean See Note. 4.9 See Note. Open Check/ Open 4.10 4.9 3.7 3.6 Check 4.17 Defrost/Clean See Note.

V-Belt loose or defective Clutch coil defective Clutch malfunction Compressor malfunction Safety device open Electrical malfunction Bus power source defective ACMS switch defective Low Ambient Thermostat open Circuit Breaker CB6/safety device open Electronic Thermostat malfunction Water Temperature Switch (WTS) open 3.2 SYSTEM RUNS BUT HAS INSUFFICIENT COOLING Compressor V-Belt loose or defective Compressor valves defective Refrigeration system Abnormal pressures No or restricted evaporator air flow Expansion valve malfunction Restricted refrigerant flow Low refrigerant charge Service valves partially closed Safety device open Liquid line solenoid valve stuck closed 3.3 ABNORMAL PRESSURES High discharge pressure Refrigerant overcharge Noncondensable in system Condenser fan rotation incorrect Condenser coil dirty Low discharge pressure Compressor valve(s) worn or broken Low refrigerant charge High suction pressure Compressor valve(s) worn or broken Low suction pressure Suction service valve partially closed Filter-drier inlet valve partially closed Filter-drier partially plugged Low refrigerant charge Expansion valve malfunction Restricted air flow Low evaporator air flow Blower running in reverse Dirty air filter Icing/dirty coil Suction and discharge pressures Compressor valves defective tend to equalize when system is operating

NOTE: Refer to Model 05G Compressor Manual, Form No. 62-02756.

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Table 3-1. Troubleshooting procedures - Continued INDICATION/ TROUBLE 3.4 ABNORMAL NOISES OR VIBRATIONS Loose mounting hardware Worn bearings Worn or broken valves Liquid slugging Insufficient oil Clutch loose, rubbing or is defective V-belt cracked, worn or loose Loose mounting hardware Defective bearings Blade interference Blade missing or broken Thermostat defective Sensor defective Defective wiring Coil frosted over Dirty coil Dirty filter Motor running in reverse (wiring polarity incorrect) Motor(s) defective Motor brushes defective Evaporator fan loose or defective Return air filter dirty Icing of coil/dirty coil Fan relays EFR1 OR EFR2 defective Safety device open Low refrigerant charge Wax, oil or dirt plugging valve orifice Ice formation at valve seat Superheat setting too high Power assembly failure Loss of bulb charge Broken capillary Check/Tighten See Note. See Note. 3.7 4.18.2 Check Check/Adjust Check/Tighten Replace Check Check/Replace Replace Replace Check Defrost coil Clean Clean/Replace Check/5.1 4.16 4.16 4.16 Clean/Replace Defrost/Clean 1.5 1.4 4.9 Check 4.7 4.12 Replace Replace 4.12 4.12 4.12 Check 4.12 4.12 Clean Check Check Check/Replace 3.5 Repair/Replace 1.4 Compressor POSSIBLE CAUSES REFERENCE SECTION

Condenser or evaporator fans

3.5

ELECTRONIC THERMOSTAT MALFUNCTION

Will not control

3.6

NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Air flow through coil blocked

No or partial evaporator air flow

3.7

EXPANSION VALVE MALFUNCTION

Low suction pressure with high superheat

Low superheat and liquid slugging Superheat setting too low in the compressor Ice or other foreign material holding valve open Loose bulb Fluctuating suction pressure 3.8 Improper bulb location or loose bulb installation Low superheat setting Dirty or plugged heater coil or filter Coolant valve malfunction or plugged Low coolant level Coolant valve malfunction or plugged Thermostat malfunction Boost relay or pump malfunction Safety device open

NO OR INSUFFICIENT HEATING

Insufficient heating

No Heating

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SECTION 4 SERVICE
WARNING

Beware of rotating evaporator fan when conducting following test.


4.1 ON X MAINTENANCE SCHEDULE UNIT OFF a. Daily Maintenance X Pre-trip inspection --- after starting Check tension and condition of V-belt(s) 2.1 and 2.2 and None 4.1a None 4.6 4.10 4.1b None Replace/Tighten None None 4.16 OPERATION REFERENCE SECTION

b. Weekly Inspection and Maintenance X X X Perform daily inspection Check condenser, evaporator coils and air filters Check refrigerant hoses and compressor shaft seal for leaks Feel filter-drier for excessive temperature drop across drier. Perform weekly inspection and maintenance Clean evaporator drain pan and hose(s) Check wire harness for chafing and loose terminals Check fan motor bearings Check compressor mounting bolts for tightness Check fan motor brushes

c. Monthly Inspection and Maintenance X X X X X X 4.2

SUCTION AND DISCHARGE SERVICE VALVES

the suction or discharge line is open to both the compressor and the gauge connection.
To Discharge or from Suction Line Valve Cap

The suction and discharge service valves used on the compressor are equipped with mating flanges for connection to flanges on the compressor. These valves are provided with a double seat and a gauge connection, which allows servicing of the compressor and refrigerant lines. Turning the valve stem counterclockwise (all the way out) will backseat the valve to open the suction or discharge line to the compressor and close off the gauge connection. In normal operation, the valve is backseated to allow full flow through the valve. The valve should always be backseated when connecting the service manifold gauge lines to the gauge ports. Turning the valve stem clockwise (all the way forward) will frontseat the valve to close off the suction or discharge line to isolate the compressor and open the gauge connection. To measure suction or discharge pressure, midseat the valve by opening the valve clockwise 1/4 to 1/2 turn. With the valve stem midway between frontseated and backseated positions,

Port to Compressor Service Valve Frontseated (clockwise)

Gauge Connection

Valve Stem

Service Valve Backseated (counterclockwise)

Figure 4-1. Suction or Discharge Service Valve 4.3 INSTALLING MANIFOLD GAUGE SET

The manifold gauge set can be used to monitor system operation pressure, add or remove refrigerant, evacuate, and equalize the system. The manifold gauge in Figure 4-2 shows hand valves, gauges and refrigerant openings. When the manifold hand valves are backseated (open), the high and low side hoses are common with the
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center hose as well as each other. When the low and high side valves are frontseated (closed), the high and low side hoses are isolated from each other and the center hose. It is in the front seated (closed) position that system pressures can be monitored. When both valves are open
Low Pressure Gauge Opened (Backseated) Hand Valve Hose Fittings (0.500-16 Acme) To Suction Service Port Blue (Refrigeration or Evacuation) Hose Low Side Field Service Coupling Hose Fitting with ORing

(backseated), pressure will cause vapor to flow from the high side to the low side across the compressor. When only the low side valve is opened, it is possible to add refrigerant in vapor form to the system.
High Pressure Gauge Closed (Frontseated) Hand Valve

B
To Discharge Service or Manual Liquid Line Port Red (Refrigeration or Evacuation) Hose Hose Fitting with ORing Yellow (Refrigeration) Hose High Side Field Service Coupling Red Knob

Blue Knob

Hose Fitting (0.500-16 Acme)

C. Connection to Vacuum A. Connection to Pump, Refrigerant Cylinder Low Side of System or Oil Container Purge Line B. Connection to High Side of System Figure 4-2. R-134a Manifold Gauge Set Connections

To service the refrigerant system, the manifold gauge set is connected to the compressor suction (low side) service valve for low pressure connection and either the compressor discharge (high side) service valve or the filter drier inlet or outlet valve for high pressure connection. The high pressure connection will depend upon the component to be serviced. (Refer to section 4.)
a. At the Compressor

4. Connect high side (red) manifold hose to the compressor discharge service valve. Open valve on manifold hose to depress service port schrader valve. 5. Midseat both suction and discharge service valves on compressor to read refrigerant pressures.
b. At the Compressor Suction Service Valve and Filter-Drier Inlet or Outlet Valve

1. Backseat both suction and discharge service valves 2. Frontseat manifold set hand valves. 3. Connect low side (blue) manifold hose to the compressor suction service valve. Open valve on manifold hose to depress service port schrader valve.

1. Backseat both suction and discharge service valves 2. Frontseat manifold set hand valves. 3. Connect low side (blue) manifold hose to the compressor suction service valve. Open valve on manifold hose to depress service port schrader valve.

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4-2

4. Backseat filter-drier inlet or outlet valve, depending upon which one will be used. 5. With manifold set valves frontseated, connect the high side manifold hose (red) to the filter drier inlet or outlet valve, whichever one was backseated in step 4. 6. Frontseat filter drier valve one turn to read high pressure.
4.4 SYSTEM PUMPDOWN

If a recovery system is not available, proceed as follows:


a. Equipment Required

1. Appropriate evacuated returnable refrigerant cylinder, preferably a 60 -- 120 lb net capacity may be used. Refrigerant removal will be faster and more complete with the larger cylinder.
WARNING

To service or replace the filter-drier, expansion valve, evaporator coil, or suction line; pump the system refrigerant into condenser coil and receiver tank as follows: a. Attach the gauge manifold as outlined in section 4.3. b. Disconnect low pressure switch quick connect. Install a jumper wire across switch connection to prevent the switch from disengaging the clutch. c. Start the unit in A/C by placing the drivers A/C switch in the cool position. The thermostat should be set below ambient temperature to ensure A/C operation. d. Run unit for 5 -- 10 minutes to allow system to stabilize. e. Frontseat (close) the liquid line valve at the inlet of the filter-drier. f. Observe the suction gauge. The pressure will drop off noticeably. Stop the unit when a 0 to 10 in. vacuum is reached.

Do not use a disposable refrigerant container to store the refrigerant, an explosion may occur. 2. Gauge manifold set. 3. Vacuum pump, preferably 5 cfm (8.5 m3/hr) or larger. CTD P/N 07-00176-01. 4. Weight scale (0 to 100 lb = 0 to 46 kg range, minimum). 5. A standard 1/4 in. charging hose.
b. To remove the refrigerant charge:

1. Install a manifold gauge set as outlined in section 4.3. 2. Connect evacuated refrigerant cylinder to the liquid line valve at the inlet valve of the filter-drier. The service line to the liquid valve of the cylinder should be attached loosely. Crack open the liquid line valve momentarily to purge service line at cylinder. Tighten connection at cylinder. 3. Place evacuated refrigerant cylinder on scale and note weight of empty cylinder. Leave cylinder on scale. 4. Frontseat liquid line valve at the inlet of the filter- drier. 5. Run the unit in high speed cool with the condenser coil completely blocked off. Head pressure will quickly rise. Stop the unit when the system pressure reaches 150 psig (for R-134a) using the rear control switch. 6. Fully open the refrigerant cylinder liquid valve. Liquid refrigerant will flow from the liquid line valve to the cylinder. Head (discharge) pressure will drop. 7. Monitor weight of the refrigerant cylinder to determine how much refrigerant is being removed. Shut off cylinder valve when the scale weight has stabilized, indicating the refrigerant flow into the cylinder has stopped. Run the unit for a few more minutes to
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g. Stop the unit. Observe the suction gauge. If the reading increases, restart the unit until the specified vacuum is achieved. h. Repeat the above step until the specified vacuum is maintained after stopping. i.
4.5

Ensure that system pressure is zero psig or below.


REMOVING REFRIGERANT CHARGE

A refrigerant recovery system is the recommended method for removing refrigerant charge. For the recovery system procedure, refer to instructions provided by the manufacture. A refrigerant recovery system should always be used whenever removing contaminated refrigerant from the system.

condense pressure.

more

liquid
NOTE

and

raise

head

7. Remove the refrigerant and nitrogen used to pressurize the system prior to leak repair. 8. Charge the unit as outlined in section 4.8.
4.7 EVACUATION AND DEHYDRATION

Refrigerant will flow from the system to the cylinder until the pressures equalize. It is possible to remove more refrigerant by cooling the refrigerant cylinder in a container of ice. 8. Backseat the liquid line valve and remove cylinder hose. 9. Service or replace the necessary component in the system.
NOTE

Proper evacuation and dehydration procedures are imperative when service repairs or component replacement are performed on the system to ensure proper unit performance and long compressor life. The results of improper evacuation are harsh. Noncondensible gases in the system result in high head pressure; moisture may cause ice blockage at the expansion valve; moisture and refrigerant may react to form an acid. This acid may cause copper plating of the bearing surfaces and eventual compressor failure.
a. Equipment Needed

When opening up the refrigerant system, certain parts may frost. Allow the part to warm to ambient temperature before dismantling. This avoids internal condensation which puts moisture in the system.
4.6 REFRIGERANT LEAK CHECK

To check for leaks in the refrigeration system, perform the following procedure. A refrigerant leak check should always be performed after the system has been opened to replace or repair a component. 1. On units equipped with liquid solenoid valve (LSV), it will be necessary to externally power the solenoid to open the valve and leak check properly. 2. If system is without refrigerant, charge system with refrigerant to build up pressure between 30 to 50 psig (2.1 to 3.5 kg/cm@).
NOTES

1. Vacuum Pump - A good vacuum pump ( minimum of 5 cfm volume displacement, at atmospheric pressure) A pump of this capacity is available through the Carrier Service Parts, CTD P/N 07-00176-01. 2. Thermistor Vacuum Gauge - A thermistor vacuum gauge (electronic vacuum gauge) measures the low absolute pressures necessary to remove moisture from the system. A compound gauge (manifold gauge set) is not recommended because of its inherent inaccuracy. A vacuum gauge is available from a refrigeration supplier. 3. Evacuation Hoses - Three 3/8 evacuation hoses, the length to be determined by the application of the service set-up. 3/8 to 1/4 adapter connector are also needed to make compressor connections. (Evacuation hoses and adapters are available from your local refrigeration supplier.) Do not use standard refrigeration hoses to evacuate. These hoses are designed for pressure not vacuum and may collapse during evacuation. 4. Recovery System - A refrigerant recovery system is recommended for removing the refrigerant. 5. Evacuation Manifold - A evacuation manifold is recommended for connecting the equipment needed for a proper evacuation. The evacuation manifold can be made easily as shown in Figure 4-3.

It is recommended that the appropriate refrigerant used, be used to pressurize the system. 3. Add sufficient nitrogen to raise system pressure to 150 to 200 psig (10.5 to 14.1 kg/cm@). 4. Check for leaks. The recommended procedure for finding leaks in a system is with a halide torch or electronic leak detector. Testing joints with soap suds is satisfactory only for locating large leaks. 5. Repeat the entire procedure if necessary. 6. Evacuate and dehydrate the system as outlined in section 4.7.

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4-4

6. Liquid Line Solenoid Jumper Harness - A liquid line solenoid jumper harness is used to apply an external 24 vdc source to energize the solenoid.
3/8 Flare Fittings (4) Packless Valve 1/8 NPT Fittings 1/8 NPT Fitting (2) Tube Stock 1--- 1/2 in. 1/2 Flare Fitting 1/4 Flare Fitting Packless Valve 1/2 Flare Fitting

remaining moisture in the system for the second evacuation. Close the cylinder valve. 7. Repeat steps 5. and 6. 8. Evacuate again, as described in step 5. to 300--500 microns Hg vacuum. 9. Charge the system to specifications through the refrigerant recovery machine (using manufactures charging procedure) or as outlined in section 4.8 (Charging the Refrigeration System). 10. Keep liquid line solenoid valve externally powered until unit has been charged. Disconnect external power to the liquid line solenoid valve before operating unit and reinstall the Weatherpac to the solenoid coil.

Figure 4-3. Evacuation Manifold b. Evacuation Procedure

To help speed up the evacuation process and to increase the evaporation of moisture, keep the ambient temperature above 60_F (15.6_C). If ambient temperature is lower than 60_F (15.6_C), ice may form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise system temperature if necessary. 1. Before refrigerant removal and evacuation, leak test unit. 2. Using an external 24 vdc power source, energize the liquid line solenoid valve coil by installing a jumper harness through the Weatherpac connector. 3. Remove all remaining refrigerant charge in the system. 4. Connect evacuation manifold, vacuum pump, vacuum gauge, reclaimer and hoses as shown in Figure 4-4. All hand valves on manifold should be closed. The compressor service valves should be midseated, if used, with service valve caps installed. The reclaimer valve should be closed. 5. Start vacuum pump. Slowly open manifold valve to the pump. Open valve to the vacuum gauge. Evacuate unit until vacuum gauge indicates 1500 microns (29.86 inches = 75.8 cm) Hg vacuum. Close gauge valve, vacuum pump valve, and stop vacuum pump. 6. Open the refrigerant cylinder vapor valve to break the vacuum. Raise the pressure approximately 2 psig. This will absorb any

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4.8 4 12 9 a.

ADDING REFRIGERANT TO SYSTEM Installing a Full Charge

1. Install a manifold gauge set as outlined in section 4.3. 2. Evacuate and dehydrate the system as outlined in section 4.7.b, as applicable, if not completed at this time. 3. Place the R-134a refrigerant cylinder on the scale and connect charging line from the cylinder to the filter-drier inlet valve. Purge charging line at valve. 4. Note weight of refrigerant cylinder.
3 8 17
UPS2 UPS1

10 13 6 7 5

14 11 16
UPS3 CFS

2 15

5. Open liquid valve on refrigerant cylinder. Open filter-drier inlet valve half way and allow the liquid refrigerant to flow into the unit. Monitor weight of refrigerant cylinder to determine how much refrigerant is entering the system. The correct charge is 17 lbs. 6. When refrigerant cylinder weight (scale) indicates that the correct charge has been added, close liquid line valve at the cylinder and backseat the filter-drier inlet valve. Disconnect lines. Check refrigerant charge. (See section 4.9.) If the entire charge cannot be added, a partial charge may be necessary.
b. Adding a Partial Charge

1 18 19 20 21 22 23 14. Charge Isolation Valve 15. Discharge Service Valve 16. Suction Service Valve 17. Liquid Line Solenoid Valve 18. Refrigerant Reclaimer 19. Vacuum Manifold 20. Thermistor Vacuum Gauge 21. Compound Gauge 22. Vacuum Pump 23. Refrigerant Cylinder

1. Start the vehicle engine and allow unit to stabilize. 2. Place the R-134a refrigerant cylinder on the scale and connect charging hose from refrigerant cylinder vapor valve to the compressor suction service valve. Purge charging line. 3. Open the refrigerant cylinder vapor valve. Midseat suction valve (if used) and monitor the weight of the cylinder to add the remaining refrigerant. When the correct charge level is obtained, as outlined in section 4.9, turn off cylinder charging valve and backseat compressor suction service valve. 4. Disconnect manifold gauge set.
4.9 CHECKING THE REFRIGERANT CHARGE NOTES

1. Compressor 2. Discharge Line 3. Discharge Line Check valve 4. Condenser Coil 5. Receiver 6. Drier Inlet Valve 7. Drier 8. Drier Outlet Valve 9. Thermal Expansion Valve 10. Evaporator Coil 11. Suction Line 12. Subcooler 13. Liquid-Suction Heat Exchanger

Figure 4-4. Evacuation Set-Up

The following conditions must be met to accurately check the refrigerant charge:
a. Bus engine operating at high idle.

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b. Unit operation in cool mode and the compressor fully loaded (6-cylinder operation) for 15 minutes. c. Head pressure at least 150 psig (for R-134a systems). (It may be necessary to block condenser air flow to raise head pressure.)

j. l.

Open both inlet and outlet valves. Check refrigerant level.

k. Test filter-drier for leaks.

Under the above conditions, the system is properly charged when the bottom receiver sight glass appears half full with refrigerant. If the bottom sight glass is not half full, add or delete refrigerant charge to the proper level.
4.10 FILTER-DRIER REMOVAL

If a pressure drop across the filter-drier is indicated or the moisture-indicator may show an abnormal (wet) condition, the filter-drier must be changed. a. Check for a restricted filter. Backseat the inlet and outlet valves of the filter-drier and attach the gauge manifold set. Midseat both valve and start unit. Observe the pressure reading. If a pressure drop of more than 10 psig is indicated the filter is plugged and must be changed. b. Pump down the system as outlined in section 4.4. c. Turn the drivers A/C switch and rear control switch to the OFF position. d. Place a new filter-drier near the unit for immediate installation. e. Using two open end wrenches, slowly crack open the flare nuts on each side of the filter-drier. Remove the filter-drier.
CAUTION

1. Valve Service Port 2. Filter-Drier Inlet Liquid Line Valve 3. Flare Nut

4. Filter-Drier 5. Filter-Drier Outlet Liquid Line Valve

Figure 4-5. Filter-Drier Removal 4.11 CHECKING PRESSURE SWITCHES

The recommended procedure for testing the High Pressure Switch (HPS), Low Pressure Switch (LPS), Condenser Fan Switch (CFS) and Unloader Pressure Switches #1, #2 & #3 (UPS1, UPS2 & UPS3) is to remove the switch from the unit and bench test it as described in the following procedure. All pressure switches are threaded into positive shut off valve connections (schrader valves) to allow easy removal and installation without pumping down or removing refrigerant from the unit. All wire leads to the switches are quick disconnects. The High Pressure Switch (black wire leads) and Low Pressure Switch (red wire leads) are located on the compressor. The Condenser Fan Speed Switch (gray wire leads) and the Unloader Pressure Switch #3 (white wire leads) are located on the discharge line above the curbside evaporator fan blower assembly. The Unloader Pressure Switches #1 and #2 are located on the suction line near the curbside evaporator motor. If the switch does not function as described below, the switch is defective and should be replaced. a. Remove switch from the unit. b. Connect an ohmmeter across switch leads (with no pressure applied to the switch) and check for continuity. Low Pressure Switch (LPS) and Unloader Pressure Switch (UPS3) will show no continuity (switches will be open). (See Table 4-1.) c. Connect switch to a cylinder of dry nitrogen as shown inFigure 4-6.
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The filter-drier may contain liquid refrigerant. Slowly open the flare nuts and avoid contact with exposed skin or eyes. f. Remove seal caps from the new filter-drier. Apply a light coat of compressor oil to the Orings.

g. Assemble the new filter-drier to lines ensuring that the arrow on the body of the filter-drier points in the direction of the refrigerant flow (refrigerant flows from left to right, as viewed). Finger tighten flare nuts. h. Tighten filter-drier flare nuts using two open end wrenches. i. Install vacuum pump on filter drier inlet valve. Evacuate to 500 microns and disconnect vacuum pump.

1 2

4 5 6 7 8

Table 4-1. Pressure Switch Continuity Check R-134a Switches High Pressure (HPS) Ohmmeter Reading No Continuity (Switch Opens ) 300 10 psig 6 3 psig 250 10 psig 35 2 psig 31 2 psig 220 15 psig Continuity (Switch Closes) 200 10 psig 25 3 psig 190 15 psig 26 2 psig 23 2 psig 270 15 psig

Low Pressure (LPS) Condenser Fan Speed (CFS)

1. Cylinder Valve and Gauge 2. Pressure Regulator 3. Nitrogen Cylinder 4. Pressure Gauge (0 to 500 psig = 0 to 36 kg/cm@)

5. Bleed-Off Valve 6. 1/4 inch Connection 7. High or Low Pressure Switch 8. Ohmmeter

Unloader Pressure #1 (UPS1) Unloader Pressure #2 (UPS2) Unloader Pressure #3 (UPS3)

Figure 4-6. Checking High Pressure Switch WARNING

Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350 psi (165 kg/cm@). Do not use oxygen in or near a refrigeration system as an explosion may occur. d. Back-off regulator adjustment completely. Open the cylinder valve. e. Slowly open the regulator valve to increase the pressure to the applicable pressures listed in Table 4-1 open or close the switch. If the ohmmeter reading does not correspond with the pressure listed in Table 4-1, the switch is defective and should be replaced. f. Close cylinder valve and release the pressure through the bleed-off valve. As the pressure drops, the applicable switch will open or close. If the ohmmeter reading does not correspond with the pressure listed in Table 4-1, the switch is defective and should be replaced.

4.12 THERMOSTATIC EXPANSION VALVE

The thermostatic expansion valve is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure. The valve functions are: (a) automatic response of refrigerant flow to match the evaporator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it seldom requires any maintenance.
a. Replacing the Expansion Valve

1. Pump down the unit. (Refer to section 4.4) 2. Remove return air access panel. 3. Loosen flare nut and disconnect equalizer line from expansion valve. 4. Remove roadside evaporator motor access panel. 5. Remove insulation (Presstite) from expansion valve bulb located on suctionline entering liquid-suction heat exchanger (LSHX). 6. Loosen bulb securing strap and pull bulb through to bus interior. 7. Remove flange screws and lift off power head and cage assemblies. Check for foreign matieral in valve body. 8. Install new gaskets and assemble new cage and power head assemblies.

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9. Attach the sensor bulb just below center of the suction line (4 or 7 oclock position viewing from cross section to the suction line, see Figure 4-8). This area must be clean to ensure positive bulb contact. Do not insulate the bulb until the superheat is measured. 10. Fasten equalizer tube to expansion valve, using oil on flare connections. 11. Connect vacuum pump to the compressor suction service valve service port and evacuate to 500 microns. Isolate pump from system. 12. Open the inlet service valve to the filter-drier. Check refrigerant level. (Refer to sections 4.5 and 4.9.) 13. Check superheat.

Place insulation around TXV bulb and thermocouple. 4. Connect suction gauge to the service port on the compressor suction service valve. 5. Set temperature selector to lowest setting. Run unit for at least 20 minutes to stabilize the system. 6. Using the temperature/pressure chart (Table 4-2) for the applicable refrigerant used, determine the saturation temperature corresponding to the pressure taken at the suction service valve. 7. Note the temperature of the suction gas at the sensor bulb. 8. Subtract the saturation temperature determined in Step 6 from the average temperature measured in Step 7. The difference is the superheat of the suction gas.
1 2 3 4 1. Suction Line (end view) 2. Clamp 3. Thermocouple 4. TXV Sensor Bulb

2 3 4
1. Power Head Assembly 2. Equalizer Connection 3. Sensor Bulb 4. Cage Assembly 5. Seat Gasket 6. Body Flange 7. Capscrew 8. Body Flange Gaskets

5 6 7

Figure 4-8. Thermostatic Expansion Valve Bulb and Thermocouple c. Superheat Adjustment

Figure 4-7. Thermostatic Expansion Valve b. To Measure Superheat NOTE

The thermostatic expansion valves used in this application are not adjustable. The valve is preset at the factory and should not require adjustment.
4.13 REMOVING THE HEATER COIL

a. Disconnect the bus battery. b. Remove evaporator motor and heater coil access panels. c. Open the air vent fitting at the top of the outlet header of the heater coil to bleed. d. Open the drain-cock on the coolant inlet tube to drain coil. e. Remove both evaporator fan motor assemblies with mounting brackets (refer to section 4.16). f. Disconnect hoses from the coil. g. Disconnect and remove coolant solenoid valve assembly from the unit.

When conducting this test the suction pressure must be at least 6 psig (0.42 kg/cm@) below the expansion valve maximum operating pressure (MOP). Refer to section 1.2.d for applicable valve settings. 1. Remove insulation from sensor bulb and suction line if installed. 2. Loosen one bulb clamp and make sure area under clamp is clean. 3. Place the temperature thermocouple above (parallel) TXV bulb and tighten loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 4-8.

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CAUTION

If unit was recently operating, be careful of remaining hot coolant in the hoses when disassembling. h. Remove coil retaining bolts on each side of the coil assembly (three each side). Pull top of coil assembly forward and down to remove from unit. i. Reverse procedure for installing new heater coil assembly.

a. Defective plunger or deformed valve body assembly. b. Foreign material in the valve.
It is not necessary to drain the coolant from the system to replace a burned out coil. Replace a burned coil as follows:

a. Place the rear control switch in the OFF position. b. Disconnect wire leads to coil. c. Remove coil retaining screw and nameplate. d. Lift burned out coil from enclosing coil assembly and replace. e. Connect wire leads and test operation.
4.15 REMOVING THE CONDENSER FAN MOTOR

4.14 SERVICING THE REHEAT COOLANT VALVE (O.E.M. SUPPLIED)

The coolant valve requires no maintenance unless a malfunction to the internal parts or coil occurs. This may be caused by foreign material such as: dirt, scale, or sludge in the coolant system, or improper voltage to the coil. There are only three possible valve malfunctions: coil burnout, failure to open, or failure to close. Coil burnout may be caused by the following: a. Improper voltage. b. Continuous over-voltage, more than 10% or Under-voltage of more than 15%. c. Incomplete magnetic circuit due to the omission of the coil housing or plunger. d. Mechanical interference with movement of plunger which may be caused by a deformed enclosing tube. Failure to open may be caused by the following: a. Coil burned out or an open circuit to coil connections. b. Improper voltage. c. Torn diaphragm. d. Defective plunger or deformed valve body assembly. Failure to close may be caused by the following:

When removing or installing the condenser fan motor, the fan blade must be removed to prevent any damage to the condenser coil. a. Remove fan blade guard. b. Using 5/16 ratchet or equivalent, loosen the two retaining screws in the fan blade hub. The fan blade will sit on the shaft of the motor. c. Remove the four motor mounting bolts from the bracket. d. Remove the motor by sliding the motor down and out from the fan blade and unit. Remove blade. e. Using a adhesive, secure the shaft key to the serviced motor shaft or fan hub slot. f. When installing the motor, secure the fan blade above the shroud before mounting the motor. Align the motor shaft through the fan blade hub and secure motor mounting bolts.

g. Position the fan blade 1/3 (the height of blade) below the shroud, tighten the two retaining screws in the fan hub.

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1/16-inch 3 4 5 6

Position 1/3 of blade height below shroud.

1. 2. 3. 4.

Condenser Coil Fan Blade Hub Retaining Set Screw 5/16 Ratchet Wrench

7 5. Fan Blade 6. Shroud 7. Fan Blade Guard

1. 2. 3. 4.

Blower Housing Fan Blower Unit Frame Venturi Clip Bolt

5. Venturi 6. Evaporator Motor 7. Hub Set Screw

Figure 4-10. Evaporator Fan Blower Assembly 4.16.1 Routine Examination and Cleaning

Figure 4-9. Condenser Fan Motor Removal 4.16 SERVICING THE EVAPORATOR FAN BLOWER MOTOR ASSEMBLY a. Removing, Disassembling and Assembly

a. At regular maintenance periods, remove brush covers and clean and examine motor interior. b. Remove all foreign material, such as dirt and carbon dust from with dry compressed air. Clean by suction if possible to avoid blowing foreign matter into the motor. c. Confirm free moving brushes to prevent binding. d. Examine brush wear and general condition. If brushes are broken, cracked, severely chipped, or worn to 1/3 the length of a new brush, replace them. Refer to section 4.16.2. e. Examine the condition of the brush springs. A discolored spring is a sign of overheating which may weaken the spring, in which case the spring should be replaced. f. Observe the condition of the commutator and the armature coils that are visible.

1. Switch the rear control switch to the OFF position. 2. Disconnect the wire leads to the junction box of the motor. Mark the leads for proper reassembly. It is not necessary to disconnect the wire leads when moving the motor assembly to replace the heater coil. 3. Remove motor mounting bolts to the bottom panel. 4. Loosen the four venturi mounting nuts. Turn clip and slide assembly out of the blower housing. 5. Loosen the two blower hub set screws to remove blower. 6. To reassemble, reverse the above procedure. Position blower 1/16 inch overlapping venturi. (See Figure 4-10.)

4.16.2 Brush Replacement

If brushes are broken, cracked, severely chipped, or worn to 1/3 their original length, replace the brush lead assembly.
NOTE

Due to limited access on some brush covers, it may be necessary to loosen motor hold down bolts and rotate motor to gain workable access to brush holders.
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a. Remove brush covers. b. With fingers or suitable hook, lift the brush spring end up so the brush may slide up and out of the holder. Loosen the brush screw to remove the brush shunt terminal. Remove brush. c. To replace, lift brush spring and place brush in holder. Position spring end on top of the brush. d. Connect the brush shunt terminal to its proper crossover with the brush screw loosely. e. Assure positioning of brush to permit the brush shunt to travel freely in the holder slot as the brush wears. If it hangs up, commutator damage and motor failure will result. f. Tighten the brush screw.

NOTE

If the compressor runs, pump down the compressor by frontseating the suction service valve until the pressure drops to 1 psig, then stop the unit. 2. Slowly release compressor pressure to a recovery system. 3. Remove the suction and discharge service valves and disconnect the high and low pressure switches (HPS and LPS). 4. Loosen the compressor to allow removal of all belts from the compressor. 5. Disconnect the wire connections to the unloader. 6. Attach sling or other device to compressor to remove. The compressor weighs approximately 146 lbs. 7. Remove the clutch from the compressor.
NOTE

4.17 REPLACING THE RETURN AIR FILTERS

The return air filters are located in front of the evaporator coil. Access to the filters is through the return air opening inside the bus. The filters should be checked periodically depending on operating conditions for cleanliness. A dirty air filter will restrict the air flow over the evaporator coil. This could cause insufficient cooling or heat and possible frost build up on the coil. Remove filters as follows: a. Remove the return air grille. b. Loosen the filter retaining clips. c. Pull the first filter forward and out through the return air opening. d. Slide the second filter past the holding channel to the center position and remove. e. Repeat the above step with the third filter. f. Reverse the procedure for installing the new filters.

If the compressor is to be returned to the factory, drain oil from defective compressor before shipping.
1 2 3 4 5 6

12

11 8 10 9 6. Suction Service Valve 7. Suction Service Port 8. Clutch Assembly 9. Oil Fill Plug 10. Oil Level Sight Glass 11. Oil Drain Plug 12. Oil Pressure Tap

4.18 COMPRESSOR 4.18.1 Replacing the Compressor a. Removing 1. Discharge Service Port 2. Discharge Service Valve 3. Unloader Coil 4. Discharge Snubber Assembly 5. High Pressure Switch

1. If compressor is inoperative and refrigerant pressure still exists, frontseat the suction and discharge service valves to isolate most of the refrigerant in the system from the compressor.

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Figure 4-11. Model 05G Compressor b. Installing NOTE

4.18.2 Checking the Compressor Oil Level NOTE

It is important to check the compressor oil level of the new compressor. 1. The original unloader valves must be transferred to the replacement compressor. The plug arrangement removed from the replacement is installed in the original compressor as a seal. If piston is stuck, it may be extracted by threading a socket head cap screw into top of piston. A small Teflon seat ring at bottom of piston must be removed.
NOTE

It may be necessary to preheat the coach and/or operate the system in the Reheat Mode to keep the compressor fully loaded throughout this procedure. a. Operate the coach for at least one-half hour at fast idle engine speed with the temperature controls at coolest setting and the compressor fully loaded (six cylinder operation). b. Ensure the system is fully charged, as indicated in section 4.9, and the compressor crankcase is warm to the touch after fifteen minutes of operation.
NOTE

The service replacement compressor is sold without shutoff valves (but with valve pads). These should be placed on the old compressor before shipping. Check oil level in service replacement compressor. If none add the applicable amount outlined in section 1.2.b. 2. Remove the high pressure switch and install on new compressor after checking switch setting (refer to section 4.11). 3. Install compressor in unit by reversing step 4.18.a. It is recommended using new locknuts when replacing compressor. Install new gaskets on service valves and tighten bolts uniformly. 4. Attach two lines to the suction and discharge service valves. Dehydrate and evacuate compressor to 500 microns (29.90 Hg vacuum = 75.9 cm Hg vacuum). Turn off valves on both lines to pump. 5. Fully backseat (open) both suction and discharge service valves. 6. Remove vacuum pump lines and install manifold gauges. 7. Start unit and check for noncondensibles 8. Check refrigerant level and add if necessary. 9. Check compressor oil level. (Refer to section 4.18.2.) Add oil if necessary. 10. Check compressor unloader operation. 11. Check refrigerant cycles.

If the compressor is not level, an average between both sight glasses will have to be made to determine proper oil level. c. Shut off the A/C system and immediately record the oil level in the compressor oil level sight glass(es). The correct level should be between the Min and Max marks on compressor crankcase adjacent to the sight glasses. If the oil level is below the Min mark, add oil to the compressor, as outlined in the following section. If the oil level is above the Max mark, remove oil. If proper oil level is obtained, the coach can be released into service.
4.18.3 Adding Oil to the Installed Compressor CAUTION

The appropriate compressor oil must be used according to the refrigerant used in the system. (Refer to section 1.2.b.) There are three methods of adding oil to the compressor , as outlined in the procedures that follow. The oil sump method, paragraph a., is the preferred method.
a. Oil Sump Method

1. With the system off, connect manifold gauge set to the compressor service valves. Connect the blue hose to the suction port and red hose to the discharge port. (See Figure 4-2.) 2. Frontseat (clockwise) the compressor suction and discharge service valves. 3. Reclaim the refrigerant in the compressor. Shut off the reclaimer and verify that the
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pressure remains at zero psig. If it does not, continue reclaiming until the pressure remains at zero psig. 4. Remove the oil fill plug and slowly add oil to the compressor sump through the oil fill opening until the proper oil level is obtained. (See Figure 4-11.) The correct oil level should be between the Min and Max marks on compressor crankcase adjacent to the sight glass(es). 5. Replace the oil fill plug. 6. Evacuate the compressor to 1000 microns, if the oil sump has been opened to atmosphere 7. Backseat (counterclockwise) service valve. discharge

2. Frontseat the suction service valve and place a jumper wire on the low pressure switch to by-pass the switch. 3. Start unit and pull crankcase pressure until suction pressure gauge indicates 5 inches/hg. Shut down unit. 4. Crack open manifold valve and allow vacuum in compressor to draw oil slowly into compressor. When level is just above one quarter glass, close manifold valve. Midseat the suction service valve. Remove the LPS jumper wire. 5. Start unit and check compressor oil level. 6. Backseat valve to remove hose from suction service valve and replace service valve caps.
Suction Service Valve Gauge Manifold

8. Restart the system and recheck oil level. (Refer to section 4.18.2.)
b. Oil Pump Method

1. Connect an oil pump to a one U.S. gallon (3.785 liters) refrigeration oil container. Using the Robinair compressor oil pump (Carrier Transicold P/N 14388) is recommended.
NOTE Compressor

When the compressor is in operation, the pump check valve prevents the loss of refrigerant, while allowing servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary. 2. Backseat suction service valve and connect oil charging hose to port. Crack the service valve and purge the oil hose at oil pump. Add oil as necessary.
c.Closed System Method

Oil Container

Figure 4-12. Compressor Oil Charge Connections 4.18.4 Adding Oil to Service Replacement Compressor CAUTION

The appropriate compressor oil must be used according to the refrigerant used in the system. (Refer to section 1.2.b.) Service replacement compressors may or may not be shipped with oil. If the replacement compressor is shipped without oil, add oil through the oil fill plug port. (Refer to section 1.2.b.)
4.18.5 Removing Oil from the Compressor

In an emergency where an oil pump is not available, oil may be drawn into the compressor through the suction service valve.
CAUTION

Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times. Otherwise air and moisture will be drawn into the compressor. 1. Connect manifold gauge set. Place center charging line into compressor oil container as shown in Figure 4-12 Slowly open discharge hand valve to purge line, then close.

a. If the oil level recorded in step 4.18.2 is aboveMax line on the the sight glass, remove oil from the compressor. b. Connect manifold gauges to the compressor. c. Frontseat (clockwise) suction service valve and pump unit down to zero psig. Frontseat (clockwise) discharge service valve and slowly

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open suction service port to ensure there is no pressure at the oil drain plug. d. Remove the oil drain plug on the bottom plate of the compressor and drain the proper amount of oil from the compressor. Replace the plug securely back into the compressor. e. Repeat step a. to ensure proper oil level.

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Table 4-2. R-134a Temperature - Pressure Chart BOLD NO. = Inches Mercury Vacuum (cm Hg Vac) Temperature _F ---40 ---35 ---30 ---25 ---20 ---18 ---16 ---14 ---12 ---10 ---8 ---6 ---4 ---2 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 _C ---40 ---37 ---34 ---32 ---29 ---28 ---27 ---26 ---24 ---23 ---22 ---21 ---20 ---19 ---18 ---17 ---16 ---14 ---13 ---12 ---11 ---10 ---9 ---8 ---7 ---6 ---4 ---3 ---2 Psig 14.6 12.3 9.7 6.7 3.5 2.1 0.6 0.4 1.2 2.0 2.9 3.7 4.6 5.6 6.5 7.6 8.6 9.7 10.8 12.0 13.2 14.5 15.8 17.1 18.5 19.9 21.4 22.9 24.5 Pressure kPa 49.4 41.6 32.8 22.7 11.9 7.1 2.0 1.1 8.3 13.8 20.0 25.5 31.7 36.6 44.8 52.4 59.3 66.9 74.5 82.7 91.0 100.0 108.9 117.9 127.6 137.2 147.6 157.9 168.9 Kg/cm@ 37.08 31.25 24.64 17.00 8.89 5.33 1.52 0.03 0.08 0.14 0.20 0.26 0.32 0.39 0.46 0.53 0.60 0.68 0.76 0.84 0.93 1.02 1.11 1.20 1.30 1.40 1.50 1.61 1.72 Bar 0.49 0.42 0.33 0.23 0.12 0.07 0.02 0.03 0.08 0.14 0.20 0.26 0.32 0.39 0.45 0.52 0.59 0.67 0.74 0.83 0.91 1.00 1.09 1.18 1.28 1.37 1.48 1.58 1.69 Temperature _F 30 32 34 36 38 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 _C ---1 0 1 2 3 4 7 10 13 16 18 21 24 27 29 32 35 38 41 43 46 49 52 54 57 60 63 66 68 Psig 26.1 27.8 29.6 31.3 33.2 35.1 40.1 45.5 51.2 57.4 64.1 71.1 78.7 86.7 95.3 104.3 114.0 124.2 135.0 146.4 158.4 171.2 184.6 198.7 213.6 229.2 245.6 262.9 281.1 Pressure kPa 180.0 191.7 204.1 215.8 228.9 242.0 276.5 313.7 353.0 395.8 441.0 490.2 542.6 597.8 657.1 719.1 786.0 856.4 930.8 1009 1092 1180 1273 1370 1473 1580 1693 1813 1938 Kg/cm@ 1.84 1.95 2.08 2.20 2.33 2.47 2.82 3.20 3.60 4.04 4.51 5.00 5.53 6.10 6.70 7.33 8.01 8.73 9.49 10.29 11.14 12.04 12.98 13.97 15.02 16.11 17.27 18.48 19.76 Bar 1.80 1.92 2.04 2.16 2.29 2.42 2.76 3.14 3.53 3.96 4.42 4.90 5.43 5.98 6.57 7.19 7.86 8.56 9.31 10.09 10.92 11.80 12.73 13.70 14.73 15.80 16.93 18.13 19.37

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SECTION 5 ELECTRICAL SCHEMATIC WIRING DIAGRAM


NOTE If you do not find your exact unit or schematic listed on page 1-2 in the front of this book, consult your local Carrier Transicold service representative or call the technical hot line at 800-450-2211 for assistance in getting a copy of the applicable schematic. 5.1 INTRODUCTION

This section contains Electrical Schematic Wiring Diagrams covering the Models listed in Table 1-1. Before performing operation and maintenance on the equipment, ensure that precautions listed in the Safety Summary in the front of the manual are read, understood and applied.

RELAY BOARD (RB)

K PLUG

K4

K4 - LOAD/UNLOAD RELAY

K2

K2 - COOL RELAY

L PLUG

K1

K1 - HIGH/LOW SPEED RELAY

K3

K3 - HEAT RELAY

ELECTRONIC THERMOSTAT (TH)


Figure 5-1. Electrical Control Panel Relay Board (RB) and Electronic Thermostat (TH) Outline Views.

5-1

T-288

LEGEND
DESCRIPTION SYMBOL ACHM A/C HOURMETER (OPTIONAL) SYMBOLS ACMS A/C MODE SWITCH (O.E.M. SUPPLIED) ACR A/C RELAY ACSR1 A/C STOP RELAY #1 INDICATES RELAY BOARD CONNECTION ACSR2 A/C STOP RELAY #2 BPM BOOST PUMP MOTOR INDICATES A WIRE GROUND BPR BOOST PUMP RELAY CB1 15A CIRCUIT BREAKER INDICATES CUSTORMER SUPPLIED CB2 40A CIRCUIT BREAKER CB3 40A CIRCUIT BREAKER INDICATES A CONNECTION CB4 60A CIRCUIT BREAKER (LUG, SCREW, ETC.) CB5 60A CIRCUIT BREAKER INDICATES A CONNECTOR CB6 10A CIRCUIT BREAKER CDR COOL DISABLE RELAY INDICATES A NORMALLY OPEN CONTACT CFR1 CONDENSER FAN RELAY #1 CFR2 CONDENSER FAN RELAY #2 INDICATES A NORMALLY CLOSED CONTACT CFS CONDENSER FAN SWITCH CL CLUTCH INDICATES BUS INTERFACE CONNECTOR CM1 CONDENSER FAN MOTOR #1 PIN LOCATION CM2 CONDENSER FAN MOTOR #2 INDICATES RELAY BOARD TRACE COL1 CONDENSER OVERLOAD #1 COL2 CONDENSER OVERLOAD #2 CR CLUTCH RELAY CSR1 CONDENSER SPEED RELAY #1 D1 - D28 DIODE #1 THRU DIODE #28 DFS DEFROST SWITCH (O.E.M. SUPPLIED) EM1 EVAPORATOR FAN MOTOR #1 EM2 EVAPORATOR FAN MOTOR #2 EFR1 EVAPORATOR FAN RELAY #1 EOL1 EVAPORATOR OVERLOAD #1 EOL2 EVAPORATOR OVERLOAD #2 ESR EVAPORATOR SPEED RELAY FR FAULT RELAY HPS HIGH PRESSURE SWITCH HR HEAT RELAY HR2 HEAT RELAY #2 LATH LOW AMBIENT THERMOSTAT 22 - PIN CONNECTOR LPS LOW PRESSURE SWITCH (A/C UNIT WIRING SIDE) LSV LIQUID SOLENOID VALVE OR1 EVAPORATOR OVERLOAD RELAY #1 OR2 EVAPORATOR OVERLOAD RELAY #2 PTB POWER TERMINAL BLOCK RCV REHEAT COOLANT VALVE RHR REAR HEATER RELAY (O.E.M. SUPPLIED) TDR TIME DELAY RELAY TH ELECTRONIC THERMOSTAT TSP TEMPERATURE SELECTOR POT UFHAT UNDER FLOOR HEAT AMBIENT THERMOSTAT (O.E.M. SUPPLIED) UPS1 UNLOADER PRESSURE SWITCH #1 UPS2 UNLOADER PRESSURE SWITCH #2 UPS3 UNLOADER PRESSURE SWITCH #3 UV1 UNLOADER VALVE #1 UV2 UNLOADER VALVE #2 WPR WATER PUMP RELAY (O.E.M. SUPPLIED) WTS WATER TEMPERATURE SENSOR Figure 5-1. Electrical Schematic Diagram Legend and Symbols (Drawing No. 68RM35-1038-12) T-288 5-2

TDR 10 SEC

Figure 5-2. Electrical Schematic Diagam (Based on Drawing 68RM35-1038-12) 5-3 T-288

INDEX
A
A/C Mode Switch, 1-7, 1-8, 2-1, 3-1 A/C Stop Light, 1-5, 1-8 A/C Stop Relay, 1-5, 1-8 A/C Switch, 1-5, 1-8, 4-3, 4-6 ACMS Switch, 1-5 Air Conditioning Relay, 1-4 Air Conditioning Stop Relay, 1-4 Air Filter, 1-3, 3-2, 4-1, 4-11 Air Filter, 3-1 Coolant Valve, 3-2

D
Description, 1-1, 3-1 Discharge Line Check Valve, 1-2 Discharge Line Isolation Valve, 1-2

E
Electrical Control Panel, 1-1, 1-3, 1-4, 1-7, 1-8 Electronic Thermostat, 1-1, 1-4, 1-7, 1-8, 1-10, 2-1, 2-2, 3-1, 3-2 Evaporator, 1-1, 1-5, 4-1, 4-8 Evaporator Coil, 1-3, 1-10, 1-11, 4-1, 4-3, 4-5, 4-11 Evaporator Fan, 1-2, 1-7, 1-8, 1-10, 2-1, 2-2, 3-2, 4-1 Evaporator Fan Motor, 1-2, 1-5, 1-6, 1-7, 1-8, 3-2, 4-7, 4-9, 4-10 Evaporator Fan Relay, 1-4, 1-7, 1-8, 2-1, 3-2 Evaporator Motor Overload, 1-7 Evaporator Overload Relay, 1-4, 1-8 Evaporator Speed Relay, 1-4, 1-8 Evaporator Speed Switch, 1-7

B
Boost Pump Motor, 1-6, 2-1 Boost Pump Relay, 1-4, 1-8, 2-1 Boost Relay, 3-2 Motor Brushes, 4-1, 4-10, 4-11

C
Circuit Breaker, 1-4, 1-5, 1-6, 3-1 Clutch, 1-4, 1-5, 1-6, 1-7, 1-8, 1-10, 2-1, 3-1, 4-11, 4-12 Clutch Coil, 3-1 Clutch Relay, 1-4, 1-8 Compressor, 1-1, 1-4, 1-5, 1-7, 1-8, 1-10, 1-11, 2-1, 2-2, 3-1, 3-2, 4-1, 4-2, 4-4, 4-5, 4-6, 4-7, 4-8, 4-11, 4-12, 4-13 Condenser, 1-1, 1-10, 4-6 Condenser Coil, 1-2, 1-7, 1-8, 1-10, 1-11, 3-1, 4-1, 4-3 Condenser Coil, 3-1 Condenser Fan, 1-7, 1-10, 3-1, 3-2 Condenser Fan Motor, 1-2, 1-5, 1-6, 1-7, 1-8, 4-9, 4-10 Condenser Fan Relay, 1-4, 1-7, 1-8 Condenser Fan Switch, 1-2, 1-5, 1-7, 1-8, 1-11, 4-7, 4-8 Condenser Motor Overload, 1-7 Condenser Speed Relay, 1-4, 1-7, 1-8 Cool Disable Relay, 1-4, 1-8

F
Fault Relay, 1-4, 1-8 Filter--Drier, 1-2, 1-10, 1-11, 3-1, 4-6 Filter--Drier Inlet Valve, 1-2, 1-10, 1-11, 3-1, 4-1, 4-2, 4-3, 4-6, 4-7, 4-8 Filter--Drier Outlet Valve, 1-2, 1-10, 1-11, 4-2 Fusible Plug, 1-2

H
Heat Relay, 1-4 Heater Coil, 1-2, 2-1, 3-2, 4-9 High Pressure Gauge, 4-2 High Pressure Switch, 1-4, 1-5, 1-6, 4-7, 4-8, 4-11, 4-12

L
Liquid Line Solenoid Valve, 1-3, 1-10, 1-11 Index-1

INDEX
Liquid line solenoid valve, 3-1 Liquid--Suction Heat Exchanger, 1-2, 1-10, 1-11 Low Ambient Switch, 1-5 Low Ambient Thermostat, 1-2, 1-7, 1-8, 2-1, 3-1 Low Pressure Gauge, 4-2 Low Pressure Switch, 1-4, 1-5, 1-6, 1-8, 4-3, 4-7, 4-8, 4-11, 4-13 Schematic Wiring Diagrams, 5-1 Service Valves, 3-1 Subcooler, 1-10, 1-11 Suction and Discharge Service Valves, 3-1, 4-1, 4-2, 4-6, 4-8, 4-11, 4-12, 4-13 Superheat, 4-8, 4-9

M
Manifold Gauge Set, 4-1, 4-2, 4-3, 4-4, 4-6, 4-13 Moisture/Liquid Indicator, 1-2, 1-9, 1-10, 2-1 Motor brushes, 3-2

T
Temperature Selector, 1-4, 1-7 Thermostatic Expansion Valve, 1-3, 1-5, 1-10, 1-11, 3-1, 3-2, 4-3, 4-4, 4-8, 4-9

O
Oil Level Sight Glass, 4-12, 4-13

U
Unloader Coil, 1-4, 4-12 Unloader Pressure Switch, 1-2, 1-5, 1-6, 1-7, 1-11, 4-7, 4-8 Unloader Valve, 1-7, 1-8, 4-11

R
Receiver, 1-2, 1-9, 1-10, 1-11, 4-3, 4-4, 4-5, 4-6 Receiver Sight Glass, 1-2 Refrigerant Charge, 1-5 Reheat Coolant Valve, 1-5, 2-1, 3-2, 4-9 Relay Board, 1-1, 1-4, 1-8 Return Air Probe, 1-4

V
V--Belt, 3-1, 3-2, 4-1 Vacuum Pump, 4-3, 4-4, 4-5, 4-6, 4-8, 4-12

S
Safety Devices, 1-5, 1-6, 3-1, 3-2

W
Water Pump Relay, 1-9, 2-1 Water Temperature Switch, 1-5, 1-7, 3-1

Index-2

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