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HEATER & AIR CONDITIONER
SECTION
HA
CONTENTS
<COMBINED EDITION>
PRECAUTIONS
...............................................................2
Introduction ..................................................................2
Identification.................................................................2
Precautions for Working with HFC-134a (R-134a)......3
General Refrigerant Precautions .................................3
Precautions for Refrigerant Connection ......................4
Precautions for Servicing Compressor ........................5
DESCRIPTION — Overall System
.................................6
Control Operation ........................................................6
Component Layout ......................................................7
Air Flow........................................................................8
DESCRIPTION — Refrigeration System
.......................9
Refrigeration Cycle ......................................................9
PREPARATION
..............................................................10
Special Service Tools.................................................10
HFC-134a (R-134a) Service Tools and
Equipment ..................................................................11
Precautions for Service Equipment ...........................13
SERVICE PROCEDURES
.............................................15
HFC-134a (R-134a) Service Procedure ....................15
Refrigerant Lines .......................................................17
Compressor Mounting ...............................................19
Belt Tension ...............................................................19
Fast Idle Control Device (F.I.C.D.) ............................19
LUBRICATION OIL — Checking and Adjusting
........20
Lubrication Oil ............................................................20
Maintenance of Oil Quantity in Compressor .............20
Checking and Adjusting .............................................20
COMPRESSOR — Model DKV-14C (ZEXEL
make)
.............................................................................22
Compressor Clutch ....................................................22
Thermal Protector ......................................................24
DIAGNOSES — Overall System
..................................25
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................25
Operation Check........................................................26
Performance Chart ....................................................28
Performance Test Diagnoses.....................................29
TROUBLE DIAGNOSES
...............................................34
Contents.....................................................................34
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
.......58
General Specifications...............................................58
Inspection and Adjustment ........................................58
<SUPPLEMENT-I>
TROUBLE DIAGNOSES
...........................................1002
Contents.................................................................1002
<SUPPLEMENT-II>
NO CHANGES
CONTENTS
(Cont’d)
<SUPPLEMENT-III>
SERVICE PROCEDURES
.........................................3002
Refrigerant Lines ...................................................3002
TROUBLE DIAGNOSES
...........................................3004
Contents.................................................................3004
<SUPPLEMENT-IV>
(For Africa and Gulf Countries)
SERVICE PROCEDURES
.........................................4002
Refrigerant Lines ...................................................4002
Compressor Mounting ...........................................4003
Belt Tension ...........................................................4003
Fast Idle Control Device ........................................4003
LUBRICATION OIL — Checking and Adjusting
....4004
Lubrication Oil ........................................................4004
Maintenance of Oil Quantity in Compressor .........4004
Checking and Adjusting .........................................4004
COMPRESSOR — Model DKS-16H (ZEXEL
make)
.........................................................................4006
Compressor Clutch ................................................4006
DIAGNOSES — Overall System
..............................4008
Performance Chart ................................................4008
TROUBLE DIAGNOSES
...........................................4009
Contents.................................................................4009
SERVICE DATA AND SPECIFICATIONS (SDS)
......4021
General Specifications...........................................4021
Inspection and Adjustment ....................................4021
<SUPPLEMENT-V>
(For Australia)
TROUBLE DIAGNOSES
...........................................5002
Contents.................................................................5002
<SUPPLEMENT-VI>
(For Europe and Australia)
TROUBLE DIAGNOSES
...........................................6002
Circuit Diagram for Pinpoint Check .......................6002
Wiring Diagram......................................................6003
Diagnostic Procedure 2 .........................................6005
<SUPPLEMENT-VII>
(For Europe)
TROUBLE DIAGNOSES
...........................................7002
Circuit Diagram for Pinpoint Check .......................7002
Wiring Diagram......................................................7003
Diagnostic Procedure 2 .........................................7005
Electrical Components Inspection .........................7009
<SUPPLEMENT-VIII>
(For Africa and Gulf Countries)
DESCRIPTION — Overall System —
......................8002
Component Layout ................................................8002
SERVICE PROCEDURES
.........................................8003
Refrigerant Lines ...................................................8003
Compressor Mounting ...........................................8004
TROUBLE DIAGNOSES
...........................................8005
Harness Layout for A/C System............................8005
Circuit Diagram for Pinpoint Check .......................8007
Wiring Diagram......................................................8009
Diagnostic Procedure 2..........................................8011
Electrical Components Inspection .........................8016
<SUPPLEMENT-IX>
(For Europe, Africa and Gulf Countries)
DESCRIPTION — Overall System
...........................9002
Control Operation ..................................................9002
Air Flow..................................................................9003
Operation Check....................................................9004
Component Layout ................................................9006
TROUBLE DIAGNOSES
...........................................9007
Harness Layout for A/C System............................9007
Circuit Diagram for Pinpoint Check .......................9008
Wiring Diagram......................................................9013
Diagnostic Procedure 1 .........................................9018
Diagnostic Procedure 2 .........................................9020
Diagnostic Procedure 3 .........................................9025
Electrical Components Inspection .........................9026
Control Linkage Adjustment...................................9026
CONTENTS
(Cont’d)
<SUPPLEMENT-X>
(For Africa and Gulf Countries)
NO CHANGES
<SUPPLEMENT-XI>
(For Europe, TD27Ti MT models)
TROUBLE DIAGNOSES
..........................................11002
Circuit Diagram for Pinpoint Check .....................11002
Wiring Diagram ....................................................11003
<SUPPLEMENT-XII>
(For Africa, Gulf Countries and Central & South America)
TROUBLE DIAGNOSES
.........................................12002
Harness Layout for A/C System..........................12002
<SUPPLEMENT-XIII>
(For Russia, Africa and Gulf Countries)
TROUBLE DIAGNOSES
.........................................13002
Circuit Diagram for Pinpoint Check .....................13002
Wiring Diagram....................................................13004
See EL section, “POWER SUPPLY ROUTING” for power distribution circuit.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES”.
Circuit Diagram for Pinpoint Check .....................12003
Wiring Diagram....................................................12005
Diagnostic Procedure 2 (KA24E Engine Models
for Russia) ...........................................................13006
Electrical Components Inspection .......................13011
When you read wiring diagrams:
Read GI section, “HOW TO READ WIRING DIAGRAMS”.
<SUPPLEMENT-XIII>
(For Russia, Africa and Gulf Countries)
HEATER &
AIR CONDITIONER
SECTION
HA
MODIFICATION NOTICE:
CONTENTS
TROUBLE DIAGNOSES
.........................................13002
Circuit Diagram for Pinpoint Check .....................13002
Wiring Diagram....................................................13004
Diagnostic Procedure 2 (KA24E Engine Models
for Russia) ...........................................................13006
Electrical Components Inspection .......................13011
See EL section, “POWER SUPPLY ROUTING” for power distribution circuit.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES”.
Wiring Diagram has been changed.
When you read wiring diagrams:
Read GI section, “HOW TO READ WIRING DIAGRAMS”.
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