modine service training -

A/S Training for Modine Bus A/CJune 2, 2009

Modine History

Windtunnel in Filderstadt2004

2001

2000

1999

1998

1993

1974

1941

1916

European Headquarters and Tech Center

Serial HT EGR-cooler worldwide

New Tech Center in Racine / USA

Sales exceed 1 billion US$

Company makes its largest acquisition, Lngerer & Reich

Sales exceed 100 million US$

Modines unique, first vehicular windtunnel

Founded by Arthur B. Modine

1926 Start of high volume production with Ford Model T

2004 Acquisition of WiniaMando ACC / Korea2005 Spin-off Aftermarket Start Transpro

Purchased balance of South America Joint Venture2006

Modine Global Network

Worldwide Headquarters &Technical CenterRacine, Wisconsin, USA

European Headquarters &Technical CenterBonlanden, Germany

Korean Headquarters &Asian Technical CenterAsan City, Korea

A/C Application : BAC, TAC & Military Item

City bus Express bus

Subway train Armored vehicle

Chunma

Bus A/C Products

Mini-Bus A/C System (Integrated and Roof Mounted)

Fully Integrated Evaporator and Condenser

Integrated Evaporator and Roof Mounted Condenser

Roof Mounted Condenser and Evaporator

Midi-Bus A/C System and Large Bus A/C Systems

Conventional Roof Mounted Bus Air Conditioner Slim Style Roof Mounted Bus Air Conditioner

New In 2007

New products- Luxury Bus A/C System

One Piece Evaporator and condenser are combined into one unit.

Two Models

Metal Frame

Fiberglass Frame

Under Development (PFC Slim type)

Weight of 15~20% lighter than Pin & Tube type Condenser

Roof-on with Separate Engine(Power pack)

Ring Fans Ring Fans

: Lower Noise

: Air Flow(5,000/Hr),High

12 Single Blower 12 Single Blower

Driven by a Separate Engine

Driven by a Separate Engine

: Hyundai D4BB (40ps/2,200 rpm)1ps = 735.5w (29.42kw)

Compressor Compressor

: MBA-58(575cc/rev)

Alternator Alternator

: DC 24Vx150A Battery less Type

MBA 260 RSN

Composition

Condenser

1. COND.MOTOR&RING FAN 2. COND.COIL 3. RECEIVER TANK 4. DRIER

MBA260RSN MBA240RN

1

1

2

2

3

3

4

Part FunctionD R I E R

The drier absorbs the harmful water inside the cooling system and also filters out the minute dust inside the system. The drier of MBA-260RSN is installed in Evaporator unit.

* The drier of MBA 240RN is installed in Condenser Unit.

When the drier is closed by some minute dust or moisture, it happens the similar symptom by throttle effect like function of Expansion valve.

Part Function

RECEIVER TANK

The Receiver tank temporarily stores the liquefied refrigerant from the Cond. Unit.

The Receiver tank has an inlet, outlet unit and a fusible plug.

When the temperature & pressure inside the liquid tank become abnormally high,

The fusible plug will be melt

Melting temperature of the fusible plug : 105

Plug

Evaporator1. EVAP.MOTOR&BLOWER 2. OPERATION PANEL 3. EXPANSION VALVE 4. TEMP. SENSOR5. EVAP. COIL 6. LOW PRESS. SENSOR 7. SOLENOID V/V 8. DRIER

MBA260RSN MBA240RN

1

1

22

3

3

4

4

5

5

6 7

8

Part Function

Low pressure switchThe Low pressure switch is installed Suction line in the Evaporator Unit.When this switch operates, open Signal sends the unloading valve(= solenoid valve) and then the Solenoid valve is operated to insertHot gas into Evaporator coil.

On 1.4 0.2kg/

Off 2.2 0.2kg/

Part Function

Part Function

EXPANSION VALVE

The Expansion v/v is installed at the evaporator inlet and changes the high pressure liquid refrigerant to a low temperature low pressure liquidby adiabatic expansion. This valve on the Evaporator outlet senses the refrigerant temperature through temperature sensor and autimatically adjusts the amount of refrigerant flowing to the evaporator.

Temperature Sensor

Part Function

SIGHT GLASS

The sight glass is installed on between expansion valve and drier.

And, This is used to check the refrigerant charge in the system and to

check the state of the refrigerant in the liquid line.

Eng. & Comp.

Part FunctionHIGH/LOW PRESSURE SWITCHThese pressure switchs are installed to the Dis. & Suc. service valve. It is a safetydevice which opreates when the refrigerant system pressure rises above thespecific pressure and drops below the specific pressure.When this switch operates, the HI/LOW PRESS alarm lamp on the control panel light on,a buzzer sounds the engine stop device operates. And the air conditioner will be stopsautomatically. The operating pressure of these high/low pressure switchs are shownin the table below.

LOW PRE. S/W

HIGH PRE. S/W

HIGH LOW28.0 1.0/15.0 0.7/

0.5 0.3/2.0 0.5/

Operating pressureResetting pressure

Operating pressureResetting pressure

Compressor

Compressor

BOLT PART TORQUEM6 SIGHT GLASS 10010 kg-

CONNECTING RODUNLOADING VALVECRANK CASE COVERBASE

M8 GLAND 30020 kg-CYLINDER HEADMAIN BEARING COVERSERVICE VALVE(SUC)

M10 OIL DRAIN PLUG 25020 kg-SERVICE VALVE(DIS) 45030 kg-

M14 OIL CHARGE PLUG 35020 kg-

15010 kg-

6-CYLINDERBOLT PART TORQUE

M6 SIGHT GLASS 10010 kg-UNLOADING VALVE 15010 kg-CRANK CASE COVERBASE

M8 GLAND 30020 kg-MAIN BEARING COVERSERVICE VALVE(SUC)CONNECTING ROD 38030 kg-

M10 OIL DRAIN PLUG 25020 kg-CYLINDER HEADSERVICE VALVE(DIS)

M14 OIL CHARGE PLUG 35020 kg-

45030 kg-

4-CYLINDER

Engine

40ps(29.42kw/2,200rpm)

Part Function

AlternatorThe alternator generate electric power during the engine operating time

and supplies electric power to the Cond.motor and the Evap.motor.

Modified Solenoid rpm control

Control PanelC O N T R O L P A N E L

- O n th e s te p s o f K e y"O N "T u rn o n th e O IL & S O U R C E lam p s .

- O n th e s te p s o f "A fte r s ta rt"T u rn o n th e B A T & S O U R C Elam p s .

Basic Circuit

Maintenance cycle

Estimated

Adjustment replacement

time or

standard number of

year

Compressor Oil level check Level check at

sight glass

Inspection Oil leakage

Overhaul 5,000hours

Piping joints Inspection Visual inspection

gas leakage for oil leakage

Inspection Leak detector

R Refrigerant Inspection No bubbles in sight

e charge glass

f Refrigerant Inspection Leakage, damage, 5years

r cylinder aging

I Condenser Cleaning Soiling

g Gas leakage Oil smears

e Inspection

r Evaporator Cleaning Soiling

a Gas leakage Oil smears

n Inspection

t Expansion valve Inspection Operation 3years

Unloading valve Inspection Operation 5years

By-pass valve Inspection Operation 5years

2years

Daily Weekly Monthly Season

Remarks

Inspection period

Inspection Item Work contents

Maintenance cycle

Estimated


time or

standard number of

year

s High and low Inspection Operation 5years

y pressure

s switches

t Relief valve Inspection Gas leakage 5years

e Dryer Inspection No difference 3years

m between inlet and

outlet temperature

Charge valve Inspection Gas leakage, 5years

operation

O-ring Inspection Flange gas leakage 2years

Evaporator filter Inspection, Soiling clogging

cleaning

Evap. Motor Inspection Operation 3years

Cond. Motor Inspection Operation 3years

Duct joint Inspection Deformation, aging 2years

sponge rubber

Moun- Unit sealing Inspection Deformation, aging 2years

ting rubber

Unit suspension Inspection Deformation, 2years

bolts and nuts damage, wear


Remarks

Inspection period


Maintenance cycle

Estimated

Adjustmentreplacement

time or

standardnumber of

year

control Selector switch Inspection Operation

Lamps Inspection Operation

Connectors Inspection Looseness

Power cable Inspection Looseness, damage

Room Inspection Operation

thermostat

Harness Inspection Damage


Remarks

Inspection period


Maintenance cycle

Estimated


time or

standard number of

year

Visual inspection

for oil and fuel No leakage

leakage

Strong:1,700rpm

Medium:1,400rpm

Weak:1,100rpm

Overhaul As stipulated by

manufacturer

P Oil level gauge Visual inspection -

O Replacement According to engine

W instruction manual

E Oil filter Replacement 200Hours

R element

Fuel filter Cleaning 300Hours

U element Replacement 600Hours

N Engine coolant Inspection Level 600Hours

I Radiator hose Inspection Damage,aging 1Year

instruction manual

According to engine

200HoursEngine oil

-

-Speed check

-

Engine


Remarks

Inspection period


Maintenance cycle

Estimated


time or

standard number of

year

Visual inspection

for oil and fuel No leakage

leakage

Strong:1,700rpm

Medium:1,400rpm

P Weak:1,100rpm

O Overhaul As stipulated by

W manufacturer

E Oil level gauge Visual inspection -

R Replacement According to engine

instruction manual

U Oil filter Replacement 200Hours

N element

I Fuel filter Cleaning 300Hours

T element Replacement 600Hours

Engine coolant Inspection Level 600Hours

Radiator hose Inspection Damage,aging 1Year

instruction manual

According to engine

200HoursEngine oil

-

-Speed check

-

Engine


Remarks

Inspection period


Maintenance cycle

Estimated


time or

standard number of

year

P Tension According to engine

O Engine fan belt adjustment instruction manual

W Inspection Damage,aging -

E Alternator Inspection Operation -

R Muffler Inspection Exhaust gas leakage

Air cleaner Cleaning

U element every

N 50Hours

I Engine air

T intake hose

Oil filter joint hose Inspection Cracking,aging 2Years

Leakage

soil

Engine air

breather hose

Engine throttle When engine

valve speed dropsInspection Soil

2YearsInspection Aging

Radiator Inspection

3YearsInspection Cracking,aging

500HoursInspection Cloggy

200Hours


Remarks

Inspection period


Trouble ShootingTrouble Probable cause Corrective cause

1.High pressure too high. 1.Air or uncondensed gas inside.2.Excessive refrigerant charge.3.Condenser air side fins clogged, or dirty.4.Condensor motor faulty.5Ambient temperature too high(poor ventilation)

6.Condenser motor fuse is disconnected.7.High pressure switch faulty.

1.Loosen liquid tank high pressure line joint and condenser inlet joint and vent uncondensed gas.

1.This operation must not be preformed while the air conditioner is operating.2.Discharge refrigerant3.Blow out with air, or wash with water4.Change the motor5.Operate in a well ventilated place.6.Change the fuse7.Inspect and replace switch.

2.High pressure too low. 1.Liquid refrigerant in intake gas from evaporator.(Liquid back)2.Expansion valve faulty.(Open state)3.Unloader valve operated.4.Unloader valve faulty.5.High pressure gauge faulty.6.Compressor discharge valve leaking7.Compressor intake strainer clogged

1.Check if temperature sensor fitted against the suction pipe.2.Inspect and replace valve.3.Set selector switch to HI position.4.Inspect and replace valve.5.Inspect and replace gauge.6.Inspect and replace compressor7.Inspect and clean strainer.


3.Low pressure too high. 1.Excessive liquid refrigerant being supplied from the expansion valve.2.Expansion valve faulty.3.Unloader valve operated.4.Unloader valve faulty.5.Low pressure intake and discharge valve leaking.

1.Check the temperature sensor is fitted against suction pipe repair, if necessary.2.Inspect and replace valve.3.Set selector switch to HI position.4.Inspect and replace valve.5.Inspect and replace gauge.6.Inspect and replace compressor

4.Low pressure too low. 1.Pipeing, drier, expansion valve, etc.Partially blocked.2.Insufficient refrigerant3.Frost on evaporator causing a drop in oil capacity.4.Compartment air intake blocked.5.Air filter closed with dust and dirty6.Dirty and dust on evaporator.7.Piping between temperature sensor and expansion valve damaged, or broken.8.Water inside system froze at expansion valve.9.Evaporator motor faulty.10.Bus compartment too cold.11Outside air temperature and compartment temperature are low.12.Expansion valve faulty.13.Low pressure switch faulty.14.Fuse is disconnected.

1.Remove and inspect parts.2.Check for gas leakage, then charge refrigerant until there are no more bubbles in sight glass.3.Inspect and replaced frosting thermostat.4.Inspectand clean intake.5.Clean air filter.6.Inspect and clean evaporator.7.Inspect and replace expansion valve8.Replace drier discharge gas from system. Remove water component with a vacuum pump, then recharge system with refrigerant.9.Change the motor.10.Switch the selector switch.11.Stop cooling.12.Inspect and replace valve.13.Inspect and replace switch.14.Cahnge the fuse.


1. Can not starting 1. Battery power not enough.2. Fuel pump has air or blocking.3. Fuse burning.4. Air cleaner/nozzle blocking.

1. Alternator/Regulator check & replace.2. Purge or replace Fuel filter assembly.3. Control & relay check replace.4.

2. Cooling is not enough 1. Gas leak or not enough.2. Motor not working. (Evap/Cond)3. Discharge air filter not clear.4. Drier has not working.

1. Check & repair recharging gas.2. Replace motor.3. Cleaning filter. 4. Replace drier.

3. Leaking problem 1. Suc. Dis hose burst.2. Comp seal leaking.3. Eng. Gasket leaking.4. Coil connecting Hose parts.

1. Replace hose.2. Seal or leak position check & replace.3. Replace gasket.4. Check & Repair.

Special checking point. 1. Filter (return air).2. Fuse & relay.3. Every Parts clearance.

Thank you

A/S Training for Modine Bus A/CModine HistoryModine Global NetworkA/C Application : BAC, TAC & Military ItemBus A/C ProductsNew productsUnder Development (PFC Slim type)Roof-on with Separate Engine (Power pack)CompositionCondenser Part FunctionPart FunctionEvaporatorPart FunctionPart FunctionPart FunctionPart FunctionEng. & Comp.Part FunctionCompressorCompressorEnginePart FunctionModified Solenoid rpm controlControl PanelBasic CircuitMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleMaintenance cycleThank you

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