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Air conditioner, related to automobile buses ect
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A/S Training for Modine Bus A/CJune 2, 2009
Modine History
Windtunnel in Filderstadt2004
2001
2000
1999
1998
1993
1974
1941
1916
European Headquarters and Tech Center
Serial HT EGR-cooler worldwide
New Tech Center in Racine / USA
Sales exceed 1 billion US$
Company makes its largest acquisition, Lngerer & Reich
Sales exceed 100 million US$
Modines unique, first vehicular windtunnel
Founded by Arthur B. Modine
1926 Start of high volume production with Ford Model T
2004 Acquisition of WiniaMando ACC / Korea2005 Spin-off Aftermarket Start Transpro
Purchased balance of South America Joint Venture2006
Modine Global Network
Worldwide Headquarters &Technical CenterRacine, Wisconsin, USA
European Headquarters &Technical CenterBonlanden, Germany
Korean Headquarters &Asian Technical CenterAsan City, Korea
A/C Application : BAC, TAC & Military Item
City bus Express bus
Subway train Armored vehicle
Chunma
Bus A/C Products
Mini-Bus A/C System (Integrated and Roof Mounted)
Fully Integrated Evaporator and Condenser
Integrated Evaporator and Roof Mounted Condenser
Roof Mounted Condenser and Evaporator
Midi-Bus A/C System and Large Bus A/C Systems
Conventional Roof Mounted Bus Air Conditioner Slim Style Roof Mounted Bus Air Conditioner
New In 2007
New products- Luxury Bus A/C System
One Piece Evaporator and condenser are combined into one unit.
Two Models
Metal Frame
Fiberglass Frame
Under Development (PFC Slim type)
Weight of 15~20% lighter than Pin & Tube type Condenser
Roof-on with Separate Engine(Power pack)
Ring Fans Ring Fans
: Lower Noise
: Air Flow(5,000/Hr),High
12 Single Blower 12 Single Blower
Driven by a Separate Engine
Driven by a Separate Engine
: Hyundai D4BB (40ps/2,200 rpm)1ps = 735.5w (29.42kw)
Compressor Compressor
: MBA-58(575cc/rev)
Alternator Alternator
: DC 24Vx150A Battery less Type
MBA 260 RSN
Composition
Condenser
1. COND.MOTOR&RING FAN 2. COND.COIL 3. RECEIVER TANK 4. DRIER
MBA260RSN MBA240RN
1
1
2
2
3
3
4
Part FunctionD R I E R
The drier absorbs the harmful water inside the cooling system and also filters out the minute dust inside the system. The drier of MBA-260RSN is installed in Evaporator unit.
* The drier of MBA 240RN is installed in Condenser Unit.
When the drier is closed by some minute dust or moisture, it happens the similar symptom by throttle effect like function of Expansion valve.
Part Function
RECEIVER TANK
The Receiver tank temporarily stores the liquefied refrigerant from the Cond. Unit.
The Receiver tank has an inlet, outlet unit and a fusible plug.
When the temperature & pressure inside the liquid tank become abnormally high,
The fusible plug will be melt
Melting temperature of the fusible plug : 105
Plug
Evaporator1. EVAP.MOTOR&BLOWER 2. OPERATION PANEL 3. EXPANSION VALVE 4. TEMP. SENSOR5. EVAP. COIL 6. LOW PRESS. SENSOR 7. SOLENOID V/V 8. DRIER
MBA260RSN MBA240RN
1
1
22
3
3
4
4
5
5
6 7
8
Part Function
Low pressure switchThe Low pressure switch is installed Suction line in the Evaporator Unit.When this switch operates, open Signal sends the unloading valve(= solenoid valve) and then the Solenoid valve is operated to insertHot gas into Evaporator coil.
On 1.4 0.2kg/
Off 2.2 0.2kg/
Part Function
Part Function
EXPANSION VALVE
The Expansion v/v is installed at the evaporator inlet and changes the high pressure liquid refrigerant to a low temperature low pressure liquidby adiabatic expansion. This valve on the Evaporator outlet senses the refrigerant temperature through temperature sensor and autimatically adjusts the amount of refrigerant flowing to the evaporator.
Temperature Sensor
Part Function
SIGHT GLASS
The sight glass is installed on between expansion valve and drier.
And, This is used to check the refrigerant charge in the system and to
check the state of the refrigerant in the liquid line.
Eng. & Comp.
Part FunctionHIGH/LOW PRESSURE SWITCHThese pressure switchs are installed to the Dis. & Suc. service valve. It is a safetydevice which opreates when the refrigerant system pressure rises above thespecific pressure and drops below the specific pressure.When this switch operates, the HI/LOW PRESS alarm lamp on the control panel light on,a buzzer sounds the engine stop device operates. And the air conditioner will be stopsautomatically. The operating pressure of these high/low pressure switchs are shownin the table below.
LOW PRE. S/W
HIGH PRE. S/W
HIGH LOW28.0 1.0/15.0 0.7/
0.5 0.3/2.0 0.5/
Operating pressureResetting pressure
Operating pressureResetting pressure
Compressor
Compressor
BOLT PART TORQUEM6 SIGHT GLASS 10010 kg-
CONNECTING RODUNLOADING VALVECRANK CASE COVERBASE
M8 GLAND 30020 kg-CYLINDER HEADMAIN BEARING COVERSERVICE VALVE(SUC)
M10 OIL DRAIN PLUG 25020 kg-SERVICE VALVE(DIS) 45030 kg-
M14 OIL CHARGE PLUG 35020 kg-
15010 kg-
6-CYLINDERBOLT PART TORQUE
M6 SIGHT GLASS 10010 kg-UNLOADING VALVE 15010 kg-CRANK CASE COVERBASE
M8 GLAND 30020 kg-MAIN BEARING COVERSERVICE VALVE(SUC)CONNECTING ROD 38030 kg-
M10 OIL DRAIN PLUG 25020 kg-CYLINDER HEADSERVICE VALVE(DIS)
M14 OIL CHARGE PLUG 35020 kg-
45030 kg-
4-CYLINDER
Engine
40ps(29.42kw/2,200rpm)
Part Function
AlternatorThe alternator generate electric power during the engine operating time
and supplies electric power to the Cond.motor and the Evap.motor.
Modified Solenoid rpm control
Control PanelC O N T R O L P A N E L
- O n th e s te p s o f K e y"O N "T u rn o n th e O IL & S O U R C E lam p s .
- O n th e s te p s o f "A fte r s ta rt"T u rn o n th e B A T & S O U R C Elam p s .
Basic Circuit
Maintenance cycle
Estimated
Adjustment replacement
time or
standard number of
year
Compressor Oil level check Level check at
sight glass
Inspection Oil leakage
Overhaul 5,000hours
Piping joints Inspection Visual inspection
gas leakage for oil leakage
Inspection Leak detector
R Refrigerant Inspection No bubbles in sight
e charge glass
f Refrigerant Inspection Leakage, damage, 5years
r cylinder aging
I Condenser Cleaning Soiling
g Gas leakage Oil smears
e Inspection
r Evaporator Cleaning Soiling
a Gas leakage Oil smears
n Inspection
t Expansion valve Inspection Operation 3years
Unloading valve Inspection Operation 5years
By-pass valve Inspection Operation 5years
2years
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Maintenance cycle
Estimated
Adjustment replacement
time or
standard number of
year
s High and low Inspection Operation 5years
y pressure
s switches
t Relief valve Inspection Gas leakage 5years
e Dryer Inspection No difference 3years
m between inlet and
outlet temperature
Charge valve Inspection Gas leakage, 5years
operation
O-ring Inspection Flange gas leakage 2years
Evaporator filter Inspection, Soiling clogging
cleaning
Evap. Motor Inspection Operation 3years
Cond. Motor Inspection Operation 3years
Duct joint Inspection Deformation, aging 2years
sponge rubber
Moun- Unit sealing Inspection Deformation, aging 2years
ting rubber
Unit suspension Inspection Deformation, 2years
bolts and nuts damage, wear
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Maintenance cycle
Estimated
Adjustmentreplacement
time or
standardnumber of
year
control Selector switch Inspection Operation
Lamps Inspection Operation
Connectors Inspection Looseness
Power cable Inspection Looseness, damage
Room Inspection Operation
thermostat
Harness Inspection Damage
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Maintenance cycle
Estimated
Adjustment replacement
time or
standard number of
year
Visual inspection
for oil and fuel No leakage
leakage
Strong:1,700rpm
Medium:1,400rpm
Weak:1,100rpm
Overhaul As stipulated by
manufacturer
P Oil level gauge Visual inspection -
O Replacement According to engine
W instruction manual
E Oil filter Replacement 200Hours
R element
Fuel filter Cleaning 300Hours
U element Replacement 600Hours
N Engine coolant Inspection Level 600Hours
I Radiator hose Inspection Damage,aging 1Year
instruction manual
According to engine
200HoursEngine oil
-
-Speed check
-
Engine
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Maintenance cycle
Estimated
Adjustment replacement
time or
standard number of
year
Visual inspection
for oil and fuel No leakage
leakage
Strong:1,700rpm
Medium:1,400rpm
P Weak:1,100rpm
O Overhaul As stipulated by
W manufacturer
E Oil level gauge Visual inspection -
R Replacement According to engine
instruction manual
U Oil filter Replacement 200Hours
N element
I Fuel filter Cleaning 300Hours
T element Replacement 600Hours
Engine coolant Inspection Level 600Hours
Radiator hose Inspection Damage,aging 1Year
instruction manual
According to engine
200HoursEngine oil
-
-Speed check
-
Engine
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Maintenance cycle
Estimated
Adjustment replacement
time or
standard number of
year
Visual inspection
for oil and fuel No leakage
leakage
Strong:1,700rpm
Medium:1,400rpm
P Weak:1,100rpm
O Overhaul As stipulated by
W manufacturer
E Oil level gauge Visual inspection -
R Replacement According to engine
instruction manual
U Oil filter Replacement 200Hours
N element
I Fuel filter Cleaning 300Hours
T element Replacement 600Hours
Engine coolant Inspection Level 600Hours
Radiator hose Inspection Damage,aging 1Year
instruction manual
According to engine
200HoursEngine oil
-
-Speed check
-
Engine
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Maintenance cycle
Estimated
Adjustment replacement
time or
standard number of
year
P Tension According to engine
O Engine fan belt adjustment instruction manual
W Inspection Damage,aging -
E Alternator Inspection Operation -
R Muffler Inspection Exhaust gas leakage
Air cleaner Cleaning
U element every
N 50Hours
I Engine air
T intake hose
Oil filter joint hose Inspection Cracking,aging 2Years
Leakage
soil
Engine air
breather hose
Engine throttle When engine
valve speed dropsInspection Soil
2YearsInspection Aging
Radiator Inspection
3YearsInspection Cracking,aging
500HoursInspection Cloggy
200Hours
Daily Weekly Monthly Season
Remarks
Inspection period
Inspection Item Work contents
Trouble ShootingTrouble Probable cause Corrective cause
1.High pressure too high. 1.Air or uncondensed gas inside.2.Excessive refrigerant charge.3.Condenser air side fins clogged, or dirty.4.Condensor motor faulty.5Ambient temperature too high(poor ventilation)
6.Condenser motor fuse is disconnected.7.High pressure switch faulty.
1.Loosen liquid tank high pressure line joint and condenser inlet joint and vent uncondensed gas.
1.This operation must not be preformed while the air conditioner is operating.2.Discharge refrigerant3.Blow out with air, or wash with water4.Change the motor5.Operate in a well ventilated place.6.Change the fuse7.Inspect and replace switch.
2.High pressure too low. 1.Liquid refrigerant in intake gas from evaporator.(Liquid back)2.Expansion valve faulty.(Open state)3.Unloader valve operated.4.Unloader valve faulty.5.High pressure gauge faulty.6.Compressor discharge valve leaking7.Compressor intake strainer clogged
1.Check if temperature sensor fitted against the suction pipe.2.Inspect and replace valve.3.Set selector switch to HI position.4.Inspect and replace valve.5.Inspect and replace gauge.6.Inspect and replace compressor7.Inspect and clean strainer.
Trouble ShootingTrouble Probable cause Corrective cause
3.Low pressure too high. 1.Excessive liquid refrigerant being supplied from the expansion valve.2.Expansion valve faulty.3.Unloader valve operated.4.Unloader valve faulty.5.Low pressure intake and discharge valve leaking.
1.Check the temperature sensor is fitted against suction pipe repair, if necessary.2.Inspect and replace valve.3.Set selector switch to HI position.4.Inspect and replace valve.5.Inspect and replace gauge.6.Inspect and replace compressor
4.Low pressure too low. 1.Pipeing, drier, expansion valve, etc.Partially blocked.2.Insufficient refrigerant3.Frost on evaporator causing a drop in oil capacity.4.Compartment air intake blocked.5.Air filter closed with dust and dirty6.Dirty and dust on evaporator.7.Piping between temperature sensor and expansion valve damaged, or broken.8.Water inside system froze at expansion valve.9.Evaporator motor faulty.10.Bus compartment too cold.11Outside air temperature and compartment temperature are low.12.Expansion valve faulty.13.Low pressure switch faulty.14.Fuse is disconnected.
1.Remove and inspect parts.2.Check for gas leakage, then charge refrigerant until there are no more bubbles in sight glass.3.Inspect and replaced frosting thermostat.4.Inspectand clean intake.5.Clean air filter.6.Inspect and clean evaporator.7.Inspect and replace expansion valve8.Replace drier discharge gas from system. Remove water component with a vacuum pump, then recharge system with refrigerant.9.Change the motor.10.Switch the selector switch.11.Stop cooling.12.Inspect and replace valve.13.Inspect and replace switch.14.Cahnge the fuse.
Trouble ShootingTrouble Probable cause Corrective cause
1. Can not starting 1. Battery power not enough.2. Fuel pump has air or blocking.3. Fuse burning.4. Air cleaner/nozzle blocking.
1. Alternator/Regulator check & replace.2. Purge or replace Fuel filter assembly.3. Control & relay check replace.4.
2. Cooling is not enough 1. Gas leak or not enough.2. Motor not working. (Evap/Cond)3. Discharge air filter not clear.4. Drier has not working.
1. Check & repair recharging gas.2. Replace motor.3. Cleaning filter. 4. Replace drier.
3. Leaking problem 1. Suc. Dis hose burst.2. Comp seal leaking.3. Eng. Gasket leaking.4. Coil connecting Hose parts.
1. Replace hose.2. Seal or leak position check & replace.3. Replace gasket.4. Check & Repair.
Special checking point. 1. Filter (return air).2. Fuse & relay.3. Every Parts clearance.
Thank you
A/S Training for Modine Bus A/CModine HistoryModine Global NetworkA/C Application : BAC, TAC & Military ItemBus A/C ProductsNew productsUnder Development (PFC Slim type)Roof-on with Separate Engine (Power pack)CompositionCondenser Part FunctionPart FunctionEvaporatorPart FunctionPart FunctionPart FunctionPart FunctionEng. & Comp.Part FunctionCompressorCompressorEnginePart FunctionModified Solenoid rpm controlControl PanelBasic CircuitMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleThank you
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