Service Manual HMK 300 LC-3 - Electrical

HMK 300 LC WORKSHOP MANUAL
20
00
0
ELECTRICAL SYSTEM
 20 - 01 GENERAL
 20 - 02 SERVICE
 CIRCUIT DIAGRAM
 21 - 01 AIR CONDITION
HMK 300 LC-3 WORKSHOP MANUAL 20
ELECTRICAL SYSTEM 01
GENERAL
SAFETY PRECAUTIONS 1
WARNING
 Good ventilation is required in welding area.
 Turn off start switch before welding.
 Disconnect battery terminals and remove batteries.
 Detach electronic control unit’s cables before welding otherwise serious damage will occur on
electronic parts.
 When welding, first remove paint from the welding area. Heated paint gives off harmful gases.
 Do not weld near flammable materials such as polymers, elastomers, flammable fluids. Before
you weld components which contains flammable materials, remove them from the welding area.
 Keep handy a fire extinguisher.
START ENGINE WITH BOOSTER CABLES (JUMP START)
When starting the engine with booster cables, observe the following.
■ CAUTIONS WHEN CONNECTING/DISCONNECTING THE BOOSTER CABLES
WARNING
 When you start the engine with booster cables, wear safety goggles.
 Ensure the positive (+) terminal does not contact the negative (-) terminal when connecting the
cables.
 When starting the engine with an other machine, be careful that the normal machine does not
touch the disabled machine.
 Prevent sparks around the battery; they could cause battery gases to explode.
 Make sure that the booster cable connections are correct. The last cable is connected to the
upper structure, but connect it as far as possible from the battery. (However, do not connect to
the attachments).
 When disconnecting the booster cables from the battery, disconnect in the reverse order.
IMPORTANT
 Booster cables and clips should be sized according to the battery capacity
 Use the same capacity battery and system voltage as the disabled machine
 Do not use corroded or damaged cables and clips
 Connect the clips firmly
20 HMK 300 LC-3 WORKSHOP MANUAL
01 ELECTRICAL SYSTEM
GENERAL
2
■ CONNECTING BOOSTER CABLE
Turn the start switch to STOP position, and connect the booster cables in numbering order shown in
the figure.
1) Turn the start key of disabled machine and normal machine to STOP position.
2) Connect clip (1) of booster cable (A) to the battery positive (+) terminal of the machine to be boost
started.
3) Connect clip (2) to the battery positive (+) terminal of the engine which is running.
4) Connect clip (3) of booster cable (B) to the battery negative (-) terminal of the engine, which is
running.
5) Connect clip (4) to the upper structure of the machine to be boost started
■ STARTING THE ENGINE
1) Make sure the clips are firmly connected to battery terminals.

2) Turn the key switch of normal machine to START position, and start the engine.
3) Turn the key switch of disabled machine to START position, and start the engine. If the engine
does not start within 30 seconds, wait for 2 minutes between cranking attempts.
■ DISCONNECTING THE BOOSTER CABLES
After the engine has started, the booster cables must be disconnected in the reverse order.
1) Disconnect clip (1) of booster cable (B) from the upper structure.
2) Disconnect clip (2) from the battery negative (-) terminal of the running engine.
3) Disconnect clip (3) of booster cable (A) from the battery positive (+) terminal of the running engine.
4) Disconnect clip (4) from the battery positive (+) terminal of the machine which was boost started.
GENERAL
3
INSTRUMENT PANEL
1. “Battery charge” indicator 16. “Low/high speed travel” indicator

2. “Engine oil pressure low” indicator 17. “Power boost” indicator
3. “Air filter clogged” indicator 18. “Auto idle” indicator
5. “Locked safety lever” indicator 19. “Power mode selection” switch
6. “Buzzer” indicator 20. “Camera ON/OFF” switch (optional)
7. “Engine error” indicator 21. “Auto idle stop / auto warm up stop / exit /
8. “Fuel level” gauge NO” switch
9. “Hydraulic oil temperature” gauge 22. “Buzzer stop / scroll up” switch
10. “Engine temperature” gauge 23. “Work mode selection” switch
11. “Power mode” gauge 24. “Low / high speed selection” switch
12. “Work mode” gauge 25. “One touch idle / menu / enter / YES” switch
13. RPM display 26. “Information screen selection / scroll down”
14. “Glow plugs active” indicator switch
15. Message and Error Display Area (MED)
GENERAL
4
Functions of Instrument Panel
Switchboard consists of three parts

a. Indicator part
b. The part that displays operating functions
c. Switch part
Indicators
“Battery charge” indicator
Comes on when the voltage from the battery falls and simultaneously
displays “CHARGING ERROR” on MED.
“Engine oil pressure low” indicator.
Comes on when the engine oil pressure is below the correct level or
when the engine oil filter clogged. Simultaneously “LOW OIL
PRESSURE” displays on MED.
“Air filter clogged” indicator
Comes on when the air filter element clogged.
“Locked safety lever” indicator
Displays when safety-locking lever is pulled and locked.
“Buzzer” indicator
Buzzer alarm comes on in case of breakdown.
“Engine error” indicator
If engine failure occurs this symbol appears on instrument panel and

simultaneously error code is displayed on MED.
“Fuel level” gauge
Shows fuel level.
“Hydraulic oil temperature” gauge
1. Shows hydraulic oil temperature level.

2. Error message appears with buzzer sound on MED when
hydraulic oil temperature is higher than desired temperature.
GENERAL
“Engine temperature” gauge 5
1. Shows engine coolant temperature level.

2. “HIGH TEMPERATURE” message appears with buzzer sound
on MED when coolant temperature is higher than desired level.
3. “LOW WATER LEVEL” message appears with buzzer sound on
MED water level in reservoir tank is lower than desired level.
WARNING
Cooling water becomes extremely hot after the engine is run for some time. Do not open the cap
until the radiator cools down. Turn the cap slowly to release the inner pressure and then open the
cap.
“Power mode” gauge

Shows which power mode is selected. The machine has four different
power modes.
F (Fine Mode): For fine control operations. Operator uses this mode
when the load is to be positioned accurately and with controlled
movements.
E (Economy Mode): For light digging and loading operations where
fuel economy is the priority.
P (Power Mode) : For general digging and loading operations where
performance is as important as fuel economy.
HP (High Power Mode) : For heavy load operations and operations
which need high speed and power. Productivity is the priority and fuel
consumption is secondary.
WARNING
Use F mode for safety while loading/unloading machine or lifting objects.
“Work mode” indicator

Shows working mode selected. Four different work modes can be set
on control panel: Digging, Trenching, Breaker, and Optional
Attachment.
RPM Display
Displays engine RPM.

“Glow plugs active” indicator
The indicator light comes ON when the glow plugs on the cylinder
heads are running. If any breakdown occurs, indicator displays with
buzzer sound.
(For detail see 12.2.2)
Message and error display area (MED)
It shows messages and errors when breakdown occurs.

(For details call authorized HIDROMEK service)
“High speed travel” indicator
Comes ON when the operator selects high speed traveling mode on the control
panel.
“Power boost” indicator
Comes ON when high power function is ON.

GENERAL
6
“Auto Idle” indicator
Comes ON when machine operates at auto idle mode.
Switches
“Power mode selection” switch
Press to browse and select between available power modes.
“Work mode selection” switch

Press to browse and select between available work modes.
“Camera ON / OFF” switch (optional)
When pressed “rear view camera” is displayed, if pressed again “arm camera”
is displayed. On third press it returns to main screen.
“Auto idle stop / Auto warm-up stop / Exit / NO” switch
1. Cancels auto idle function

2. Cancels auto warm-up by pressing 3 seconds
3. Exits actual menu and goes to upper menu when working in control system
menu mode
4. Function as “NO” button when using menu
“Low / high speed selection” switch
Switch for controlling low / high travel speed of vehicle. If high speed
is selected rabbit symbol, if low speed selected tortoise symbol is
displaced on the screen.
“One touch idle / menu / enter / YES” switch
1. Switch to return immediately to the first idle by one touch

2. Switch to enter menu when pressed for 3 seconds
3. Function as “ENTER” button on menus
4. Function as “YES” button on menus
“Buzzer stop / scroll up” switch
1. Switch to cancel buzzer.

2. Switch to browse a menu item by scrolling up in the control menu
page.
“Information screen selection / scroll down” switch
1. Switch to select information screen.

2. Switch to browse a menu item by scrolling down in the control
menu page.
GENERAL
MENU ITEMS 7
Enter the control menu by pressing menu switch for 3 seconds; menu is displayed on MED. The main
menu includes 7 sub-menus.
1. Language
Use this menu to choose your preferred language among the available options.
2. State Information
Press to see current operational parameters such as temperatures, pressures, fuel consumption,
current etc.
3. Periodic Maintenance
Hours left for the next maintenance, last maintenance hours and maintenance period can be
viewed. Additionally, maintenance hours can be updated and maintenance periods can be
changed.
4. Operating Hours
26 different types of operating hours can be registered and viewed.
5. Settings
Breaker and optional attachment flow values can be adjusted and active attachment can be
selected. Date-time, camera function, auto idle and backlight level of the screen can be adjusted.
User can assign a password and change the request period.
Seven types of setting can be done.
6. Failures
Up to 258 current and previous failures registered in the memory can be viewed.
7. Machine Information
Instrument panel and machine control unit version can be viewed.
Language
To set your preferred language, perform the

followings.
1. Select “Language” item by using item selection

switches (▲/▼).
2. Move the cursor by item selection switches

(▲/▼) to highlight the desired language.
3. When the cursor is on desired language, press

“enter” switch (►).
4. To exit from the menu, press “menu page exit”

switch (◄).
GENERAL
8
State Information
To view the state information contents follow

these steps.
1. Move the cursor (▲/▼) to find “state

information”.
2. When the cursor is on “state information”,

press “enter switch” (►).
State information menu has six pages

and every page has six different
information items. To enter each page,
select the item by SCROLL switches
(▲/▼)and press IDLE/MENU.
On page 1/6
PV-I : Instant proportional valve current

BATT.V. : Instant battery voltage
ENG.LOAD: Instant engine load by %.
FUEL-I: Instant fuel consumption.
FUEL-A: Average fuel consumption after trip.
F.TOTAL: Total fuel consumption after trip is
reset.
On page 2/6
P1: First pump pressure.

P2: Second pump pressure.
P.Eng.Oil: Engine oil pressure
T.Coolant: Coolant temperature
T.Hyd.Oil: Hydraulic oil temperature.
T.Fuel: Fuel temperature on feed pump
GENERAL
9
On page 3/6
P.Baro: Atmosphere pressure

T.In.Air: Turbocharger inlet air temperature.
T.Int.Manifold: Engine intake manifold air
temperature.
Eng.Boost: Air pressure from turbocharger to
engine
Sup.Pump.: Electromagnetic fuel supply pump
pressure
C.Rail.D.: Pressure difference on common rail.
On page 4/6
Eng.Spd.Pot.: Voltage from throttle control dial.

Travel Sw.: Shows if machine travels or not. If
travels, it indicates 1. If not, it indicates 0.
Attach.Sw.: Shows if attachments are operated
or not. If operated, it indicates 1. If not, it
indicates 0.
Op.Attach.Sw.: Shows if optional attachment
pedal (or button-located on joystick) is activated
or not. If activated, it indicates 1. If not, it
indicates 0.
On page 5/6
Preheat Relay: Shows if glow plugs relay

operates or not. If operates, it indicates 1. If not,
it indicates 0.
P.Boost Sw.: Shows if power boost switch
it indicates 0.
Hyd.Lock Sw.: Shows if safety lock lever locked
or not. If locked, it indicates 1. If not, it indicates
0.
Arm-in Sw.: Shows if left lever is pulled at least
2/3 of its stroke and arm moves inwards. If
operated, it indicates 1. If not, it indicates 0.
Boom-up Sw.: Shows if right lever is pulled at
least 2/3 of its stroke and boom moves up. If
operated, it indicates 1. If not, it indicates 0.
O.Heat Prot.: Shows over heat protection state.

If there is no over heat, it indicates 0. If over
heat function operates, it indicates 1.
GENERAL
10
On page 6/6
P.Boost Sol.: Shows power boost solenoid

operating state. If operates, it indicates 1. If not,
it indicates 0.
Op.Attach.Enab.: Shows if optional attachment
is activated from the instrument panel or not. If
activated, it indicates 1. If not, it indicates 0.
Travel Sol.: Shows if travel solenoid operates or
not. If operates, it indicates 1. If not, it indicates
0.
A.Conflux Sol.: Shows if arm conflux solenoid
it indicates 0.
B.Conflux Sol.: Shows if boom conflux solenoid
it indicates 0.
GENERAL
11
Periodic Maintenance
Periodic maintenance menu covers various maintenance issues that differ according to the type of the
machine. Operator can register any maintenance activity that he performed and update the control
menu. If it is not updated, machine will buzz and update message will display on MED. To view and
update periodic maintenance, follow steps.
1. Select “Periodic Maintenance“ item by

using up or down scroll switches (▲/▼).
2. Press “enter” switch (►) to enter.
3. When you enter periodic maintenance

menu, periodic maintenance list will be
displayed on MED.
4. Move cursor (▲/▼) to find the desired

periodic maintenance item according to
the maintenance type on your machine.
5. Press “enter” switch (►) to enter

maintenance type.
6. When *PERIODIC MAINTENANCE

TIME UPDATE* is highlighted and
IDLE/MENU (►) switch is pressed, the
operator will be asked on MED to
approve if “new maintenance is
completed”.
GENERAL
12
7. Press “YES” (►), to update the

maintenance time. If it is not wanted to
update, press “NO” (◄).
Before 20 hours to the periodic maintenance, a notification message is displayed on the screen. And a
wrench symbol comes on the top of the screen. After maintenance period ends, the system continues
displaying the message for another 50 hours. After only the wrench symbol is displayed.
In the periodic maintenance list, oncoming, current and elapsed maintenances are displayed with
different colors.
GENERAL
13
Operating Hours
The following Operating Hours can be selected on the control panel. Only trip hours can be changed,
others are not adjustable.
TRIP 00:00:00 STARTER ON HOURS 00:00:00

WORKING HOURS 00:00:00 LOW IDLE HOURS 00:00:00
TRAVEL HOURS 00:00:00 1000-1099 RPM HRS 00:00:00
ATTACHMENT HOURS 00:00:00 1100-1199 RPM HRS 00:00:00
BREAKER HOURS 00:00:00 1200-1299 RPM HRS 00:00:00
OP. ATTACH.-2 HRS 00:00:00 1300-1399 RPM HRS 00:00:00
DIGGING HOURS 00:00:00 1400-1499 RPM HRS 00:00:00
TRENCHING HOURS. 00:00:00 1500-1599 RPM HRS 00:00:00
MODE-E HOURS 00:00:00 1600-1699 RPM HRS 00:00:00
MODE-P HOURS 00:00:00 1700-1799 RPM HRS 00:00:00
MODE-HP HOURS 00:00:00 1800-1899 RPM HRS 00:00:00
MODE-F HOURS 00:00:00 1900-1999 RPM HRS 00:00:00
MANUAL MODE HOURS 00:00:00 2000-… RPM HRS 00:00:00
To view operating hours items, follow the steps.
1. Enter the menu by pressing the menu

switch (►) for three seconds.
2. Move cursor (▲/▼)to select the “operating

hours” menu and press IDLE/MENU (►) to
enter.
3. Move cursor (▲/▼) to select the desired

operating hour item.
4. To exit the menu, press “menu page exit”

switch (◄).
GENERAL
14
Resetting the Trip Hour
The trip hour function counts the operating hours

starting from a pre-set point of time. The trip hour
can be reset by the operator. To reset the trip
hour do the following steps.
1. Turn the starter key to “ON” position.

2. Wait until “READY” message is displayed in
the screen.
3. Press “information screen selection switch”
to view the trip hour.
4. To reset “users hour” press “information

screen selection switch” continuously.
5. Press the “information screen selection

switch” twice to exit the page.
Fuel Economy
While main screen is displayed, press information
button twice to see fuel economy screen.

Fuel consumption can be followed and optimal
operation can be experienced.
GENERAL
15
Settings
The “SETTINGS” menu under the main menu

allows the operator to set seven different
functions.
 Optional Attachments
 Date-time
 Rear View Camera
 Arm View Camera
 Auto Idle Times
 Display backlight level
 Password
Optional Attachments
See “Hydraulic Breaker” and “Optional
Attachment 2” section in chapter “Working
Equipment and Optional Attachments”.
Date-Time Setting
1. Select “Settings” item and enter (►) key to

set date-time. Move cursor (▲/▼) to find
“date-time” and enter (►) to set the correct
date and time.
2. When the cursor is on desired item, enter

(►) to set.
GENERAL
16
3. To change the number use item selection
switch (▲/▼).
4. When the item is updated, press exit switch

(◄) to approve the updated number.
Turning the Camera ON (Optional)
Camera is optional for this machine. Perform the

following steps to start the camera if equipped.
1. Enter settings (►) from control menu and

move (▲/▼)cursor to select “rear view
camera” or “arm view camera” as
appropriate. When the cursor is on desired
item, enter (►) item for settings.
2. To start the “Rear View Camera” or “Arm

View Camera” select “CAMERA
OPERATION” and enter (►).
3. Select “ON” and enter (►) to operate the

camera.
4. Press EXIT key (◄) to approve your choice.

GENERAL
17
When AUTOMATIC TRAVEL CAMERA is
activated, the camera view of camera is
displayed on the screen only when the machine
is in travel mode. Camera view is not displayed
on the screen during digging operation.
5. To operate “AUTOMATIC TRAVEL

CAMERA”, move (▲/▼) cursor and enter
(►) the item.
6. Move (▲/▼)cursor to “ON” and enter (►) to

activate “AUTOMATIC TRAVEL CAMERA”.
Auto-Idle Times Settings
For the AUTO IDLE TIMES function to take

effect, AUTO IDLE must be activated. To
activate or deactivate auto idle “press AUTO
IDLE STOP” switch . When auto idle is
activated, auto idle symbol will be

indicated on the left-bottom part of the
instrument panel. Do the following steps to set
auto idle times.
1. Enter “SETTINGS” sub-menu from the

main menu. Move (▲/▼)cursor to select
“AUTO-IDLE TIMES” and enter (►)to view
preset time levels.
GENERAL
18
2. There are two preset time levels.

Auto-Idle time is set to allow operator a time
before the engine speed is decreased to IDLE
speed during when the attachments are not
controlled.
LEVEL-1 TIME: AUTO-IDLE time can be set at

any value between 3 seconds to 30 seconds.
LEVEL-2 TIME: AUTO-IDLE time can be set at

any value between 20 seconds to 250 seconds.
3. Select “LEVEL-1 TIME” or “LEVEL-2 TIME”

by pressing “enter switch” (►).
4. Press “UP” switch to increase (▲) and

press “DOWN” switch (▼) to decrease auto
idle time.
5. To approve the desired time value press

“exit switch” (◄).
Display Backlight Level
1. To increase the backlight level of the screen

press (▲) button and to decrease the backlight
level press (▼) button.
GENERAL
Password 19
There is a password security system in your machine

against unauthorized start of engine.
1. Password request
If you want to turn the password protection on you
must set a value on this menu. You will be prompted
to enter your password in order to start the engine.
Prompting will be according to the period you have
selected from this menu. Select one of the periods
below.
 NEVER
 ALWAYS
 EVERY 1 HOUR
 EVERY 12 HOURS
 EVERY 24 HOURS
2. Change Password
After entering the change password menu you will be
asked for the current password of your machine.
Factory default of the password is “0 0 0 0”.
Enter your password by selecting the digits by
pressing up (▲) and down (▼) buttons.
Press “Enter” button after entering every digit.

After entering current password you will be asked for
a new password.
Enter a new password in the same way and you will
be prompted to enter the password again for
verification. Enter the password again correctly and
your new password is set.
GENERAL
20
Failures
Previously registered failures can be viewed by

entering “FAILURES” sub-menu. Instrument
panel can save 258 failures in its memory. To
view previous failures enter menu and follow the
below steps.
1. Move (▲/▼)cursor to select “FAILURES”

and enter (►) to view.
2. Failure codes are displayed the left hand

side of the screen and error times are
displayed on the right hand side of the
screen.
3. Highlight the error code you are interested

in and enter (►)to view description of the
error.
4. To exit the page, press “EXIT” switch (◄).

GENERAL
21
Machine Information
“MACHINE INFORMATION” menu includes;
 Display Unit Software Version

Information about instrument panel
software version, machine type, engine
type, and instrument panel type
 Machine Control Unit (MCU) Version

Information about MCU version, machine
type, engine type, and MCU type
To view machine information, enter (►) menu

and follow steps.
1. Move (▲/▼) cursor to the desired

information item and enter (►) to view.
2. To exit the page press “exit switch” (◄).

GENERAL
22
START SWITCH
This switch is used to start, run or stop the engine.
 "OFF" position
The start switch key can only be inserted or pulled out in
the OFF position. The electric circuit to the system is cut-
off.
 "ON" position
The electric circuit to the engine is ON. Leave the key in
this position after starting. The electrical system is ON and
accessories such as interior lamp, fuel filler pump, cigar
lighter, car stereo are functional but engine stops.
 "START" position
Used to start the engine. Release the key immediately
after starting. The key returns to "ON" position.
THROTTLE CONTROL DIAL
Throttle control dial is placed on right console.
Dial controls the engine speed manually. Turn in plus (+)

direction to increase the engine speed; turn in opposite
direction to reduce the speed.
(+) High idle

(- ) Low idle
WARNING
Do not suddenly shut off the engine when operating at
high speed. First, rotate dial to low speed to allow the
engine and turbocharger speeds to stabilize, and then
shut it off.
GENERAL
SWITCHES 23
1. Low beam switch

2. Working lamp switch
3. Wiper motor switch
4. Washer pump switch
5. Engine emergency stop switch
Low beam switch
Switch for low beam.
Working lamp switch
Switch for lighting working lamp.
Wiper motor switch
Switch for operating wiper motor.
Washer pump switch
Switch for ejecting the window washer liquid.
Engine emergency stop switch
Use this switch if the engine can not be shut and only in case of an
emergency situation to stop the engine immediately.
LIGHTER
Press it down, and in a few seconds it will return to the original
position. At this moment, it is ready to use.
GENERAL
24
FUSE BOX
Fuses are equipped to protect the electric system from an electrical overload.
IMPORTANT
 When replacing the fuses, make sure to turn the start key to “stop” (OFF) position.
 When replacing fuses, ensure that they are at the same capacity.
 Replacement method
- Open the cover of the fuse box.
- Remove the burnt fuse using a fuse holder tool.
- Install a new fuse with same capacity as the burnt one.
 Placement of fuses and relays are shown in figures below.
Fuse box placement rev 00

GENERAL
25
Fuse box placement rev 01 : counter weight changed, swing lamb relay and fuse removed. Starter
relay’s, battery relay’s and breaker relay’s places are changed.
GENERAL
26
BATTERY RELAY
Battery relay is located under the air filter. When

the operator stops the engine it will
automatically cut off the circuit after 7-8 seconds
and an audio warning will be heard.
It will automatically cut the power off in case of

an electrical short circuit or overload. This will
prevent the electric wiring and components from
burning or damage.
SERVICE
1
CONTROL PANEL FAULT & TROUBLE MESSAGES
ERROR CODE DESCRIPTION TEXT

50 ALTERNATOR CHARGE FAILURE
51 LOW ENGINE OIL PRESSURE
52 ENGINE OVER-TEMPERATURE
53 AIR FILTER CLOGGED!
60 LOW COOLANT WATER LEVEL!
72 FUEL FILTERS CLOGGED (1) !!
73 FUEL FILTERS CLOGGED (2) !!
12 PV FAILURE !!
14 TS VALVE FAILURE!!
15 PB VALVE FAILURE!!
16 A-CONFLUX FAILURE!!
17 B-CONFLUX FAILURE!!
26 CRUISE VALVE FAILURE!!
27 TRANSMISSION PRESSURE LOW !!
74 HIGH ENGINE BOOST TEMPR. !!
75 HIGH FUEL TEMPERATURE !!
29 LOW BRAKE PRESSURE !!
30 CAN-BUS FAILURE!!
31 FOOT ACCELERATOR PEDAL FAILURE
32 P1 PUMP PRES. SENSOR FAILURE(1)
33 P2 PUMP PRES. SENSOR FAILURE (1)
34 SPEED POTENTIOMETER FAILURE!
35 STEP MOTOR FAILURE
36 ENGINE OIL FILTER CLOGGED!
18 TRENCHING VALVE FAILURE
54 HYDRAULIC OVER-TEMPERATURE
61 ALTERNATOR HIGH CHARGE LEVEL !
37 ATTACHMENT PRESSURE SW. FAIL.
38 TRAVEL PRESSURE SW. FAILURE
39 BOM-UP PRESSURE SW. FAILURE
40 ARM-IN PRESSURE SW. FAILURE
41 T. SWING PRESSURE SW. FAILURE
44 HYD.OIL TEMPERATURE SEN. FAIL.(1)
46 ENGINE TEMPERATURE SENS.FAIL.(1)
45 HYD.OIL TEMPERATURE SEN. FAIL.(2)
46 ENGINE TEMPERATURE SENS.FAIL.(2)
SERVICE
2
TROUBLESHOOTING
FAULT PROBABLE CAUSE REMEDY
 Terminal segregation or wire

 Inspection, replace
The lamp fades out or disconnection
blinks even though
the engine is operated  Loose belt tension  Adjust
The battery recharge  Alternator trouble  Inspection, replace

warning lamp doesn’t
work  Wire disconnection  Inspection, replace
The alternator
generates an  Alternator trouble  Replace
abnormal sound
 Wire disconnection  Replace

Starting motor
doesn’t work while  Battery discharge  Recharge
the key ON
 Starting motor trouble  Replace
The pinion of starting
motor is projected or  Battery discharge  Recharge
not
 Battery discharge  Recharge

The starting motor
can’t start the engine
 Starting motor trouble  Replace
The starting motor is  Wire problem  Inspection, replace

stopped before the
engine is started  Battery discharge  Recharge
 Monitor trouble  Replace

Engine oil pressure
warning lamp doesn’t
light up when engine  Wire disconnection  Inspection, replace
is stopped
 Pressure switch trouble  Replace
Battery recharge
warning lamp does  Monitor trouble  Replace
not light up when
engine is stopped.  Wire problem  Inspection, replace
(Key is ON)
SERVICE
3
MAIN HARNESS Rev 00

SERVICE
4
MAIN HARNESS Rev 01

SERVICE
5
ENGINE HARNESS
SERVICE
6
CABIN HARNESS
SERVICE
7
PARTS OF CONTROL PANEL
1 Back Lid
2 Control panel circuit board
3 Screen holder
4 Screen holder (back)
5 Screen
6 Front Lid
7 Keypad
8 Screen holder (front)
9 Seal
SERVICE
8
Harness side
Tyco Electronics
C-0206037-01-3
1 Fuel level sensor

2 Engine temperature sensor (Tier 2)
3 Alternator charging equipment
4 -----
5 Can-L
6 Can-H
7 Manual mode signal (+)
8 Alternator rpm signal (+) (Tier 2)
9 Chassis (-)
10 Overload warning sensor (-) (Optional)
11 Engine diagnostics lamp (-) (Tier 3)
12 ----
13 Engine oil pressure switch (-) (Tier 2)
14 Engine diagnostics lamp-2 (Tier 3–Tier 2)
15 Hydraulic temperature sensor
16 (+) 24 V (5 Amper Fuse)
SERVICE
9
HARNESS SIDE
TYCO ELECTRONICS
C-0968879-11-3
NO EXPLANATION NO EXPLANATION NO EXPLANATION

1 --- 24 --- 48 ---
Transmission pressure switch (-) IN
2 ‘P/V valve’ OUT 25 --- 49 (W excavator)
3 --- 26 Cruise switch (-) IN (W exc) 50 ---
Forward direction Brake 1.5 bar (-) IN
4 selection(+) (W exc)
27 (W exc)
51 ---
Reverse direction selection (+) (W
5 ‘P/V valve’ return 28 exc)
52 ---
6 Manual sw manual part 29 Breaker pedal (-) IN 53 Attachment pressure switch (-) IN
Travel pressure switch (-) IN (LC
7 Travel speed valve OUT 30 exc)
54 ---
8 Cruise valve out (W exc) 31 Brake2 40 bar (-) IN (W exc) 55 ---

Manual sw auto part (+) 24 V
9 feed
32 --- 56 ---
B Conflux, trenching valve
10 OUT
33 --- 57 Speed sensor1–B
11 A Conflux OUT 34 Speed sensor1-A 58 Pump pressure sensor, GND
12 --- 35 Pump2 pressure sensor 59 Pump pressure sensor, (+) 5V feed
13 Power boost valve OUT 36 --- 60 ---
14 Breaker valve OUT 37 Air filter clogged switch (-) IN 61 Coolant level switch (-) IN
15 (+) 24V feed (15 Amper fuse) 38 Hydraulic safety lock lever (+) IN 62 Preheat (+) IN
Brake pressure low switch (-) IN (W Mode switch travel position (+) (W
16 --- 39 exc)
63 exc)
Mode switch work and travel nd
17 --- 40 position (+) IN (W exc)
64 2 gear selection (W exc)
18 --- 41 --- 65 Arm-in pressure switc (-) IN
19 14 ton selection valve 42 Fuel filter clogged sensor 66 Swing speed increase (-) IN
20 Buzzer OUT 43 Engine oil filter clogged sensor 67 Boom-up pressure switch (-) IN
Engine speed control dial
21 warning
44 Pump1 pressure sensor 68 Throttle pedal warning (W exc)
22 (+) 24 V feed 45 --- 69 CanH optional line resistance
23 Chassis (-) feed 46 CanL optional line resistance 70 ---

AIR CONDITIONER
1
1. The Definition of Air Conditioning
In general, air conditioner is an apparatus, used for controlling the temperature and humidity of an
enclosed area in order to get the most comfortable air for humans and to maintain the temperature to
required needs for objects. To that end, the following requirements should be properly accomplished.
(1) Dry-bulb temperature and its distribution(temperature)
(2) Air humidity and its distribution(humidity)
(3) Air flow(air current)
(4) Air freshness(cleanness)
If any of the following requirements is not properly accomplished, the original purpose can not be
achieved.
Air conditioning falls into two categories depending on its serving subject: comfort air conditioning and
industrial air conditioning. Comfort air conditioning means air conditioning in houses, offices,
department stores, theaters and a variety of buses and cars and industrial air conditioning means air
conditioning aimed at maintaining the temperature suitable for production and preservation of products
in textile mills, confectionary plants and each refrigerator car.
2. The Structure of Air Conditioning System

The air conditioning system basically consists of 4 main parts in accordance with the refrigerant
operation.
(1) Compressor :
The compressor is a belt driven pump that is fastened to the engine. It is responsible for compressing
refrigerant gas of low pressure and low temperature as high pressure and high temperature gas and
transferring the gas to the condenser.
• Magnetic clutch is mounted to control the compressor.
(2) Condenser :
The condenser is located in front of the vehicle. As hot compressed gasses are introduced into the
condenser, they are cooled off. As the gas cools, it condenses as a high pressure and high
temperature liquid.
• Hot compressed gasses transferred from the compressor are cooled off and condensed in this
condenser.
(3) Expansion valve :
The expansion valve is very efficient at regulating refrigerant flow to the evaporator. As high pressure
refrigerant is passing through this valve, it rapidly becomes low temperature and low pressure wet
vapor.
(4) Evaporator :
Misty refrigerant enters the evaporator as a low pressure liquid. The warm air passing through the
evaporator fins caused the refrigerant to boil. As the refrigerant begins to boil, it can absorb large
amount of heat.
(The surrounding environment is cooled off.)
AIR CONDITIONER
2
3. Cooling Cycle
1. Compressor 7. Expansion valve

2. Compressor pulley and electromagnetic clutch 8. Duct sensor
3. Condenser 9. Low pressure line
4. Dryer 10. High pressure line
5. Pressure switch 11. Electro motor fan
6. Evaporator 12. Motor fan
Refrigerant circulates through the closed-circuit system and its components. Refrigerant repeats this
kind of circulation and it is referred to as “Cooling Cycle.” What happens in the refrigerant circulation in
the cycle is related to changing pressure and temperature as the refrigerant becomes a gas and is
condensed as a liquid back.
The cooling system is based on a few unchanged physical principles.
These principles are discussed in the section concerning what is happening to refrigerant when the
cooling system is in operation.
Refrigerant gas is drawn into the intake side of the compressor and compressed and discharged as
high temperature and high pressure gas. The compressed gas is sent to the condenser and then
cooled off by the cooling fan. As the gas cools, it condenses because its latent heat is absorbed by the
air traveling through the condenser. The condensed refrigerant is sent to the receiver-drier and the
receiver-drier removes moisture and filters out dirt. Then the refrigerant is introduced into the
expansion valve.
The high pressure liquid refrigerant rapidly expands in the valve and becomes low temperature and
low pressure misty refrigerant. Then it goes to the evaporator.
AIR CONDITIONER
3
The misty refrigerant enters the evaporator and absorbs latent heat of vaporization from the air
introduced through the blower, providing cooling. At the same time, it becomes from misty state to
gaseous state and drawn into the compressor again.
As mentioned above, the refrigerant repeatedly circulates in the cooling cycle providing cooling.
In general, the gas needs to be compressed to become liquid. But it becomes easier by cooling off at
the same time while compressing. Therefore, both the compressor and the condenser are needed for
the car air conditioner.
4. Refrigerant
A refrigerant is a substance used to provide cooling. It absorbs and radiates heat while circling in the
closed-circuit cooling cycle.
4-1) Characteristics of Refrigerant
There are various types of refrigerant. In the cooling system, mainly R-12(CFC:Chloro Fluoro
Carbon)was used. But its use has been regulated since it was proved that Freon gas results in
damage of ozone layer. Consequently, new refrigerant R-134a(HFC) has been used.
4-2) Characteristics of R-134a(Hydro Fluoro Carbon)
(1) Merits
① Alternative refrigerant to R-12, containing no chlorine causing damage of Ozone layer.
② Chemically safe
③ Thermal properties most similar to R-12
④ Incombustibility and no toxicity
(2) Demerits
① low refrigeration capacity at the same condensation temperature as R-12
(To get the same refrigerating capacity of R-12, the condensation temperature should be lowered.)
② Change of refrigeration oil due to the insolubility of R-12 refrigeration oil
③ Problems concerning absorptiveness of R-134a refrigeration oil and change of Rubber quality
④ Problems concerning moisture permeability of R-12 Freon hose(Nitrile)
4-3) Flammable HC(Hydrocarbon) refrigerants
(1) Use depending on its type
① R-290(Propane), R-1270(Propylene)
• Applied to most heat pumps for heating and residential home in some countries in Europe
② R-600(Butane), R-600a(isobutane)
• Mainly used for household refrigerators
• The Auto-Ignition Temperature of 460℃ and very small refrigerant charge
(2) Characteristics
① GWP, Global Warming Potential(3) and ODP, Ozone Depletion Potential(0)
② It is inexpensive and only a small quantity can work.
③ Easy to use (well mixed with mineral lubricant)
④ Flammable and non-toxic
(3) The regulation of hydrocarbon refrigerants
① Europe
• CEN Standard EN 378 (specifies safety and surrounding conditions for refrigerators and heat pump
systems)
- Among the systems providing comfort, it is banned from applying to the direct systems (household air
conditioners and car air conditioners).
• Specified in German standard DIN 7003 and NPR 7600 of the Netherlands.
- Hydrocarbon refrigerant is applied on a limited basis depending on the room size and the number of
residents.
② The United States
• ANSI/ASHRAE Standard 15
- Flammable refrigerants (refrigerants classified as A3) are banned from using for high-risk systems
(namely direct system).
AIR CONDITIONER
4
③ IEC(International Electrotechnical Commission) Publication
• Specifies the quantity of flammable refrigerants which is able to make 335-2-40 - 130㎥ room
flammable
(4) Possibility of being used as substitutes for R-134a

① Hydrocarbon refrigerants work similarly to R-134a, but if they are used for a long period, a leak from
hoses or the Fitting part is expected due to different components of refrigeration oil.
② The use of two kinds of hydrocarbon blends can raise the possibility of explosion
(Hydrocarbon blends for car air conditioning systems in the market all use more than two kinds of
refrigerants.)
③ If air is drawn into imperfect vacuum conditions by a system leak, the possibility of explosion will be
raised.
④ A systematic review is needed for the potential flame sources due to metal spark in the rotating part of
the compressor and other safety devices.
⑤ When mixed with R-134a, hydrocarbon refrigerants aren’t recyclable.
⑥ For hydrocarbon refrigerants, concentration is more important than the absolute quantity of refrigerant.
Even with a very small quantity, if hydrocarbon blends reach the combustion concentration, there can
be an explosion.
(5) Substitutes for R-134a

① The Kyoto Protocol
• Industrialized nations who sign up to the treaty are legally bound to reduce worldwide emissions by
an average of 5.2% below their 1990 levels by the period 2008-2012.
• HFC refrigerant(R-134a) should be also reduced in accordance with the treaty.
② Decision by the European parliament
• The use of HC refrigerants will be prohibited for new car air conditioning systems beginning in 2011
and for all kinds of automobiles in 2017.
• Pursuing a system change to CO2(BMW is expected to mass-produce in 2008.)
③ R-152a: under consideration for North America OEM
AIR CONDITIONER
5
5. Components of the Air Conditioning System

5-1) COMPRESSOR
The compressor is responsible for raising pressure of refrigerant gas, namely for compressing it.
Refrigerant is circulated in the cycle due to this compressor. When compared to the human body,
refrigerant can be referred to as the blood and the compressor can be referred to as the heart.
(1) The Functions of COMPRESSOR
Specifically speaking, the intake side of the compressor draws in low pressure refrigerant gas from the
outlet of the evaporator. Once the refrigerant is drawn into the intake side, it is compressed and sent to
the condenser. Therefore, the refrigerant can be circulated in the cycle and the heat drawn from the
inside of the vehicle in the evaporator is sent to the condenser by the compressor and radiates heat to
the air passing through the condenser.
① Sucking:
The compressor lowers the refrigerant pressure in the evaporator so that liquid refrigerant can
evaporate at low temperature.
② Compressing:
The compressor compresses the evaporated refrigerant and sends it to the condenser where it can
condense at normal temperature.
③ Pumping:
The refrigerant can be circulated due to the above-mentioned sucking and compressing functions and
a consecutive work cycle is formed.
(2) Compressor Inspection

① Inspection for clutch operation
※ Connect the battery(+) terminal to the compressor side terminal and earth the battery(-) terminal
to the compressor Body.
If it is in normal condition, you can hear the “click” sound from the magnetic clutch.
② Inspection for the clutch AIR-GAP

Air-gap gauge
※ Inspect whether the clutch air-gap is a required value.

AIR CONDITIONER
6
(3) Causes for faulty compressor

① Insufficient lubrication due to a lack of refrigerant(low refrigerant charge, refrigerant leak)
The oil in the A/C System provides the lubrication by being sprayed on compressor’s working part
(Swash plate &Piston) in misty condition while circulating with the refrigerant. If there is a lack of
refrigerant, the oil amount drawn into the compressor also decreases, diminishing the lubrication and
lowering air conditioning performance at the same time. Then, the intake temperature goes up to
create abnormal superheat. Consequently, early damage to the operating friction part can result in,
thus causing stick occurring.
• If the air conditioning capacity is lowered, you need to instantly inspect the refrigerant amount and
recharge it.
• In the winter time when the air conditioner is not in use, operate it periodically(one time in two weeks)
at an idle condition to enhance the circulation of the refrigerant and the oil.
② Liquid compression due to the inflow of liquid refrigerant

Liquid compression by overcharge of refrigerant and the unevaporated liquid refrigerant introduced
into the compressor causes overload to the compressor’s working part, resulting in compressor
damage and stick of disk slip occurrence.
When the A/C system is turned on at high-speed after it is mounted to the vehicle, the simultaneous
outflow of the oil in the compressor occurs and low-pressure liquid refrigerant is drawn into the
compressor, wiping out the oil on the friction surface of the working part. Thus, the compressor is
operated under unlubricated condition before the compressor oil circulates, resulting in a stick.
A lack of lubrication due to the clogged refrigerant circuit

Moisture can exist in the remaining air of the system due to poor vacuum level before refrigerant
charging. It can result in expansion valve icing, causing instant circuit clogging. Thus, the compressor
is operated under unlubricated condition, resulting in a stick and a lack of lubrication.
• For moisture inflow vehicle, sufficient vacuum work(for more than 30 minutes) should be done after a
recovery of refrigerant in order to remove the moisture in the system.
Phase separation and migration of the compressor oil

The refrigerant and the oil are separated and oil is migrated by the outdoor temperature deviation
because of the nature of the new refrigerant(R-134a) if the system is transported or neglected for a
long time. Therefore, at the initial stage of the A/C operation, only the refrigerant is drawn into the
compressor, diminishing the lubrication.
• Pre-running is required with the A/C system on at an idle condition in initial days of the A/C season
after winter or for export car port.
AIR CONDITIONER
7
(4) Compressor Structure
Section manifold
Discharge
manifold
O-Ring
Pulley clutch connector
Pulley and bearing assembly
Disk and hub
spacer
Compressor
Field coil
Pulley snap-ring
AIR CONDITIONER
8
(5) Refrigeration Oil

Refrigeration oil is charged to provide the lubrication of the compressor which pressurizes the
refrigerant.
But only specified amount should be charged since the characteristics of the old and the new
refrigerants differ as follows and air conditioning performance also varies depending on the refrigerant
charge amount.
Classification Mineral Oil PAG Oil
Applied refrigerant R-12(CFC) R-134a(HFC)
Molecular Polarity Non-polar Polar
Lubrication Excellent Good
5-2) CONDENSER
(1) Function
The condenser cools off and condenses high temperature and high pressure gas refrigerant from the
compressor.
The condenser transfers the heat inside the vehicle drawn from the evaporator to the outside of the
vehicle by taking advantage of the cooling fan and the wind by driving. Therefore, high temperature
and high pressure gas refrigerant cools off while traveling through the condenser and becomes mid-
temperature and high pressure liquid at the exit.
The condenser is usually located in front of the radiator and its location causes the amount of air
passing through the radiator decrease and the air temperature increase, thus deteriorating the
efficiency of radiator.
Therefore, the engine cooling fan should be bigger and radiator shroud should be attached in order to
support the system cooling operation and enhance the heat radiation from the condenser.
(2) Quality Characteristics

Dirt and dust accumulated on the cooling fins of the condenser reduce the efficiency of not only the
radiator but also the condenser and result in insufficient heat radiation. As a result, the condenser fails
to fully condense the refrigerant.
In some extreme cases, dirt and dust not only can be directly attributed to engine overheat but also
abnormally increase cycle pressure only to reduce the system’s cooling ability.
In addition, crushed or damaged cooling fins can result in the above-mentioned situation as they can
bring about a lack of air.
Mixed air due to insufficient air bleeding before charging refrigerant fails to fully condense in the
condenser, causing the pressure in the cycle to greatly increase. Thus, perfect air bleeding and proper
refrigerant charge are required.
(3) Mounting Location
Radiator
Condenser
Inter cooler
AIR CONDITIONER
9
(4) Condenser Model
Model Spec
size(㎜) 490(L)×365.7(H)×22(D)
Frontal area(㎡) 0.179193
type LOUVER
(5) Condenser Components

The condenser, just as other heat exchangers, comprises fins for air and tubes for refrigerant and the
fins and tubes are mainly aluminum.
Refrigerant gas radiates heat into the air while traveling through the tubes and discharges heat into
the air passing through the fins.
Header Pipe
Tube
Fin
(6) Mounting Location of Condenser
Condenser
Receiver Drier
AIR CONDITIONER
10
5-3) RECEIVER-DRIER
(1) Function
Liquid refrigerant containing bubbles can lower the cooling ability. The primary function of the receiver-
drier is to separate gas and liquid and transfer liquid refrigerant only to the expansion valve. The
secondary purpose is to remove moisture from the refrigerant and filter out dirt.
(2) Structure
The receiver-drier contains a steel or aluminum body, baffle, desiccant, a sight glass and a safety
valve and provides the following functions.
Storing function
As shown in the below figure, it stores liquid refrigerant to send to the evaporator depending on heat
load.
Bubble-separating function
While refrigerant is condensing in the condenser, it can contain some bubbles. The receiver-drier
completely separates gas and liquid and transfers liquid refrigerant only to the expansion valve.
Moisture-removing function
It removes moisture and small amounts of debris from the refrigerant.
Recently, a sight glass is disappearing as R-134A is increasingly being used as refrigerant.
(3) Receiver Drier Check-up

The receiver drier can break down due to internal blockage.
The blocked entrance side of the receiver drier can cause the gauge pressure to rise and the blocked
exit decreases the gauge pressure, reducing the cooling ability.
The excessively cold discharge pipe of the receiver drier means a blockage in the receiver drier.
5-4) Dual Pressure Switch

(1) Function
It is mounted to the upper part of the receiver drier.
It is connected to the A/C relay and turns it off to shut off the compressor if abnormal pressure
occurs.
Dual pressure s/w serves as a safety device and it is operated by the refrigerant pressure in the
system.
If the air conditioning system is turned on with no refrigerant in it, the compressor continues to run
with the evaporator not cooled. Therefore, overheating can result in damage to the compressor.
In this case, the dual pressure s/w is turned off to cut off the power to the A/C relay.
Conversely, overcharged refrigerant or blocked system rapidly increases the pressure of refrigerant,
resulting in damage to the compressor and the system. In order to prevent this, the dual pressure
switch is turned off.
AIR CONDITIONER
11
5-5) EXPANSION VALVE

Mid-temperature and high-pressure liquid state refrigerant is introduced into the expansion valve
under normal operating conditions and becomes low-temperature and low pressure state while
passing through the orifice valve.
This liquid refrigerant absorbs heat from the air and exits the evaporator as a gaseous state. At this
time, the temperature of gaseous refrigerant goes up a little higher than that of the liquid state. The
amount of liquid-state refrigerant passing through the expansion valve is controlled by the thermostatic
valve and the pressure of the liquid-state refrigerant in the evaporator. In short, the expansion valve
controls the amount of refrigerant coming into the evaporator.
(1) ANGLE TYPE

Structure
The expansion valve is opened and closed by the size of gas pressure in the sensitive tube. High-
pressure and high-temperature liquid refrigerant drawn from the receiver drier is turned into low-
pressure and Low-temperature misty vapor by throttling and transferred to the evaporator.
• SENSITIVE TUBE • DIAPHRAM
• BALL • P/SPRING
• FILTER
Operating Principle
The opening and closing of the expansion valve is automatically controlled by three forces, the
pressure in the sensitive tube containing liquid or gas (P1), the pressure of evaporator outlet (P2) and
the spring tension (F).
• Pressure in the sensitive tube (P1) …… Press the diaphragm downward (Valve opened)
• Pressure of Evaporator outlet (P2) …… Move the diaphragm upward. (Valve closed)
• Spring Tension(F) …… Move the ball upward (Valve closed)
Capillary tube Top chamber

Uniform internal
Uniform external Diaphragm pressure port
pressure port
Sensitive tube
Bottom chamber
Stem
Refrigerant outlet
Ball valve Ball seat

Refrigerant inlet
Adjustment screw Spring
(2) BLOCK TYPE (High sensitivity Expansion valve)

Structure
The expansion valve is usually attached to the evaporator entrance and senses the temperature of the
evaporator outlet by using the sensitive tube. But the high- sensitivity expansion valve exhibits
excellent sensitivity since it is assembled in the middle of the evaporator entrance and the outlet.
AIR CONDITIONER
12
Operating Principle
If room temperature is high, the pressure of the evaporator outlet is transferred to the diaphragm,
causing the pressure to rise and opening the valve.
• ＰＢ： Gas pressure in the diaphragm
(pressure change by gas pressure & TL temperature)
• ＰＬ：Evaporator outlet pressure
• ＴＬ：Evaporator outlet temperature
• Ｆｓ：Spring Tension
☞ The refrigerant gas at the evaporator

outlet comes into the expansion valve
to sense ＰＬ and ＴＬ.
- Operated like the ANGLE Type
Features
• The heat sensors are quick to respond to fluctuations in heat load because they have direct contact
with the refrigerant. (approximately 17 times quicker than usual)
• Even with fluctuations in heat load, it can enhance the performance of evaporator because it is good
at controlling a flow rate of the refrigerant so as to consistently maintaining a proper degree of
superheat.
• When the system is initially operated, the cool-down in the vehicles is okay.
5-6) EVAPORATOR
(1) Function
As the low-temperature and low-pressure misty refrigerant is traveling through the evaporator core,
warm air passing through fins and plate evaporates the refrigerant into low-temperature and low-
pressure gas, providing cool air inside the vehicle.
(2) Quality Characteristics
The amount of heat which is cooled in the evaporator is determined by heat sources both inside and
outside of the vehicle and solar radiation. During the cooling process, moisture contained in the air
condenses on its surface. So, the structure should be designed to discharge this condensed water.
Moreover, if the system is operated in high-temperature and humid conditions, micro-organisms can
propagate on the evaporator surface, causing a bad smell. Thus, an anti-bacterial system is required
to prevent the propagation of the micro-organism on the surface.
(3) Structure
There are three types of evaporators. First, a dry evaporator consists of aluminum alloy cooling tube,
cooling fins and the distributor (fin under tube type). For a laminated evaporator, fins are attached
between thin rectangular aluminum plates. Lastly, a serpentine evaporator consists of colgate fins
which exist within 5mm-thick flat porous serpentine tube.
AIR CONDITIONER
13
4) EVAPORATOR Model
Model Spec
Overall size(㎜) 240(L)×211(H)×78(D)
Effective Size(㎜) 0.05064
Core type Laminated Type
Performance 4200(kcal)
(5) EVAPORATOR Components

② Fin : 20EA
① Tube Plate : 38EA
③ In/Out Pipe: Each 1EA
④ Side Plate : 2EA

AIR CONDITIONER
14
5-7) Duct Sensor

(1) Function
The duct sensor detects the temperature of the evaporator core to keep the evaporator from freezing
and turns the compressor on or off to provide a continuous pleasant atmosphere.
In addition, the resistance inside the duct sensor chip increases with temperature decreasing and
decreases with temperature rising thank to NTC (Negative Temperature Cofficient) duct sensor.
(2) Test for the Duct Sensor Working

Connect the multi-tester to the duct sensor and measure output voltage.
If the measured output voltage is beyond the defined range, find out what is wrong through item
inspection.
If the measured voltage is normal, check out resistance properties depending on duct sensor
temperature so as to on/off working is in normal condition.
(3) Characteristic Table (temp -resistance-output voltage)
Temp Resistance Voltage Temp Resistance Voltage

( ) (㏀) (V) ( ) (㏀) (V)
30.00 1.98 0.99 2.00 7.23 2.37
25.00 2.45 1.17 1.00 7.60 2.44
20.00 3.06 1.38 0.00 8.00 2.50
15.00 3.85 1.62 -1.00 8.42 2.56
10.00 4.88 1.89 -2.00 8.87 2.63
5.00 6.22 2.19 -3.00 9.34 2.69
4.00 6.54 2.25 -4.00 9.48 2.71
3.00 6.87 2.31 -5.00 10.37 2.82
AIR CONDITIONER
15
(4) Duct Sensor position
5-8) BLOWER
(1) Function
The blower forcefully blows air into the evaporator, turning hot and humid air into low-temperature and
moist air so that it can be carried off to the inside of the vehicle.
Air flow has a great impact on the cooling ability. In general, for the cooling capacity of
3600 4000㎉/h, a blower motor of 180 210W is used and mostly a centrifugal fan is used.
(2) Structure
A centrifugal fan is mounted on the motor and the edge of the fan is the synthetic resin case. Air is
introduced into the center from the centrifugal fan and its case shape makes a contribution to good-
efficient air flow.
(3) Features of Centrifugal Fan
Simple structure and capable of being used at low wind pressure and low horsepower
Small shape and less noise
(4) Control parts and control circuit
The rotating of the blower motor is controlled by using a resistor to control motor current.
The following is an example of circuit.
AIR CONDITIONER
16
1. HVAC Composition
Blower Fan
Heater Core Water Valve
Actuator
Blower Motor
Filter
Resister
Duct sensor
Relay Expansion Valve
Evaporator Core
AIR CONDITIONER
17
2. HVAC Harness Composition

AIR CONDITIONER
18
3. Heater
3-1) Overview of Heater
(1) This heater is for automobile using engine cooling water as heat source.
(2) It heats the inside of the car for driver and rider to have pleasant and comfortable feeling in the car.
(3) It prevents the car front window and other windows from being frozen or dimmed for safe driving.
(4) Generally for passenger car, it is installed at the center in front of the driver’s seat.
(5) For BUS type cars, it consists of DEFROSTER UNIT (1 each) installed at the side of the driver’s
seat and indoor units (2~4 each) installed under the passenger seats
3-2) Operation Principle of Heater

1) The heat source, Engine cooling water, is heated up to about 85 by the combustion heat of engine
using fuel.
2) This cooling water is passed to the radiator through hot water piping.
3) When the cooling water passing through radiator, heat is exchanged between the air forced to be
flown in by Blower Unit fan and radiator, so that the air is heated up to about 65 .
4) This heated air heats the car going around inside the car.
ENGINE RADIATOR
ENGINE 냉각수
Cooling water
차실외
Inside of car
75 85℃ BL OWER 외기
Outdoor
온수배관
차실내 Pipe
Outside of 60℃ 방 20℃
car 열
기
증기배관 FAN M OTOR
H/ T
Duct
내기
Indoor
AIR CONDITIONER
19
4. Heater Parts
4-1) Heater core
(1) Function
This is a heat exchanger that receives the cooling water heated by engine and circulates such heated
cooling water into Heater core to heat the cool air inside the car.
(2) Features
The calorie of Heater core for heating is depending on the heating load in/outside the car. Especially in
winter, this device is absolutely needed to defrost the window in front of the driver. This is identified as
a security part to which driver safety relevant law is applied to be managed.
(3) Heater Model (Fin & Tube Type)
Model Spec
Effective size(㎜) 142.4(L)×189(H)×41(D)
Frontal area(㎡) 0.026914
Core type Copper
Performance 4945(kcal)min
4-2) Blower & Fan motor

This device sends the air generated by fan to the Heater for needed work to be done.
.
Blower
FAN
Motor
AIR CONDITIONER
20
4-3) Resistors
This electric safety device uses resistor to change the current flowing into Motor and adjust the Motor
circulation speed; and blocks power when the motor circulation is forced to be stopped by external
factor or motor’s own defect.
4-4) Water valve

This controls the flow into heater core and air temperature (Hot Air and Cool Air) when A/CON is used
or constantly warm temperature (17 ~32 ) is set.
AIR CONDITIONER
21
4-5) Damper
This device changes the air flow direction to the position desired by the user and is required for mode
setting.
4-6) Link Part

This moves the damper to change the air flow direction to the position desired by the user and is the
most essential part in the heater design.
(1) Vent actuator
(2) Intake actuator

AIR CONDITIONER
22
(3) Temp actuator
(4) Def/Foot actuator

AIR CONDITIONER
23
4-8) FILTER
(1) Function
Filter is used to eliminate alien substance and smell inside the vehicle to keep the indoor environment
pleasant constantly.
(2) Exchange Cycle

• If not replaced for a long period, Filter can be blocked by alien substance and air flow extremely
decreases; Blower Motor may make noise; and bad odor may be generated out of Air discharge
port.
• Filter should be frequently checked and replaced depending on the area, device and work site
environment where air pollution is serious and/or dust or smoke is largely generated due to bad road
condition.
(3) How to replace

External Filter
• As shown below, turn the Filter top handle toward the arrow direction to detach.
• Based on the contamination level of the detached Filter, brush it first. If not well cleaned, replace it.
Internal Mesh Filter
• As shown below, turn the Mesh Filter top handle toward the arrow direction to detach.
• Check the contamination level of the detached Mesh Filter and then remove the dust on the
contaminated part by Air or Water.
Mesh Filter Handle Filter Handle
Mesh Filter
Filter
HVAC UNIT
AIR CONDITIONER
24
1. Defective Cooling and Heating
1-1) Defective Cooling
AIR CONDITIONER
25
1-2) Defective Cooling

(1) Fan Motor Not Turning
Cause How to check Action to take
Fuse Cut Check the air-con fuse. Replace it with a new one.
Repair the cut wire with a
Wiring Cut and Check if the wiring is cut and connector is
new one or connect it
Defective Connection properly connected.
correctly.
Check 2 lead wires from Motor by circuit
Fan Motor Broken Replace it with a new one.
tester. If current not flown, it is broken.
Check if the resistor electrically works by
Resistor Cut circuit tester. If not electrically works, it is Replace it with a new one.
cut on wire.
Run the Fan Switch in order and check the
Fan Switch Broken Replace it with a new one.
fan turning.
(2) Fan Motor is normal with little air flow.

Evaporator Intake is Remove the disturbance
Evaporator Contaminated
disturbed. and clean it.
Check the assembly state of the cooling
Air Leakage Modify and Adjust
unit.
Duct Sensor Defect Check if the Evaporator is frozen. Replace it with a new one.
(3) Compressor does not turn or hardly turns.

Belt Loosen Belt largely shakes. Tension Adjust

Compressor Inner Repair or replace it with a
Belt slips.
Breakage new one.
Battery Voltage Short Slips when turning Battery Charge
Coil Layer Short Slips when turning Replace it with a new one.
Clutch ambient part is contaminated and Replace it with a new one

Clutch Face Oiled
slippery. or clean it,
Big Interval between Modify the interval or
Push the clutch plate by hands and it is
Clutch Plate and Clutch replace the part with a new
adsorbed.
Wheel. one.
Replace the compressor
Coil Cut Not adsorbed or resistence is
with a new one.

Wiring Cut or Earth and Not adsorbed regardless operation control;
Repair
Connection Defective and check the earth and connection part.
Check if input switch, thermo switch and relay Replace it with a new
Wiring Parts
work electrically. one.
AIR CONDITIONER
26
(4) Air flow is normally and Compressor turns normally with defective cooling.
Temp little changes when touching the high-low Repair the leaking
pressure pipe 5~10min after air-con works. part and charge
Refrigerant lacks.
Bubble flow is seen through the check-glass and refrigerant up to
fog-type flow is little seen. proper volume.
The high-compressed pressure is high. Bubble is Draw the refrigerant
Refrigerant is over
not seen through the check-window even when little by little until
charged.
the condenser is cooled by water. bubble is seen..
High-Compressed Pressure: 14~15㎏/㎠G
Compression Pressed Low-Compressed Pressure: 1.5~2.0㎏/㎠G Normal Pressure
by Inlet/Outlet
External Temp: 30~35 ; Engine: Approx. 2000
rpm
• Duct Sensor Defect
Adjust or replace it
Magnetic Clutch is cut before the discharged air
with a new one.
is cooled enough.
• Compressor Gasket or Valve Defect Replace the
Right after the magnetic clutch is OFF, the high- compressor with a
low pressure gauge pressure is balanced. new one or repair it.
Low Pressure is high.
• Expansion Valve Over-Opened
Same as above; and pressure little changes Replace it with a new
when the temp reduction tank is attached to or one.
detached from the pipe.
• Compressor Suction Filter Clogged
The low-pressure hose is not cool enough and Clean the filter.
only the Compressor connection part is cool.
• Refrigerant lacks.
Add refrigerant.
Refer to the section, ‘Refrigerant lacks’.
Low Pressure is low.
• Receiver Drier Clogged
Replace the Receiver
Temp largely varies at the tank outlet.
Drier with a new one.
Also, the tank is frosted.
AIR CONDITIONER
27

Replace the
• Expansion Valve Clogged
expansion valve with
Expansion valve inlet is cool and frosted.
a new one.
• Tank reduction tank of expansion valve leaks
Replace the
gas.
expansion valve with
Expansion valve outlet is not cool and the low-
Low Pressure is low. a new one.
pressure gauge is vacuumed.
• Piping is clogged and distorted. Replace the piping
Clogged piping indicates that the low-pressure with a new one or
may be low or lower than atmospheric pressure. clean it.
• Duct Sensor Defect
Add refrigerant.
Evaporator is frozen.
• Condenser Cooling Defect Clean, repair or
Condenser is contaminated or clogged. Fan turns replace the fan with a
defectively. new one.
• Refrigerant Over-Charged Adjust the refrigerant
High Pressure is high.
Check the volume of refrigerant volume.
Vacuum Work; and
• Air Mixed inside Cycle
recharge the
Refer to the section, ‘Refrigerant Over-Charged’.
refrigerant.
• Refrigerant lacks.
High Pressure is low. Add refrigerant.
Refer to the section, ‘Refrigerant lacks’.
1-3) Defective Heating

(1) Fan Motor works normal with little air flow.
Aeration is too much
Check if Duct is clogged or distorted. Modify
resistant.
Air Leaking from Duct Check Duct connection part.
Modify
Connection Part Check Duct assembly state.
(2) Air flow is discharged normally but hot air does not come out.
Cooling Water Temp is Check the water temp after heating Replace the thermostat
low. operation. with a new one.
Cooling Water is little. Check the water volume of Radiator. Add cooling water.
AIR CONDITIONER
28

Cooling Water
Check if the cooling water piping and
circulation volume is Get rid of air or Modify
heater blocking valve are clogged.
little.
Modify or replace the control
Air does not pass Check the operation and seal state of
cable with a new one. Check the
through Heater Core. the air-mix door.
seal.
(3) Water drop leaks.

Check any leakage from Heater core, Replace it with a new one or
Seal Defect
Core Connection Part, Hose and Pipe. modify it.
Core is punctured. Heater core Replace it with a new one.
2. Visual and Auditory Troubleshooting

2-1) Noise is made as V-belt is getting loosen.
If V-belt is loosen or too much worn, frictional sound (halt) is made. Adjust the V-belt tension. If torn
away, replace it.
2-2) Abnormal noise is made around Compressor.
Check the compressor and installed bracket bolts are loosen. If loosen, tighten them.
2-3) Abnormal noise is made from Compressor.
Abnormal noise inside the compressor may indicate damage of Suction Valve. Detach it for repair or
replace it with a new one.
2-4) Condenser is stained with clay and dust.
Clay and dust remarkably degrade the heating effect influencing cooling capability. Wash out such
clay and dust with water. At the moment, make sure that the pin is not damaged or distorted.
2-5) Piping Connection Part and Compressor Part are contaminated with oil.
The part contaminated with oil indicates that refrigerant leaks with compressor oil from the cycle due to
some reason. If any contamination is found, check the relevant part by gas leakage sensor and tighten
it or replace it with a new one.
Compressor O-ring, connected parts O-Ring and shaft seal part should be checked fully.
2-6) Abnormal noise is made from Fan Motor.
If Fan Motor makes abnormal noise or defective turning, replace the Fan Motor with a new one.
Such abnormal noise may be made by alien substance inside the fan or defective joint of the fan.
Work on this matter with full care.
AIR CONDITIONER
29
3. Checking Methods per Case

3-1) Gauge based Checking Method
(1) Open the bonnet.
(2) Close the Manifold Gage low-pressure side and high-pressure side value and then install the
gauge onto the service valve.
(3) Release the low-pressure side valve little by little to discharge the air inside the hose and then
close it. Same procedure is used also for the high-pressure side.
(4) Start the device and raise the engine rpm to about 1,500rpm.
(5) Turn the air-con switch ON and position the air flow switch at the biggest and the temp adjusting
switch at the coolest.
☞ Note
• Put the device on even place and support the parking brake and wheel with wooden
support.
• Put
☞ every lever to neutral.
Caution
• Manifold Gage measuring value is subject to little change by external temp and
• depends on the specific conditions as follow:
Door
: All Opened
• External-Internal Circulation: Internal
• Engine RPM: Approx. 1,500rpm
• Air Flow Adjusting Switch: Biggest
• Air-Con Switch: ON
• Temp Adjusting Switch: Coolest Position
• External Temp: 30 ~ 35
The following 3-2) ~ 3-9) show the ideal input state. Actually, however, the high-pressure low-
pressure may be displayed differently depending on temp, humidity, operation condition
and etc.
AIR CONDITIONER
30
3-2) Normal:
If air-con works normally, the gauge pressure at the low
pressure side and high pressure side is seen as follows:
i.e.) High/Low pressure may be displayed differently
depending on temp, humidity, operation condition and etc.
• Low Pressure Side (Blue) (1): 1.5 ~ 2.0㎏/㎠
• High Pressure Side (Red) (2): 14.5 ~ 15㎏/㎠
3-3) Refrigerant is little.

(1) Case: Not Cool
(2) Symptom:
• Low Pressure at Both Low Pressure and High Pressure
Sides
- Low Pressure Side (Blue) (1): 0.8㎏/㎠ 이하
- High Pressure Side (Red) (2): 8~9㎏/㎠
• Bubble Seen through Check-Window
• Discharging Temp Not Down
(3) Cause: Refrigerant leaks.
(4) Action to Take: Check the part by gas leakage sensor to
repair the leaking part and charge proper volume of
refrigerant.
AIR CONDITIONER
31
3-4) Refrigerant is over-charged. Condenser is not fully cooled

(1) Case: Not Cool
(2) Symptom: High at Both High and Low Pressure Sides
(3) Cause:
• Pressure rises up because refrigerant is over-charged.
- Low Pressure Side (Blue) (1): 2.5 ㎏/㎠
- High Pressure Side (Red) (2): 20㎏/㎠
• Condenser is not fully cooled.
• Air-Con belt is loosen.
(4) Action to Take:
• Clean the condenser.
• Check the fan or condenser motor and adjust it.
• Check the refrigerant volume.
3-5) Air Contained in Cycle

(1) Case: Not Cool
(2) Symptom:
• High at Both High and Low Pressure Sides
- High Pressure Side (Red) (2): 23㎏/㎠
• Piping at Low Pressure Side is not cool
(3) Cause: Air is contained in the cooling cycle.
If not vacuuming, indication is displayed as shown right
in the figure.
(4) Action to Take:
• Check the indication while charging refrigerant after
vacuuming.
• To operate the device for a long period with air contained,
replace the receiver drier.
• Check the refrigerant and oil contamination.
AIR CONDITIONER
32
3-6) Expansion Valve Broken

(1) Case: Not Cool
(2) Symptom: High at Both High and Low Pressure Sides
- High Pressure Side (Red) (2): 19 ~ 20 ㎏/㎠
(3) Cause: Expansion valve is defective and temp
reduction tank is defectively assembled, so that
refrigerant flow is defectively adjusted.
(4) Action to Take: Check the assembly state, position
and insulation state of the temp reduction tank. If
normal, replace the expansion valve.
3-7) Compressor Compression Defect

(1) Case: Not Cool
(2) Symptom:
• High at Low Pressure Side while Extremely Low at High
Pressure Side
- Low Pressure Side (Blue) (1): 4 ~ 6 ㎏/㎠
- High Pressure Side (Red) (2): 7 ~ 10 ㎏/㎠
• As soon as operation stops, low and high pressures
become same.
(3) Cause: Compressor gasket is defective and
suction valve is damaged making defective compression.
(4) Action to Take:
• Detach the compressor and repair it.
• Replace the compressor assembly.
AIR CONDITIONER
33
3-8) Moisture Contained in Cooling Cycle

(1) Case: Cool Sometimes and Not Cool Other-Times
(2) Symptom: Low Pressure Side is lower than the
atmospheric pressure and gets normal sometimes.
• Low Pressure Side (Blue) (1): vacuum ~ 1.3 ㎏/㎠
• High Pressure Side (Red) (2): 6 ~ 18 ㎏/㎠
(3) Cause: The moisture is frozen inside the cooling cycle
and then closes the cycle in the expansion valve, or it is
melted and then makes normal operation.
(4) Action to Take: Replace the Receiver Drier with a new
one.
• Vacuum it 2-3 times.
• Charge the proper volume of refrigerant.
3-9) Refrigerant Circulation Defect

(1) Case: Not Cool (Sometimes Cool)
(2) Symptom:
• Low Pressure Side is lower than atmospheric pressure and
High Pressure Side is 5~6㎏/㎠.
- High Pressure Side (Red) (2): 6 ㎏/㎠
• The front/rear piping connection parts of the Receiver Drier
or Expansion Valve are frosted or dewed.
(3) Cause:
• Moisture frozen or dust inside the freezing cycle closes the
cycle.
• Expansion valve temp reduction tank is defective and
blocks the cycle.
(4) Action to Take:
• Stop the operation and to check if it is blocked by moisture
and dust.
• If moisturized, vacuum it.
• Detach the expansion valve and wipe out the dust by air.
• Replace the Receiver Drier with a new one.
AIR CONDITIONER
34
4. Air-Con System Checking and Adjustment
4-1) Note for Working with Refrigerant:
(1) Refrigerant is frozen at low temp.
Touching it by skin may make you frostbitten and touching it by eye may makes you blind.
Note
If the refrigerant gets in your eyes or contacts your skin:
Wash it with fresh water and then get treatment by optical or skin doctor.
Do not scrub eyes with hands or handkerchief.
(2) For refrigerant wok, the work site should be well ventilated and clean. Refrigerant is harmless.
If, however, it is largely discharged in closed place,
Oxygen gets reduced.
Exposure Allowance Limit: 1,000ppm(4,184㎎/㎡)
- If risk increases by exposure,
You may get abnormality in/on the parts as follow:
heart, cardiovascular system, immune system,
allergy, respiratory organs and skin.
(3) While working on refrigerant, get any flammable and firing object away from the car.
Make sure that the refrigerant container is not exposed to heat.
Otherwise, it may burst or explode.
AIR CONDITIONER
35
(4) A/CON parts are sealed to prevent dust inflow.
Remove the cap before work. Seal it after work.
PAG cooling oil for R-134a absorbs moisture more easily than the oil for R-12. Its absorption rate is
about 10 times MINERAL cooling oil.
Too much moisture may make trouble on the compressor circulation and then affect durability.
(4) Add the refrigerant oil after replace any of A/CON parts or check the refrigerant.
OIL OIL
Item Item
Volume Volume
Recharge the refrigerant. 30cc Replace Hose and Pipe with new ones. 10cc
Replace EVAP. with a new one. 50cc Replace R/Drier with a new one. 30cc
Replace COND. with a new one. 30cc
(6) Replace a new compressor with another new one after checking the oil volume of the compressor
to be replaced and then discharging excessive oil as shown right in the figure.
• Discharge about 70cc.
신품콤프레서
New compressor 교환콤프레서
Replaced compressor
여분의오일을
Discharge
제거한다
excessive
oil
• Compressor oil absorbs moisture in the air fast. Protect it from moisture.
AIR CONDITIONER
36
(7) When detaching A/CON System and installing it again, spread cooling oil onto O-Ring.
Briefly assemble the bolt type connection part by hands and then tighten it using 2 spanners so that
the tube cannot be twisted. Then, tighten it to meet its specified torque.
Make sure that O-Ring is not bitten due to careless work and the refrigerant shall not leak.
(8) When connecting the pipes, make sure that O-Ring part shall not be contaminated by alien
substance or deformed. Coat them with cooling oil (PAG) and then assemble them.
(9) Promptly detach and attach them so that dust or moisture cannot penetrate into the air-con system.
(10) After working on refrigerant, operate the air-con for about 5min in Idle state and then use it.
(After working on refrigerant, if the air-con is operated by turning the engine at high speed, the
compressor may be broken.)
(11) Before collecting the refrigerant completely, do not detach the A/CON System.
Otherwise, the refrigerant and oil are discharged into the air by the system inner pressure and then
pollute the ambient environment.
(12) Inject specified volume of refrigerant.

If the compressor inner part is broken or it is broken by penetration of alien substance and moisture,
Receiver Drier is also recommended to be replaced with a new one.
4-2) Note for Maintenance

(1) If the air-con performance gets loose, check the volume of refrigerant and recharge it immediately.
(Using it for a long period with little volume of refrigerant may make the compressor broken.)
(2) Condenser needs to be cleaned periodically.

If the condenser is stained by alien substance (soil, weed and etc) on its outer surface, abnormally
high pressure is made degrading the cooling performance and generating high pressure cycle that
cause the compressor to be broken. Periodic check is needed.
3) Internal filter built in HVAC Unit and external filter should be cleaned and replaced with new ones
periodically.
AIR CONDITIONER
37
4-3) Working Method on A/CON Refrigerant
To secure A/CON performance and Compressor durability, it is basically needed to keep proper
volume of refrigerant inside the SYSTEM. The system vacuum state and injection method largely
influence the compressor. Therefore, before injecting refrigerant, clearly understand the refrigerant
injection method and correctly work on it.
A/CON refrigerant work should be done in the order as follows. If possible, use automatic
collecting/charging device to prevent working error.
GAS Leakage Test
Refrigerant Collected (Discharged) Repair the leaked part.
Vacuum (at least 15min)
Vacuum LEAK CHECK (5min) Repair the leaked part.
Vacuum Again (10min)
Refrigerant Injected
LEAK
Operation Test and Leakage Check
(1) GAS Leakage Test

Check any leakage of each part by gas leakage sensor.
Visual Identification Method of Leaking Part

• The connection part of each Hose & Pipe is stained by oil trace and dust.
• Condenser has changed on the surface of its leaking part that is contaminated by dust and oil.
• When Evaporator leaks, oil is mixed in the condensate water of Drain Hose.
AIR CONDITIONER
38
4-4) A/CON Refrigerant Collecting and Charging Method
(1) When using MANIFOLD GAUGE

1) Refrigerant Discharging (Manifold Gauge Used)
When Manifold Gauge is used, "CLOSE" the high/low pressure valves and then the high/low
pressure hose coupling to the service valve of A/CON SYSTEM.
①: Low Pressure
②: High Pressure
③: Recycling Device
☞ Important
• Do not take out refrigerant to the outdoor.
• Use HRC-134a device only.
• Check if the maintenance hose is correctly connected.
☞ Caution
• Wear protective glasses and gloves.
As shown in the figure, attach the manifold gauge and recycling device to the refrigerant line.
☞ Note
• Make sure that the low/high pressure valves’ connection parts are not switched each other.
Open the high pressure valve slowly to discharge refrigerant through the recycling device.
☞ Note
• Make sure that refrigerant does not leak and open the valve slowly.
When Manifold Gauge dial gets down to 3.5 ㎏/㎠ (50 psi) or lower, open the low pressure valve
slowly.
Until Manifold Gage dial displays 0 ㎏/㎠ (0 psi), open both high/low pressure valves slowly.
AIR CONDITIONER
39
2) Vacuum
After refrigerant is completely discharged, connect the discharging hose to the vacuum pump and then
open the high/low pressure valves. Operate the vacuum pump to vacuum the system inner part for
approximately 15min so that it can be fully vacuumed.
☞ Note
If vacuum is not enough, it cannot be charged and the moisture contained in the system is not
eliminated causing the expansion valve to be frozen and clogged on its circuit decreasing its
performance; and Compressor Oil reacts to the moisture and is blazed causing the compressor to be
damaged earlier.
①: Low Pressure
②: High Pressure
③: Vacuum Pump
A: Opened
Connect the manifold low pressure maintenance hose (blue) and high pressure maintenance hose
(red) to the service valve.
Connect the manifold central hose (yellow) to the vacuum pump.
Open the low/high pressure side valves and operate the vacuum pump as directed to vacuum.
Vacuum it for about 15min. When the low pressure gauge gets to the lowest safety vacuum level
(711.2~736.2 mmHg), stop the vacuum pump and close the manifold low/high pressure side
valves. Approximately 5min later, check if the gauge does not get to “0”.
• The said vacuum level can be gotten at 0m above sea level. The vacuum level decreases by
25.4mmHg as the altitude gets higher by 340m (1000 feet).
Ex) At 1524m (5000 feet) high, work with the device until the vacuum level gets to 584.2 ~ 609.7
mmHg.
When the gauge gets to 0, it indicates leakage. Check and repair the pipe connection part and then
vacuum it. Then, check if gas leaks.
☞ Note
• After vacuum is formed, close the gauge valve at high/low pressure sides. Detach the hose after
the vacuum pump completely stops. Otherwise, alien substance is sucked into.
AIR CONDITIONER
40
3) Charging
After vacuuming, close the manifold high pressure valve and connect the discharging hose to the
charge cylinder. Then, open the connection part between the manifold and hose. Close the connection
part when it is full with refrigerant. Before injection, mark the correct charging volume on the charge
cylinder and open the high pressure valve to charge refrigerant through the high pressure side.
☞ Note
• Refrigerant must be charged through the high pressure side. If charged through the low pressure side,
liquid refrigerant flows into the compressor and causes the compressor to be stuck when A/CON is
turned "ON".
If not fully vacuumed, refrigerant cannot be charged. Full vacuum is needed.
①: High Pressure Gauge

②: Low Pressure Gauge
③: Refrigerant
A: High Pressure (Opened)
B: Low Pressure (Closed)
☞ Important
• Discharge the gas and vacuum before charge the gas.
• When charging the gas, do not start the engine. Charge it from the edge of the High Pressure Side and
then start the engine to charge the specified volume of gas.
☞ Caution
• When charging gas at the edge of High Pressure Side, do not start the engine. Otherwise, refrigerant
flows backward and the device may be broken; and the compressor may be damaged due to shortage
of refrigerant.
Open the high pressure valve and inject refrigerant of about 700g.
Close the high pressure valve and check if gas leaks.
After checking with the high pressure valve closed, start the engine and operate it at about
2000rpm.
Set the temp control lever at Cooling and position the blower switch at High Speed.
Open the low pressure valve and charge refrigerant until bubble disappears from Receiver Window.
When refrigerant fully charged, close the low pressure valve and stop the engine.
Test if refrigerant leaks.
• Refrigerant Volume to be Charged: 1,300g (2.866 ibs)
• Manifold Gauge Pressure (External temp is 30 (86 ).)
• High Pressure: 14.5 ~ 15 kgf/㎠ (1.42~1.47 Mpa. 206.2~213.3 psi)
• Low Pressure: 1.5 ~ 2.0 kgf/㎠ (0.15~0.19 Mpa. 21.3~28.4 psi)
AIR CONDITIONER
41
☞ Caution
• Replace the service can after discharging the air from the charging hose (red).
• When the service can is used, connect it to the discharging hose for charging. If the ambient temp is
low, warm the service can by 40℃ or colder hot water and then charge the refrigerant.
☞ Note
• Do not turn over the service can to charge refrigerant. Put the service can on a scale so that specified
volume can be charged.
4-5) Checking of Refrigerant Volume

Refrigerant volume can be checked by seeing the pressure gauge and the flowing state of the
refrigerant shown through Check-glass of Receiver Drier. The bubble state and discharging pressure
seen through Check-glass largely depend on external temp, condenser front temp, air flow speed of
the fan, weather and etc. Therefore, check the air-con system under the conditions as follow:
(1) Operate the air-con under the conditions as follow:

• External Temp: 20 or higher
• Engine Speed: Approximately, 1500rpm
• Temp Control Lever: Positioned at the Coldest Temp
• Fan Control Switch: High
• Air-Con Switch: ON
(2) Open the hood and check the temp difference between the high pressure pipe and low pressure
pipe.
Normal:
Temp largely differs between the high pressure pipe and low pressure pipe.
(High pressure pipe is hot while low pressure pipe is cold.)
Abnormal:
• Temp little differs between the high pressure pipe and low pressure pipe.
(Refrigerant almost or completely lacks.)
• High pressure pipe is hot while low pressure pipe is cold, so that temp largely differs between
them.
(Too Much Refrigerant)
AIR CONDITIONER
42
Action to Take:
If refrigerant almost lacks, discharge the air and then recharge the refrigerant. Then, check if it leaks.
If refrigerant is too much, discharge it down to the specified volume.
(3) Check the Receiver Drier Check-glass.
Receiver drier
A, Normal: Air drop sometimes passes through.

B, Short: Air drop keeps passing through.
C, Too Much: Air drop does not keep passing through.
AIR CONDITIONER
43
1. Air-con system Components
1. HVAC UNIT 4. Receiver Drier
4-1. Dual pressure s/w
5,7. Suc-Hose
Radiator
Inter cooler
6,8 Dis-Hose
12. DRAIN HOSE
9,10. Liq-Hose(A)
11. Liq-Hose(B)
2. Control 3. Condenser
AIR CONDITIONER
44
2. HVAC UNIT Components
1-3. FAN & Motor Ass’y 1-1 Heater Core

1-2 Water Valve
M/Actuator
Blower Fan
Blower Motor
1-18 HOSE CLAMP
1-14 1-15 1-12 1-13
1-8. FRE Air Filter
1-19 Wire Holder

1-20. H/RAD PIPE CLAMP
1-4. Resistor
1-9. REC Air Filter

1-16. Wiring Ass’y
1-10. O-RING
1-7. Duct sensor

1-17. Relay 1-6. Expansion Valve
1-5. Evaporator Core
HMK 300 LC WORKSHOP MANUAL 29
00
PAGE SERIAL
DRAWING NAME EXPLANATION
NO NO
1.1 Electric Circuit Diagram 9125501 -
Counter weight changed. Swing lamp cables are

1.2 Electric Circuit Diagram 9125511 -
removed. Car stereo connected to the starter key.
2.1 Cabin Harness 9125501 -
Counter weight changed. Swing lamp cables are

2.2 Cabin Harness 9125511 -
removed. Car stereo connected to the starter key.
3.1 Main Harness 9125501 -
Solenoid valve of quick coupling changed. Counter

3.2 Main Harness 9125511 -
weight changed. Swing lamp cables are removed.
4.1 Engine Harness 9125501 -
Engine Harness –
4A.1 4HK1X
9125501 -
5.1 Working Lamp Harness 9125501 -
Cable
6.1 (Master Cutter-Fuse)
9125501 -
Cable
7.1 (Relay_Preheater-Fuse)
9125501 -
Cable
8.1 (Master Cutter-Fuse)
9125501 -
Cable
9.1 (Safety Switch)
9125501 -
Cable
10.1 (Battery (-) _ Battery(+)
9125501 -
Cable
11.1 (Battery(+)_Master 9125501 -
Cutter)
Cable
11.2 (Battery(+)_Master Battery is placed under the air filter. 9125511 -
Cutter)
Cable
12.1 (Battery (-)_Frame)
9125501 -
Cable
13.1 (Master Cutter_Starter 9125501 -
Engine)
Cable
14.1 (Working Lamp)
9125501 -
Cable
15.1 (Swing Lamp)
9125501 -

Service Manual HMK 300 LC-3 - Electrical

Uploaded by

Copyright:

Available Formats

Service Manual HMK 300 LC-3 - Electrical

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual HMK 300 LC-3 - Electrical

Uploaded by

Copyright:

Available Formats

HMK 300 LC WORKSHOP MANUAL

START ENGINE WITH BOOSTER CABLES (JUMP START)

■ CAUTIONS WHEN CONNECTING/DISCONNECTING THE BOOSTER CABLES

■ CONNECTING BOOSTER CABLE

■ STARTING THE ENGINE

1) Make sure the clips are firmly connected to battery terminals.

■ DISCONNECTING THE BOOSTER CABLES

1. “Battery charge” indicator 16. “Low/high speed travel” indicator

Functions of Instrument Panel

Switchboard consists of three parts

“Battery charge” indicator

“Engine oil pressure low” indicator.

“Air filter clogged” indicator

Comes on when the air filter element clogged.

“Locked safety lever” indicator

Displays when safety-locking lever is pulled and locked.

Buzzer alarm comes on in case of breakdown.

“Engine error” indicator

If engine failure occurs this symbol appears on instrument panel and

“Fuel level” gauge

Shows fuel level.

“Hydraulic oil temperature” gauge

1. Shows hydraulic oil temperature level.

1. Shows engine coolant temperature level.

“Power mode” gauge

“Work mode” indicator

Displays engine RPM.

Message and error display area (MED)

It shows messages and errors when breakdown occurs.

“High speed travel” indicator

“Power boost” indicator

Comes ON when high power function is ON.

“Auto Idle” indicator

Comes ON when machine operates at auto idle mode.

“Power mode selection” switch

Press to browse and select between available power modes.

“Work mode selection” switch

“Camera ON / OFF” switch (optional)

“Auto idle stop / Auto warm-up stop / Exit / NO” switch

1. Cancels auto idle function

“Low / high speed selection” switch

“One touch idle / menu / enter / YES” switch

1. Switch to return immediately to the first idle by one touch

“Buzzer stop / scroll up” switch

1. Switch to cancel buzzer.

“Information screen selection / scroll down” switch

1. Switch to select information screen.

To set your preferred language, perform the

1. Select “Language” item by using item selection

2. Move the cursor by item selection switches

3. When the cursor is on desired language, press

4. To exit from the menu, press “menu page exit”

To view the state information contents follow

1. Move the cursor (▲/▼) to find “state

2. When the cursor is on “state information”,

State information menu has six pages

PV-I : Instant proportional valve current

P1: First pump pressure.