Doosan DL200 User manual

1Electrical System

SP001211
Page 1
Air Conditioner
SP001211
AIR CONDITIONER SP001211
Air Conditioner
Edition 1

SP001211
Air Conditioner
Page 2
MEMO

SP001211
Page 3
Air Conditioner
Table of Contents
Air Conditioner
Safety Precautions............................................... 5
Applicable Models................................................ 5
General Description ............................................. 6
Refrigerant Circulation ......................................... 8
Control Panel ..................................................... 10
Control Specifications ........................................ 11
Temperature Level Control and Display.......... 12
Air Discharge According to Path Selection..... 13
Air-conditioning System Circuit Diagram.......... 16
Troubleshooting.................................................. 18
Weight of R134a Gas Used In Machines....... 20
Refrigerant System Repairs.............................. 21
Refrigerant Safe Handling Procedures ....................... 21
Repair and Replacement Procedure........................... 22
Refrigerant Recovery.................................................... 24
Vacuuming Refrigerant System ................................... 24
Leakage Check............................................................. 26
Refrigerant Charging .................................................... 26
Inspecting System for Leakage................................... 28

SP001211
Air Conditioner
Page 4
MEMO

SP001211
Page 5
Air Conditioner
SAFETY PRECAUTIONS
APPLICABLE MODELS
The contents of this section apply to the following models
and serial number ranges.
CAUTION!
Follow all safety recommendations and safe shop
practices outlined in the front of this manual or those
contained within this section.
Always use tools and equipment that are in good
working order.
Use lifting and hoisting equipment capable of safely
handling load.
Remember, that ultimately safety is your own personal
responsibility.
MODEL SERIAL NUMBER RANGE
DL200 5001 and Up

SP001211Air Conditioner
Page 6
GENERAL DESCRIPTION
The heater and air conditioner are combined into one blower
unit in the right control stand of operator's seat. If
necessary, the operator can control inner temperature using
the operation panel installed in the top of the right side
door.
FG009195
Figure 1

SP001211
Page 7
Air Conditioner
The unit is equipped with an air filtration system which filters
out dirt and dust particles from air being circulated into the
operator's cab. This filter (1, Figure 2) should be cleaned
out at approximately every 500 hours and replaced with a
new one every 1,000 hours.
NOTE: In the event that the unit is being operated in a dusty
environment, cleaning and replacement should be
performed more frequently.
NOTE: Refer to appropriate operation and maintenance
manual for latest service intervals.
1
1
AJS0530L
Figure 2
WARNING!
All service and inspection of the air-conditioning system
should be performed with the starter switch in the "O"
(OFF) position.

SP001211Air Conditioner
Page 8
REFRIGERANT CIRCULATION
1
2
3
4
5
6
HBOI020L
7
Figure 3
Reference
Number Description
1Evaporator
2 Expansion Valve
3 Condenser
4 Condenser Fan
5 Compressor
6BlowerFan
7 Receiver Dryer
Reference
Number Description

SP001211
Page 9
Air Conditioner
• Refrigerant (R134a) is compressed to
approximately 15 kg/cm2(213 psi) within the
compressor.
• The compressed refrigerant flows into the
condenser at high temperature (approximately
80°C (176°F)).
• The refrigerant in the condenser is cooled to
approximately 60° by the condenser fan. At this
time the refrigerant changes from the gas to the
liquid state, even though the temperature has only
been reduced 20°C (68°F). (From 80° - 60°C
(176° - 140°F)).
• The refrigerant in its liquid form is injected into
the evaporator through the expansion valve. At
this time the pressure is reduced by approximately
2 kg/cm2(28 psi) and the temperature is also
reduced. As a result, the refrigerant absorbs the
heat from the air surrounding the evaporator
creating a cooling effect and changes from the
gas to the liquid state.
• The refrigerant again flows into the compressor in
the gaseous state and the process is repeated.
Shading Temperature Refrigerant State
High High-pressure Gas
High High-pressure Liquid
Low Low-pressure Liquid
High High-pressure Gas/Liquid
Low Low-pressure Gas
WARNING!
Refrigerant gas is pressurized and sealed in the
air-conditioning system. Special precautions are required
for the proper recharging or release of refrigerant.
Release of refrigerant into the atmosphere is strictly
regulated by law. Make sure that you are in compliance
with all mandated federal, state and municipality
requirements, before starting any service or repair of the
air conditioner. Refrigerant gas used in the system must
meet or exceed specifications for R134a refrigerant, or
any subsequently issued environmentally mandated
standard.

SP001211Air Conditioner
Page 10
CONTROL PANEL
FG004455
Figure 4
OFF SW
A / C SW
VENT SW
DEF. SW
HEAT SW
FRE SW
REC SW
LOW SW
MID SW
HI SW
COOL SW
WARM SW
INPUT CONTROL
PANEL
OUTPUT
A/C
CONTROL
PANEL
DISPLAY
LOW SPEED RELAY
TEMPERATURE
SENSOR
MID SPEED RELAY
HIGH SPEED RELAY
BLOWER
MOTOR
VENT ACTUATOR
DEF. ACTUATOR
INTAKE
ACTUATOR
COMP. RELAY
CONDENSER
FAN RELAY
MIX DOOR
VENT CONTROL
FOOT / DEF.
RECYCLE/FRESH
AIR CONTROL
COMPRESSOR
CONDENSER
FAN
TEMPERATURE
CONTROL ACTUATOR
HDA6048L
TEMP. CONTROL
ACTUATOR
Figure 5

SP001211
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Air Conditioner
CONTROL SPECIFICATIONS
Control Item Control Switch Control Specifications
Temperature
Control
"COOL" Switch
"WARM" Switch
Temperature control switch consists of a 24 step
variable selector. The display uses 7, Green / Red
two color LED's to display the selected
temperature.
Blower Fan
Speed
Control
"OFF" Switch
"LOW" Switch
"MID" Switch
"HI" Switch
Compressor
Control
Temperature Sensor
100%
50%
0%
MAX HOT
MAX COOL
HDA6049L
Figure 6
HI RELAY
MID RELAY
LOW RELAY
OFF LOW MID HI
HDA6050L
Figure 7
COMP OFF
COMP ON
1.5 C 4.0 C
HDA6051L
Figure 8

SP001211Air Conditioner
Page 12
TEMPERATURE LEVEL
CONTROL AND DISPLAY
Step LED
1
LED
2
LED
3
LED
4
LED
5
LED
6LED 7
Position
Sensor
Voltage
Remark
0 Green Green Green Green Green Green Green 4.50 V ±0.2 MAX. COOL
1 Green Green Green Green Green Green Green 4.33 V ±0.2
2 Green Green Green Green Green Green Green 4.15 V ±0.2
3Red Green Green Green Green Green Green 3.98 V ±0.2
4Red Green Green Green Green Green Green 3.80 V ±0.2
5Red Green Green Green Green Green Green 3.63 V ±0.2
6Red Red Green Green Green Green Green 3.46 V ±0.2
7Red Red Green Green Green Green Green 3.28 V ±0.2
8Red Red Green Green Green Green Green 3.11 V ±0.2
9Red Red Red Green Green Green Green 2.93 V ±0.2
10 Red Red Red Green Green Green Green 2.76 V ±0.2
11 Red Red Red Green Green Green Green 2.59 V ±0.2
12 Red Red Red Red Green Green Green 2.41 V ±0.2
13 Red Red Red Red Green Green Green 2.24 V ±0.2
14 Red Red Red Red Green Green Green 2.07 V ±0.2
15 Red Red Red Red Red Green Green 1.89 V ±0.2
16 Red Red Red Red Red Green Green 1.72 V ±0.2
17 Red Red Red Red Red Green Green 1.54 V ±0.2
18 Red Red Red Red Red Red Green 1.37 V ±0.2
19 Red Red Red Red Red Red Green 1.20 V ±0.2
20 Red Red Red Red Red Red Green 1.02 V ±0.2
21 Red Red Red Red Red Red Red 0.85 V ±0.2
22 Red Red Red Red Red Red Red 0.67 V ±0.2
23 Red Red Red Red Red Red Red 0.50 V ±0.2 MAX. HOT

SP001211
Page 13
Air Conditioner
AIR DISCHARGE ACCORDING
TO PATH SELECTION
Face + Rear
Foot + Rear
FG009196
Figure 9
FG009197
Figure 10

SP001211Air Conditioner
Page 14
Defroster + Rear
FG009198
Figure 11

SP001211
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Air Conditioner

SP001211Air Conditioner
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AIR-CONDITIONING SYSTEM
CIRCUIT DIAGRAM
15A
11
10
85
FOOT
DEF
M3
2
86
M
8
-
87
87a
9
30
+87
87a
85
30
86
7
10
3
6
II
I
9
2
0
6
13
19
(CN7)
12
26
13
23
10
24
25
12 11
202122
7698
(CN1)
15
2
18 17
54
16
3
14
1
1213 1011 8 79
(WARM)
(COOL)
15-9
HRS NO.GT7A-26PD-DS 26P
HRS 26P
CN7
14
6
7
9
26 16
16
4
1
15
14
2
5
1
6
2
3
4
RECIRCLE/FRESH
TEMP. CONTROL
BLOWER SPEED
MODE SELECT
10
AIR MODE
11
LED 1~12
23
21
20
19
7
17
8
10
3
8
5
18
13
11
13
12
9
15-8
AMP MIC 13P
AMP MIC 13P + 250 4P
CN1
15
564
M
123
15-6
15-7
M
M
VENT
DEF
FOOT
FRE
HIGH
LOW
MID
REC
5
22
10A15A 30A
14
15
4
3
15-515-4
+
15-3
M
15-1
-
15-2
E
BR
BA
1
2
FG004394
Figure 12

SP001211
Page 17
Air Conditioner
Reference
Number Description
1 Battery
2BatteryRelay
3 Fusible Link
4 Circuit Breaker
5 Fuse Box
6 Headlight Switch
7 Condenser Fan Relay
8 Condenser Fan Motor
9 Compressor Relay
10 Foot / Defrost Control Actuator
11 Receiver Drier
12 Diode
13 Compressor
14 A/C Control Panel
15 A/C Unit
15-1 Blower Motor
15-2 Resister
15-3 High Speed Relay
15-4 Mid Speed Relay
15-5 Low Speed Relay
15-6 Recirculate / Fresh Air Control
Actuator
15-7 Vent Actuator
15-8 Temperature Control Actuator
15-9 Temperature Sensor
(Evaporator)
Reference
Number Description

SP001211Air Conditioner
Page 18
TROUBLESHOOTING
Refrigerant Pressure Check
1. Open all doors and windows.
2. Install manifold gauge set.
3. Start engine and maintain engine speed at 1,800 -
2,000 rpm.
4. Check high / low-pressure of refrigerant.
Figure 13
1High-pressure: 8 - 10 kg/cm2(114 - 142 psi)
Low-pressure: Approximately 1 kg/cm2 (14 psi)
Possible Cause: Low Refrigerant Level
Step Inspection Item Remedy
1 Check for traces of refrigerant oil. Yes Reassemble using correct tightening
torque.
No Go to next step.
2
Using a leak detection device or soapy water
check for refrigerant leakage at all major
components and joints.
Yes Repair leaking component.
No Recharge system to correct pressure.
2High-pressure: Over 23 kg/cm2(327 psi)
Low-pressure: Approximately 2.5 - 3 kg/cm2 (36 - 43 psi)
Possible Cause: Overcharge, Frost on condenser
Step Inspection Item Remedy
1Check for condenser pin damage or
contamination.
Yes Clean, repair or replace condenser.
No Refrigerant overcharge.