Mazda TTCC007700--1155--0011H User manual

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Air Conditioning
Operation & Diagnosis
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Student Guide
Mazda Motor Corporation
Technical Service Training

AIR CONDITIONING
SG00 - General
SG00-1
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OUTLINE
Air conditioning operation & diagnosis course is 2-day training and centered on
Manual air conditioning system. Through this course, you can learn most frequent
services for air conditioning, such as Performance check, Refrigerant charge, and
Symptom troubleshooting.
The course begins with reviewing A/C Fundamentals (Mazda Masters Level F); you
are required to bring your textbook “A/C Fundamentals” to this training session.
Student guide and Student activity sheet are to be provided before the session starts.
In the Student guide and the Student activity sheet, you will find some questions and
tables that some information is intentionally removed. Try to answer to the question in
reference to what you have learnt so far and get information from relevant service
materials, such workshop manual and wiring diagram.
NOTE This course is developed based on the service materials of Mazda 3 included
in the CD-ESI (Electronic Service Information) 2/2004 Ver. 3.0 CD08-XX-04BE.
OBJECTIVES
After completing this course, you will be able to:
 Describe a refrigeration cycle and what part the components play in the
cooling process.
 Identify major components of a manual A/C system
 Identify the components of Manual Air Conditioner and distinguish the
components from those of Full-auto Air Conditioner.
 Describe a control system and how the system controls the Manual Air
Conditioner.
 Identify major components of a manual A/C system
 Locate A/C system protection devices
 Explain the function of protection devices
 Conduct A/C performance checks
 Perform A/C refrigerant charging
 Perform checks for A/C components
 Isolate trouble cause based on Symptom based approach

AIR CONDITIONING
SG00 - General
SG00-2
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CONTENTS
SG00 – General
SG01 – Basic System
Activity01 - Identifying A/C Components
Activity02 - Locating A/C Protection Devices
Activity03 - A/C performance Check
Activity04 - Refrigerant Charging
SG02 – Control System [Manual Air-conditioning]
Activity05 - Units and parts checks*
Activity06 - Symptom troubleshooting

AIR CONDITIONING
SG00 - General
SG00-3
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TIMETABLE
Day 1
Time Session Remark
8:30 – 9:00 Introductions
9:00 – 10:20 Review A/C Fundamentals A/C Fundamentals textbook
10:20 – 10:30 Break
10:30 – 11:50 Basic System SG (Classroom)
12:00 – 13:00 Lunch
13:00 – 14:50
Identifying AC Components
Locating AC Protection Devices
Refrigerant Pressure Check
SG Activity (Workshop)
14:50 – 15:00 Break
15:00 – 17:00 Performance Check SG Activity (Workshop)
Day 2
Time Session Remark
8:30 – 9:50 Control System SG (Classroom)
9:50 – 10:00 Break
10:00 – 11:50 Units and parts checks SG Activity (Workshop)
12:00 – 13:00 Lunch
13:00 – 14:50 Symptom troubleshooting SG Activity (Workshop)
14:50 – 15:00 Break
15:00 – 16:40 Course completion test
16:40 – 17:00 Session evaluation
Conclusion
Attendees satisfaction survey
This schedule is subject to change when necessary.

AIR CONDITIONING
SG00b - Pre-Test
SG00b-1
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1. Technician A says the refrigerant used in the A/C system absorbs and releases
large amounts of heat as it changes from a liquid to a gas.
Technician B says as the refrigerant circulates through the tubes and hoses of an
operating A/C system, it constantly changes from a liquid to a gas and back to a
liquid again.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
2. Technician A says that at point E in
this illustration the refrigerant is high
pressure vapor.
Technician B says at point E in this
illustration the refrigerant is a low
pressure vapor.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
3. One BTU is the amount of heat needed at sea level to raise the temperature of
one pound of water;
a. One degree Centigrade
b. Ten degrees Centigrade
c. Ten degrees Fahrenheit
d. One degree Fahrenheit
4. Technician A says the latent heat applied to change a substance from a liquid to a
vapor is called the latent heat of vaporization.
Technician B says the latent heat applied to change a substance from a liquid to a
vapor is called the latent heat of condensation.
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician

AIR CONDITIONING
SG00b - Pre-Test
SG00b-2
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5. Technician A says in a Mazda A/C system the refrigerant changes state from a
liquid to a vapor in the compressor while losing heat.
Technician B says the compressor acts as a pump for the refrigerant in an A/C
system.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
6. Technician A says the compressor increases the temperature of the vaporized
refrigerant without adding heat.
Technician B says the compressor raises the pressure of the vaporized refrigerant
and not the temperature.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
7. Which component in this
illustration receives hot, high
pressure refrigerant gas from the
compressor and transfers the heat to
the outside air.
a. 2
b. 3
c. 4
d. 5
8. Technician A says the expansion valve or orifice tube controls the amount of
refrigerant entering the evaporator.
Technician B says the accumulator regulates the refrigerant flow to the evaporator.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
1
2
3
4
5

AIR CONDITIONING
SG00b - Pre-Test
SG00b-3
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9. Which component in this
illustration removes heat from the
passenger compartment and
transfers it to the refrigerant?
a. 2
b. 3
c. 4
d. 5
10. At point A the refrigerant is;
a. High pressure liquid
b. High pressure vapor
c. Low pressure liquid
d. Low pressure vapor
11. Technician A says R-12 and R-134a system have different-sized service valves,
to prevent accidental mixing of refrigerants.
Technician B says R-134a systems use larger, metric-thread, quick connect service
valves.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
1
2
3
4
5

AIR CONDITIONING
SG00b - Pre-Test
SG00b-4
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12. Technician A says do not expose refrigerant to open flame. R-12 may produce
poisonous phosgene gas, and R-134a may support combustion.
Technician B says a propane torch style leak detector is the best type of detector for
R-12 and R134a systems.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
13. Technician A says if refrigeration oil is not sealed properly, it will absorb moisture
from the air.
Technician B says you can reuse refrigeration oil removed from an operating A/C
system.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
a. Neither technician
14. Technician A says after repairs have been performed, or if a system has been
open for a long period of time, the system must be evacuated to remove moisture
and ensure that it will hold a vacuum.
Technician B says the minimum time any system should be evacuated is 15 minutes.
The longer the system has been open, the longer it should be evacuated.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
15. Technician A says all refrigerant should be recovered and recycled.
Technician B says only R-12 needs to be recovered and recycled.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician

AIR CONDITIONING
SG00b - Pre-Test
SG00b-5
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16. Technician A says the accumulator traps liquid refrigerant allowing it time to
completely vaporize.
Technician B says if liquid refrigerant reaches the compressor it could be damaged.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
17. Technician A says small refrigerant leaks are normal and the refrigerant should
be replaced once a year as a maintenance item.
Technician B says if the refrigerant has leaked out of an A/C system the technician
should charge the system with a small amount of refrigerant for leak testing purposes.
Who is correct?
a. Technician A
b. Technician B
c. Both Technicians
d. Neither technician
18. This method of charging an A/C system adds gaseous refrigerant through the
low-side service valve while the compressor is running.
a. Liquid charging
b. Vapor charging
c. Both answers a and b
d. Neither answer a or b
19. The component in this illustration divides the A/C system into high and low
pressure sides, what is it?
a. Fixed orifice tube
b. Expansion valve
c. Accumulator
d. Receiver dryer

AIR CONDITIONING
SG00b - Pre-Test
SG00b-6
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20. Which statement is true about this
climate control plenum assembly?
a. All air passes through the
evaporator
b. The air is being re-circulated
c. The temperature blend door is set
for max heat
d. All the above