AC–15
AIR CONDITIONING – TROUBLESHOOTING
TROUBLESHOOTING
Use the table below to help you find the cause of the problem. The numbers indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts.
AC–17
AC–23
AC–51
AC–48
AC–52
AC–44
AC–43
AC–49
AC–49
AC–46
See Page
Inspect cooing system for refrigerant
Inspect A/C control lever adjustment
Blower speed control switch
Condenser fan relay No. 2
Condenser fan relay No. 3
Part Name
Inspect engine coolant volume
Radiator fan main relay
Inspect volume of refrigerant
Condenser fan motor
Condenser fan fuse
Inspect drive belt tension
Inspect outlet air control
Heater main relay
Blower resistor
Blower motor
Trouble
No blower operation
No air temperature control
No compressor operation
Compressor operates
intermittently
No condenser fan operation
No cool air comes out
Cool air comes out
intermittently
Cool air comes out only at high
engine rpm
insufficient cooling
No engine idle up when A/C
switch on
No warm air comes out
AC–16
Pressure switch
AC–45
Water temperature switch
Inspect refrigerant lines
Compressor AC–30
Magnetic clutch AC–30
Condenser AC–38
AIR CONDITIONING
Receiver AC–37
Evaporator AC–40
Expansion valve AC–40
Inspect refrigeration control
–
A/C fuse
TROUBLESHOOTING
A/C switch AC–53
Magnetic clutch relay
Pressure switch AC–45
Thermistor AC–47
A/C amplifier AC–55
Wiring and wiring connections
Vacuum switching valve (VSV )
AC–41
Heater radiator
AC–17
AIR CONDITIONING – TROUBLESHOOTING
REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE
SET
This is a method in which the trouble is located by using a manifold gauge set.
(See ”USE OF MANIFOLD GAUGE SET” on page AC–14)
Read the manifold gauge pressure when the following conditions are established:
(a) Temperature at the air inlet with the switch set at RECIRC is 30 – 35 °C (86 – 95 °F)
(b) Engine running at 1,500 rpm
(c) Blower speed control switch set at high
(d) Temperature control set at max. cool
HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature
conditions.
1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM
Gauge reading:
Low pressure side:
0.18 – 0.25 MPa (1.5 – 2.5 kgf/cm2)
High pressure side:
1.37 – 1.57 MPa (14 – 16 kgf/cm2)
AC–18
AIR CONDITIONING – TROUBLESHOOTING
2. MOISTURE PRESENT IN REFRIGERATION SYSTEM
Condition: Periodically cools and then fails to cool
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
• During operation, • Moisture entered in re- • Drier In oversaturated (1) Replace
frigeration system state receiver/drier
pressure on low ↓
pressure side freezes at expansion (2) Remove moisture in
valve orifice and • Moisture in refrigera- cycle through repeat–
sometimes be- tion
comes a vacuum temporarily stops cycle, edly evacuating air
but normal state is • system freezes at ex- (3) Charge new
and sometimes nor- pansion valve orifice
mal restored after a time when refrigerant to proper
.the ice melts and blocks circulation amount
of refrigerant
3. INSUFFICIENT REFRIGERANT
Condition: Insufficient cooling
Symptom seen in Probable cause Diagnosis Remedy
refrigeration system
• Pressure low on • Gas leakage at (1) Check for gas
• Insu ffic ient leakage with leek
both low and high some place in re-
refrigerant in detector and repair if
pressure sides frigeration system
system necessary
• Bubbles seen in
↓ (2) Charge refrigerant to
sight
• Refrigerant proper amount
glass continuously
leaking (3) If pressure indicated
• Insufficient cooling
performance value is near 0 when
connected to gauge,
create the vacuum after
inspecting and repairing
the location of the leak
AC–19
AIR CONDITIONING – TROUBLESHOOTING
4. POOR CIRCULATION OF REFRIGERANT
Condition: Insufficient cooling
Symptom seen in Probable cause Diagnosis Remedy
refrigeration system
• Pressure low on both
• Refrigerant flow ob- • Receiver clogged • Replace receiver
low and high pressure
sides structed by dirt in re-
ceiver
• Frost on tubes from
receiver to unit
5. REFRIGERANT DOES NOT CIRCULATE
Condition: Does not cool (Cools from time to time in some cases)
Symptom seen in Diagnosis Remedy
Probable cause
refrigeration system
(1) Check heat sensing
tube, expansion valve
• • Refrigerant flow ob- and EPR
Vacuum indicated on • Refrigerant does (2) Clean out dirt in
low pressure side, structed by moisture not circulate
very low pressure in- or dirt in refrigeration expansion valve by
dicated on high pres- system blowing with air
sure side • Refrigerant flow ob- If not able to remove
• Frost or dew seen on structed by gas leak- dirt, replace expansion
piping before and af- age from expansion valve
ter receiver/drier or valve heat sensing (3) Replace receiver
expansion valve tube (4) Evacuate air and
charge new refrigerant
to proper amount.
For gas leakage from
heat sensing tube,
replace expansion valve.
AC–20
AIR CONDITIONING – TROUBLESHOOTING
6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER
Condition: Insufficient Cooling
Symptom seen in
refrigeration system Probable cause Diagnosis Remedy
• Pressure too high on
both low and high • Unable to develop suffi- • Excessive refrigerant in (1) Clean condenser
pressure sides cient performance cycle → refrigerant over- (2) Check fan motor operation
• No air bubbles seen due to excessive charged (3) If (1) and (2) are in normal
through the sight refrigerant in system • Condenser cooling in- state, check amount of
glass even when the • Insufficient cooling of con- sufficient → condenser refrigerant
engine rpm is low- denser fins clogged or fan motor Charge proper amount of
ered. faulty refrigerant
7. AIR PRESENT IN REFRIGERATION SYSTEM
Condition: Insufficient Cooling
NOTE: These gauge indications are shown when the refrigeration
system has been opened and the refrigerant charged without vacuum
purging.
Symptom seen in
refrigeration system Probable cause Diagnosis Remedy
• Pressure too high on both • Air–entered in refrig- • Air present in refrigera- (1) Check compressor
low and high pressure eration system tion system oil to see if dirty or
sides • Insufficient vacuum insufficient
• The low pressure piping purging (2) Evacuate air and
is hot to the touch charge new refrigerant
• Bubbles seen in sight
glass
AC–21
AIR CONDITIONING – TROUBLESHOOTING
8. EXPANSION VALVE IMPROPERLY
MOUNTED/HEAT SENSING TUBE DEFECTIVE
(OPENS TOO WIDE)
Condition: Insufficient cooling
No41s2
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
• Pressure too high on • Trouble in expansion • Excessive refrigerant in (1) Check heat sensing tube
both low and high valve or heat sensing low pressure piping installed condition
pressure sides tube not installed correctly ↓ (2) If (1) is normal, check
• Frost or large amount • Expansion valve opened expansion valve
of dew on piping on low too wide Replace if defective
pressure side
9. DEFECTIVE COMPRESSION COMPRESSOR
Condition: Does not cool
N04146
Symptom seen in
refrigeration system Probable cause Diagnosis Remedy
• Pressure too high on • Internal leak in com- • Compression defective • Repair or replace
low pressure side pressor ↓ compressor
• Pressure too low on • Valve leaking or broken,
high pressure side sliding parts
