Machine Air Conditioning System Operation and Components

Lesson 2: Machine Air Conditioning System

Operation and Components
Lesson 2 Objective:
Given the proper worksheet, the student will identify vehicle air
conditioning components and state the component function, identify
the various air conditioning systems and state the systems operation
with 90% accuracy.
Given an air conditioning training unit, students will demonstrate the
effect of individual component operation on the air conditioning
system.
Reference Materials
Air Conditioning and Heating R-134a, All Caterpillar Machines
Service Manual, (Form No. SENR5664);
Student Reading Assignment: Pages 63 - 106
Unit 1 1-2-2 Air Conditioning Fundamentals
Lesson 2

DO NOT HEAT KEEP UPRIGHT

KEEP AWAY FROM FLAME

WEAR SAFTY
GLASSES

DO NOT DROP
DO NOT FREEZE R-134a
DANGER
WEAR GLOVES WHEN HANDLING

Fig. 1.2.1
REFRIGERANT HFC-134A

The substance used in air conditioning systems is called "refrigerant."

Many refrigerants are available. In fact, any liquid that will boil at
temperatures near the freezing point of water can be used as a
refrigerant. However, a good refrigerant should be non-poisonous
and non-explosive to be safe. A good refrigerant should also be non-
corrosive, odorless and mix well with oil.
The refrigerant that is used in current Mobile Air Conditioning
Systems is known as "Refrigerant HFC-134a." HFC-134a is made
from Hydrogenated Fluorocarbons. HFC-134a has the same
advantages of R-12 plus HFC-134a will not harm the atmosphere.
Some "do nots" about HFC-134a are:
The following safety precautions should be followed when servicing
air conditioning systems, operating air conditioning equipment or
handling refrigerants.

1. Do not weld or steam clean near vehicle installed air conditioning

lines. The heat can cause excessive refrigerant pressure.

2. Do not transport refrigerant in passenger compartment of a

vehicle.

3. Do not expose refrigerant to open flames, high temperatures or

direct sunlight.
Unit 1 1-2-3 Air Conditioning Fundamentals
Lesson 2

4. Wear safety goggles. Escaping refrigerant coming in contact

with the eyes can cause serious injury.

5. Do not use excessive heat on refrigerant containers during the

charging process. Never use direct heat. Use a container of
water that does not exceed 52°C (125°F).

6. Do not discharge refrigerant to the atmosphere. In addition to

being harmful to the earth's ozone layer, Refrigerant 12 when
subjected to an open flame results in a very deadly phosgene gas.

7. Always work in a well ventilated area. Inhaling refrigerant, even

in small amounts, can be cumulative and cause light-headedness.
Refrigerants can also cause irritation to the eyes, nose and throat.

8. Do not weld or steam clean an air conditioning system.

Excessive pressure could build up in the system.

9. Do not mix R-134a with air for the purpose of leak testing.
When under pressure the mixture could explode.

10. When charging a system with the engine running, be sure the
high pressure gauge valve is closed.

11. Be alert when the engine is running and stay clear of rotating
components.

12. Do not recover or transfer refrigerant into a disposable tank.

Always use a DOT approved tank. Look for DOT4BA or
DOT4BW on the tank.

13. Do not fill a storage tank to more than 80% of its gross weight
rating.
Unit 1 1-2-4 Air Conditioning Fundamentals
Lesson 2

HFC-134a

Fig. 1.2.2

BASIC AIR CONDITIONING SYSTEM

Shown is an open flask of Refrigerant-HFC-134a at room

temperature. When at atmospheric pressure (14.7 psi), HFC-134a
boils at -27°C (-16°F). The heat in the room causes the refrigerant to
boil. As the refrigerant boils, heat is drawn away from the
surrounding area. The absence of heat makes the surrounding area
cooler. However, such a system is not economical nor is it good for
the atmosphere.
Unit 1 1-2-5 Air Conditioning Fundamentals
Lesson 2

COMPRESSOR

HIGH PRESSURE LOW PRESSURE

Fig. 1.2.3

In Figure 1.2.3, a compressor and a high pressure flask have been

added. As the liquid refrigerant boils, the vapor is drawn through a
hose into the compressor. The compressor increases the pressure of
the vapor and the intensity of the heat. Since temperature is a
measurement of the heat intensity, the temperature of the vapor
increases. The high pressure, high temperature vapor flows into the
high pressure flask. The temperature of the high pressure vapor is
higher than the temperature of the surrounding area. Therefore, heat
flows from the high pressure vapor to the surrounding area. The high
pressure vapor cools and changes into a high pressure liquid.
Unit 1 1-2-6 Air Conditioning Fundamentals
Lesson 2

COMPRESSOR

ORIFICE

HIGH PRESSURE LOW PRESSURE

Fig. 1.2.4

Complete the system by adding a hose to connect the flask of high

pressure liquid to the flask of low pressure liquid. An orifice is
inserted in the hose to maintain a pressure difference between the
high pressure liquid and the low pressure liquid.
When the flask of low pressure liquid refrigerant boils, the boiling
process collects heat from the surrounding area. The low pressure
refrigerant vapor is drawn through a hose into the compressor. The
compressor raises the pressure and temperature of the vapor and
stores it in the high pressure flask. The high pressure, high
temperature vapor gives up heat to the cooler surrounding area,
causing the high pressure vapor to cool and condense into a high
pressure liquid. The high pressure liquid refrigerant flows through a
hose and orifice to the flask for low pressure liquid refrigerant. The
low pressure liquid refrigerant boils, and repeats the cycle.
Unit 1 1-2-7 Air Conditioning Fundamentals
Lesson 2

CONDENSER
COIL
COMPRESSOR

IN-LINE CONDENSER FAN

DRYER

EVAPORATOR
COIL
ACCUMULATOR

ORIFICE TUBE SYSTEM

EVAPORATOR BLOWER FAN

Fig. 1.2.5

AIR CONDITIONING SYSTEMS AND COMPONENTS

Orifice Tube System

The standard air conditioning system contains five basic components:

Compressor - Increases pressure and temperature of
refrigerant vapor

Condenser - Removes the heat from the high pressure

high temperature refrigerant vapor
causing the vapor to change into high
pressure liquid refrigerant

In-line dryer - Contains the desiccant and the orifice

tube. Quick disconnects allow the in-line
dryer to be easily changed when needed

Evaporator - Low pressure liquid refrigerant boils,

collecting heat from the surrounding area

Accumulator - Acts as a liquid/vapor separator and

ensures that only vapor will reach the
compressor
On the orifice tube system, the liquid refrigerant leaving the
evaporator can damage the compressor. Therefore, an accumulator is
located in the suction line after the evaporator. The accumulator acts
as a liquid/vapor separator and ensures that only vapor will reach the
compressor.
Unit 1 1-2-8 Air Conditioning Fundamentals
Lesson 2

On some orifice tube systems, the orifice tube is located in the low
pressure liquid line to the evaporator and the desiccant is in the
accumulator.
On systems with an in-line dryer, the desiccant is in the dryer.

COMPRESSOR
INTAKE EXHAUST INTAKE EXHAUST
PASSAGE PASSAGE PASSAGE PASSAGE

EXHAUST
VALVE EXHAUST
INTAKE VALVE
VALVE
INTAKE
VALVE

INTAKE STROKE COMPRESSION STROKE

Fig. 1.2.6
Compressor

The dual purpose of the compressor is:

- Increase the temperature and pressure of refrigerant gas from the
evaporator
- Circulate the refrigerant throughout the system.

The compressor has reed valves to control the entrance and exit of
refrigerant gas during the pumping operation.
As the piston moves downward in the bore, the suction reed valve
opens and the discharge reed valve closes. The low pressure, heat
laden refrigerant gas is drawn from the evaporator into the
compressor. As the piston moves upward in the bore, the compressor
pressurizes the gas, thus increasing the intensity of the heat.
Since temperature is a measurement of heat intensity, the temperature
of the gas increases. The high pressure, high temperature gas closes
the suction reed valve and opens the discharge reed valve. The gas is
forced through a hose to the condenser.
The pressure increase is accomplished by adding a restriction in the
high pressure side of the system. The restriction is caused by the
orifice tube. The orifice tube is explained later in this presentation.
Unit 1 1-2-9 Air Conditioning Fundamentals
Lesson 2

CONDENSER
FROM
COMPRESSOR

TO
RECEIVER-
DRYER

Fig. 1.2.7

Condenser

The purpose of the condenser is to transfer the heat in the refrigerant

gas to the atmosphere and convert the refrigerant gas into a liquid.
High pressure, high temperature refrigerant gas flows from the
compressor into the condenser. As the hot, high pressure gas flows
through the condenser, heat flows from the hot gas to the cooler air
flowing through the condenser coils. The high pressure refrigerant
gas cools and condenses into high pressure liquid. The high pressure
liquid flows from the condenser to the in-line dryer.
Two basic types of condensers are commonly used:
Ram Air - Used in automotive applications
Forced Air - Used on construction equipment.
The ram air condenser depends on machine movement to force large
volumes of air through the condenser coils.
The forced air condenser uses fans to move large volumes of air
through the condenser coils. The air is cooler than the refrigerant gas
inside the condenser. Heat flows from the hot refrigerant gas to the
cooler air.
Unit 1 1-2-10 Air Conditioning Fundamentals
Lesson 2

IN-LINE DRYER
QUICK DISCONNECT DESICCANT
OUTLET

ORIFICE TUBE MOISTURE QUICK DISCONNECT

ASSEMBLY INDICATOR INLET

TUBE O-RINGS TABS

SCREEN BODY SCREEN

Fig. 1.2.8

In-line dryer and orifice tube

The in-line dryer contains a desiccant bag and two quick disconnects.
The disconnects allows the in-line dryer to be changed without
reclaiming the refrigerant. Some in-line dryers may have a moisture
indicator.
On most orifice tube systems, the orifice tube is installed in the in-
line dryer. The orifice tube consists of a small tube through the
center of a plastic body, two o-rings, two screens and two tabs.
The two screens (one on each end) filter the refrigerant that flows
through the small tube. The two o-rings are positioned to seal against
leakage past the outside of the orifice tube. The two tabs engage the
tooling when installing and removing the orifice tube.
The orifice tube separates the A/C System high side from the low
side. High pressure liquid refrigerant enters the orifice tube and low
pressure liquid refrigerant exits the orifice tube.
The orifice tube has a fixed diameter and does not have the regulating
capability of the expansion valve. The refrigerant flows from the
orifice tube to the evaporator. The amount of liquid refrigerant
entering the evaporator is usually more than the evaporator can boil
off, therefore, some refrigerant will leave the evaporator in the liquid
form.
On some orifice tube systems, the orifice tube is installed in the
evaporator inlet line.
Unit 1 1-2-11 Air Conditioning Fundamentals
Lesson 2

FROM ORIFICE EVAPORATOR

TUBE

TO COMPRESSOR

BLOWER FAN

Fig. 1.2.9

Evaporator Unit

The purpose of the evaporator unit is to transfer the heat in the

operator's compartment to the refrigerant in the air conditioner.
A blower fan is a necessary part of the evaporator unit in the air
conditioning system. The blower fan draws heat laden air from the
operator's compartment over the evaporator fins and coils where the
air surrenders heat to the refrigerant.
When the low pressure liquid refrigerant enters the evaporator, the
refrigerant is cooler than the air from the blower fan. The heat in the
air causes most of the low pressure liquid refrigerant to boil and
change into refrigerant gas. The heat laden low pressure refrigerant
gas/liquid combination flows to the accumulator. The cooler air
flows back into the operator's compartment.
Unit 1 1-2-12 Air Conditioning Fundamentals
Lesson 2

WITH DIVERTER WITHOUT

DESICCANT CAP DESICCANT

INLET INLET

VAPOR
LINE

OIL
BLEED
HOLE

DESICCANT

OUTLET ACCUMULATOR OUTLET

Fig. 1.2.10

Accumulator

The accumulator stores the refrigerant gas/liquid mixture and allow

only gas refrigerant to flow to the compressor. The refrigerant gas
flows through the opening at the top of the vapor line.
Earlier accumulators contain a diverter cap to keep the liquid away
from the opening in the vapor line. The oil bleed hole allows oil to
flow back to the compressor.
Some accumulators contain a desiccant bag to remove moisture from
the refrigerant. On systems with an in-line dryer, the desiccant is
removed from the accumulator an placed in the in-line dryer.
Unit 1 1-2-13 Air Conditioning Fundamentals
Lesson 2

CONDENSER
COIL

RECEIVER-DRYER COMPRESSOR

CONDENSER
FAN

CAPILLARY TUBE

EXPANSION
VALVE

EVAPORATOR
COIL
TO
COMPRESSOR

THERMOSTATIC EXPANSION
VALVE SYSTEM
EVAPORATOR
FAN

Fig. 1.2.11

Thermostatic Expansion Valve System

Many earlier model machines are equipped with the thermostatic

expansion valve system. The purpose of the thermostatic expansion
valve is to:
- Restrict refrigerant flow and allow the compressor to increase
the pressure on the high side of the air conditioning system

- Control the amount of refrigerant entering the evaporator

The part of the air conditioning system from the compressor outlet to
the expansion valve inlet is called the "high side." The thermostatic
expansion valve causes a restriction to refrigerant flow that increases
the pressure between the expansion valve (restriction) and the
compressor. The increase in pressure allows the refrigerant to change
from a gas to a liquid.
Just as the compressor increases the temperature of the refrigerant by
concentrating the refrigerant into a smaller space, the expansion valve
decreases the temperature by allowing the refrigerant to spread out as
it leaves the orifice in the expansion valve. Because the pressure is
greatly decreased, the refrigerant is coldest as the refrigerant leaves
the expansion valve and enters the evaporator. The part of the air
conditioning system from the expansion valve outlet to the
compressor inlet is called the "low side."
The thermostatic expansion valve system is equipped with a receiver-
dryer.
Unit 1 1-2-14 Air Conditioning Fundamentals
Lesson 2

EXPANSION VALVES

TUBE TUBE

EXTERNAL
EQUALIZER
DIAPHRAGM TUBE DIAPHRAGM

PIN INLET INLET

INTERNAL
EQUALIZER PIN
PASSAGE ORIFICE ORIFICE

SEAT
SEAT

SUPERHEATER
SUPERHEATER
SPRING
SPRING

OUTLET OUTLET
THERMAL BULB THERMAL BULB

INTERNALLY EQUALIZED EXTERNALLY EQUALIZED

Fig. 1.2.12

Thermostatic expansion valve

Two types of expansion valves are used on machines: internally

equalized and externally equalized. Both the internally equalized and
the externally equalized expansion valves have a thermal bulb
connected to a diaphragm by a small tube. The thermal bulb contains
a refrigerant. A clamp holds the thermal bulb securely to the
evaporator exhaust line. The thermal bulb is sensitive to exhaust
temperature. If the exhaust temperature increases, the refrigerant
inside the bulb expands. The expanding refrigerant exerts pressure
against the diaphragm in the top of the valve. The diaphragm is
connected through a pin to the valve seat. Pressure exerted against
the diaphragm causes the diaphragm pin and valve seat to move. As
the valve seat moves away from the orifice, more refrigerant flows
into the evaporator. An increase in the flow of refrigerant causes the
evaporator exhaust to become cooler. The cooler exhaust
temperature causes the refrigerant to condense in the thermal bulb,
reducing the pressure against the diaphragm, pin and valve seat. The
valve seat moves to reduce flow through the orifice.
In the internally equalized valve, the pressure of the refrigerant
entering the evaporator is fed to the bottom of the diaphragm through
the internal equalizing passage. Gas expansion in the thermal bulb
must overcome the internal balancing pressure and the spring before
the valve will open to increase refrigerant flow.
On the external equalizer valve, the pressure fed to the bottom of the
diaphragm is taken from the evaporator exhaust line by an equalizer
tube. The equalizer tube balances the evaporator exhaust pressure
against the pressure caused by the expansion of the gas in the thermal
bulb.
Unit 1 1-2-15 Air Conditioning Fundamentals
Lesson 2

The superheat spring prevents surges of excessive liquid from

entering the evaporator. "Superheat" is an increase in temperature of
the refrigerant gas above the temperature at which the refrigerant
evaporated. The superheat spring is installed against the valve and
adjusted to a predetermined setting at the time of manufacture. The
expansion valve is designed so that the temperature of the refrigerant
at the evaporator exhaust line must have 3°C (5°F) of superheat
before more refrigerant is allowed to enter the evaporator. The spring
tension is the determining factor in the opening and closing of the
expansion valve. During opening and closing, the spring tension
retards or assists valve operation as required.

FROM CONDENSER

TO EXPANSION
VALVE

SCREEN

RECEIVER-DRYER

Fig. 1.2.13

Receiver-dryer

The receiver-dryer has three functions: dry, store and filter liquid
refrigerant. As the high pressure liquid refrigerant flows into the
receiver-dryer, the refrigerant is filtered through a desiccant that
removes any moisture that may have entered the refrigerant. The
refrigerant is stored until needed by the system. When the system
calls for refrigerant, high pressure liquid flows through a fine mesh
screen fitted on the pickup tube. (The screen prevents any debris
from circulating through the air conditioning system.) High pressure
liquid flows from the receiver-dryer to the thermostatic expansion
valve.
Unit 1 1-2-16 Air Conditioning Fundamentals
Lesson 2

CONDENSER
COIL

RECEIVER-DRYER

CONDENSER
COMPRESSOR

"H" BLOCK
EXPANSION "H" BLOCK EXPANSION
VALVE
VALVE SYSTEM
EVAPORATOR BLOWER FAN

Fig. 1.2.14

"H" Block Expansion Valve System

In the "H" Block expansion valve system the thermostatic expansion

valve is replaced with the "H" Block expansion valve.
When the "H" Block expansion valve opens, liquid refrigerant is
metered into the bottom of the evaporator. The low pressure
refrigerant begins to boil as it flows through the evaporator coil. The
refrigerant vapor attracts the heat from the warmer air circulated by
the evaporator fan. The compressor draws the refrigerant vapor out
of the top of the evaporator and past the temperature sensor. The
cooler vapor cools the temperature sensor. As the temperature sensor
cools, the gas in the sensor condenses and decreases the pressure on
the top of the temperature sensor diaphragm. The diaphragm
expands upward moving the rod away from the ball and spring. The
ball and spring starts to close restricting flow through the expansion
valve.
The temperature sensor controls the operation of the air conditioning
system by allowing the exact amount of liquid refrigerant to be
metered past the ball and spring.
Unit 1 1-2-17 Air Conditioning Fundamentals
Lesson 2

"H" BLOCK EXPANSION VALVE

TEMPERATURE SENSOR

DIAPHRAGM

FROM TO
EVAPORATOR COMPRESSOR

ROD

TO
EVAPORATOR
FROM
CONDENSOR

BALL AND SPRING

Fig. 1.2.15

"H" Block expansion valve

Some air conditioning systems use the "H" Block expansion valve to
control the amount of refrigerant into the evaporator.
During the compressor cut-out mode, the pressure on the bottom of
the temperature sensor diaphragm increases above the pressure on top
of the diaphragm. The diaphragm expands upward retracting the rod
and allowing the ball and spring to close the valve.
During the compressor cut-in mode, the pressure on the bottom of the
temperature sensor diaphragm decreases rapidly. The higher pressure
on the top of the diaphragm causes the diaphragm to contract
downward moving the rod against the ball and spring, thus opening
the valve.
Unit 1 1-2-18 Air Conditioning Fundamentals
Lesson 2

R-12
COMPRESSOR CAPILLARY TUBE
ELECTRICAL
CIRCUIT CAPILLARY BELLOWS
PIVOTING FRAME ASSEMBLY

CLUTCH

BATTERY THERMOSTATIC TEMPERATURE

POINT OPENING
SWITCH ADJUSTING SCREW

Fig. 1.2.16

Thermostatic switch

The thermostatic switch in the compressor electrical circuit cycles the

compressor, allowing the operator to adjust the amount of coolness
desired and prevent the evaporator from freezing.
The thermostatic switch consists of a stationary contact and a
pivoting frame attached to a capillary bellows assembly. The
capillary tube is filled with R-12 or a similar refrigerant. The
capillary tube is inserted between the evaporator core fins. The
refrigerant in the capillary tube expands or contracts, depending on
the temperature of the evaporator.
The expanding and contracting refrigerant in the capillary tube causes
the bellows to expand and contract. The expanding and contracting
bellows cause the pivoting frame to pivot.
Part of the wire to the evaporator clutch coil is connected to the
stationary contact, and the other part is connected to the pivoting
frame. The contact and pivoting frame must come together for the
switch to close and operate the compressor clutch.

The operator regulates evaporator cooling by varying the space

between the stationary contact and pivoting frame.. Moving the
contact and pivoting frame farther apart (decreasing cooling) causes
the bellows to expand farther before closing the switch. Moving the
contact and pivoting frame closer together (increasing cooling) causes
the switch to close with less bellows movement.
Unit 1 1-2-19 Air Conditioning Fundamentals
Lesson 2

Adjustable thermostats have provisions for regulating the range

between the opening and closing of the switch. The adjustment
screw is located under a removable cover. If the adjustment screw is
not found in this location, the thermostat is non-adjustable.
The non-adjustable thermostat system (sometime called a Freeze
Control System) contains one temperature control knob. The knob is
connected to the heater control valve, which controls the flow of
coolant through the heater coil. The evaporator air flow temperature
is controlled by the non-adjustable thermostat. The cab temperature
is maintained by monitoring the air flow across the heater and
evaporator coils. When air flow across the heater and evaporator
coils reaches 2.2° C (36° F), the non-adjustable thermostat turns the
compressor ON. When air flow temperature decreases to -1.1° C
(30° F), the non-adjustable thermostat turns the compressor OFF.

PULLEY ASSEMBLY

DRIVE PLATE

HUB

SHAFT

BEARING

COIL ASSEMBLY COMPRESSOR

CLUTCH

Fig. 1.2.17

Compressor clutch

The clutch is driven by the engine crankshaft through a belt to the

pulley assembly on the magnetic clutch. The pulley assembly turns
on the bearing and is not connected to the shaft. The drive plate is
splined through the hub to the shaft. The coil assembly is mounted
on the frame of the compressor and does not rotate.
The electrical current from the thermostat creates a magnetic field in
the coil assembly. The magnetic field pulls the drive plate against the
pulley assembly. The pulley assembly then turns the drive plate, hub
and shaft to operate the compressor.
Unit 1 1-2-20 Air Conditioning Fundamentals
Lesson 2

Fig. 1.2.18
Low pressure switch
Shown is the low pressure sensing switch (arrow) threaded into the
receiver-dryer. The low pressure sensing switch is used to protect the
system from damage due to the lack of oil. Located in the electrical
circuit to the magnetic clutch, the switch opens when system pressure
decreases below 175 kPa (25 psi) and shuts off the compressor. The
switch can be located on the dryer, expansion valve, liquid line, or on
the compressor.
A similar high pressure switch (not shown) is used on some machines
to shut off the system before system pressure reaches the high
pressure relief valve setting. The high pressure switch is located in
the electrical circuit to the magnetic clutch. High system pressure
opens the switch and shuts off the compressor.

Fig. 1.2.19
High pressure relief valve

The high pressure relief valve is located on the compressor and/or the
receiver-dryer. The high pressure relief valve (arrow) allows the
refrigerant to be released to the atmosphere if system pressure
increases above 3450 kPa (500 psi). On todays systems, the high
pressure relief valve opens a high pressure switch. This prevents
refrigerant from being vented into the atmosphere.
Unit 1 1-2-21 Air Conditioning Fundamentals
Lesson 2

Fig. 1.2.20

Moisture indicator

Shown is the moisture indicator. The moisture indicator is located in

the line between the receiver-dryer and the expansion valve. The
moisture indicator measures the relative moisture in the system. A
moisture reference color chart is on the face of the indicator. The
color blue represents a dry system and the color pink represents a wet
system.
The moisture indicator should be checked at the end of each shift. To
check the moisture indicator, look at the indicator ring (2) through the
sight glass (1). If indicator ring is blue in color, the system is dry. If
indicator ring is pink in color, the system has moisture. The moisture
must be removed and the receiver-dryer must be changed.
NOTES
Unit 1 -1- Air Conditioning Fundamentals
Student Copy Lab 1.2.1

Student Copy: Lab 1.2.1

LAB 1.2.1
TRAINER START-UP
Tools and Materials:
Caterpillar Air Conditioning Trainer (Orifice Tube)
NOTE: The following cautions should ALWAYS be followed when working with any part of the
refrigeration system.
CAUTION:
For personal protection, goggles should be worn and a clean cloth wrapped around fittings valves and
Connections when doing work that includes opening the refrigeration system. If Refrigerant R-134a
comes in contact with any part of the body, severe frostbite and personal injury can result. The
exposed area should be flushed immediately with cold water and prompt medical help should be
obtained.
PROCEDURE:
1. List the components on the Air Conditioning Trainer that are actual vehicle A/C components.

START-UP:
Plug the A/C trainer into the 220 volt outlet
Turn the Master Switch ON
Turn the Key Switch ON
Turn the A/C Evaporator Power Switch ON
Turn the Condenser Fans ON
Turn the A/C Evaporator Unit ON
Turn the Temperature Control to Maximum Position
Turn the Blower Motor Speed Control HIGH

Allow the system to operate for 1 Minute

Unit 1 -2- Air Conditioning Fundamentals
Student Copy Lab 1.2.1

LAB 1.2.1
TRAINER START-UP (continued)
2. What do you notice about the temperature of the air being discharged from the vents?

3. What do you notice about the blower motor speed?

SHUT-DOWN:
Turn the Temperature Control to Minimum Position
Turn the A/C Evaporator Unit OFF
Turn the Condenser Fans OFF
Turn the A/C Evaporator Power Switch OFF
Turn the Key Switch OFF
Turn the Master Switch OFF
Unplug the trainer from the 220 volt outlet

CONCLUSION:
The Air Conditioning Trainer contains the same components that are used on the equipment. These
components provide the student with "real world" operation and diagnostic experiences. All safety
precautions associated with work around moving parts and refrigeration systems MUST be observed.
Unit 1 -1- Air Conditioning Fundamentals
Student Copy Lab 1.2.2

Student Copy: Lab 1.2.2

LAB 1.2.2: THERMOSTATIC EXPANSION VALVE
TRAINER START-UP

Tools and Materials:

Caterpillar Air Conditioning Trainer (Thermostatic Expansion Valve)

NOTE: The following cautions should ALWAYS be followed when working with any part of the
refrigeration system.

CAUTION:
For personal protection, goggles should be worn and a clean cloth wrapped around fittings valves and
Connections when doing work that includes opening the refrigeration system. If Refrigerant R-134a
comes in contact with any part of the body, severe frostbite and personal injury can result. The
exposed area should be flushed immediately with cold water and prompt medical help should be
obtained.

PROCEDURE:
1. List the components on the Air Conditioning Trainer that are actual vehicle A/C components.

START-UP:
Plug the A/C trainer into the 220 volt outlet
Turn the Master Switch ON
Turn the Key Switch ON
Turn the A/C Evaporator Power Switch ON
Turn the Condenser Fans ON
Turn the A/C Evaporator Unit ON
Turn the Temperature Control to Maximum Position
Turn the Blower Motor Speed Control HIGH
Allow the system to operate for 1 Minute
Unit 1 -2- Air Conditioning Fundamentals
Student Copy Lab 1.2.2

LAB 1.2.2: THERMOSTATIC EXPANSION VALVE

TRAINER START-UP (continued)

2. What do you notice about the temperature of the air being discharged from the vents?

3. What do you notice about the blower motor speed?

SHUT-DOWN:

Turn the Temperature Control to Minimum Position

Turn the A/C Evaporator Unit OFF
Turn the Condenser Fans OFF
Turn the A/C Evaporator Power Switch OFF
Turn the Key Switch OFF
Turn the Master Switch OFF
Unplug the trainer from the 220 volt outlet

CONCLUSION:

The Air Conditioning Trainer contains the same components that are used on the equipment. These
components provide the student with "real world" operation and diagnostic experiences. All safety
precautions associated with work around moving parts and refrigeration systems MUST be observed.
Unit 1 -1- Air Conditioning Fundamentals
Student Copy Lab 1.2.3

LAB 1.2.3: VISUAL INSPECTION

Tools and Materials

Student Copy Lab 1.2.3

Caterpillar Air Conditioning Trainer or Caterpillar Machine
NOTE: Read and observe the warnings listed under "Visual Inspection" in the Service Manual
(Form No. SENR5664).

PROCEDURE:
1. Check the compressor belt.
A. Belt should not be worn or frayed.
B. Pulleys should be in alignment
C. Use belt tension gauge when tighten belt
(Specifications are found in the Service Manual (Form No. SENR5664).
2. Check the evaporator for dirt and other debris that may restrict the air flow.
3. Inspect the fresh air and recirculating air filters. Clean or replace as needed.
4. Operate all duct and louver controls. Controls should move freely.
5. Check the condenser for dirt and other debris that may restrict the air flow.
6. Check the moisture indicator. If the indicator is "Pink" or "White" change the dryer.
7. Operate the blower motors at all speeds. Repair if needed.
NOTES