HVAC

Heating, Ventilation and Air Conditioning

Basic Principles and

the Challenger
System
Basic principals of Air Conditioning
Temperature
A measure of the intensity of heat usually measured in degrees
Celsius (°C).
Heat
Heat is a form of energy, the unit of measurement is a Joule or kJ.
Pressure
Atmospheric pressure at sea level is 1.01 bar. A difference in
pressure will mean that a liquid will have a different boiling point.
Lower pressure = Lower boiling point
Higher pressure = Higher boiling point
R134a has a boiling point of -26°C at normal atmospheric pressure so it can be safely
stored under pressure in a liquid form.
Compression – Condensation - Evaporation

Condensation

Compression

Evaporation

1 Air heated by absorbing heat 2 Air cooled by removing heat

High pressure vapour

High pressure liquid

Low pressure saturated vapour

Low pressure vapour

There are 3 different kinds of compressors available for air con systems;

Piston Type
Scroll Type
Rotary Vane
Condenser

• Input to the condenser is high pressure,

high temperature vapour.

• Output of the condenser is high pressure,

high temperature liquid.

• The vapour is condensed into a liquid due

to the ambient air being blown over/through
the condenser.
Receiver Drier

The purpose of the receiver drier is to;

• Filter and dry the refrigerant before going to the TXV
There are two systems within the Challenger brand;

Fixed Orifice Tube (FOT)

Before ‘W’ serial no.

TXV (Thermostatic Expansion

Valve) found on tractors from
January 2011.
The Fixed Orifice Tube

• supplies a fixed amount of refrigerant to the evaporator

• efficiency is dependant on ambient temperature
• requires an accumulator to protect the compressor from liquid
refrigerant.
FOT

The FOT reduces the pressure in the system before going to the evaporator.
TXV

Advantages of TXV’s over FOT are;

• The volume of refrigerant is regulated by the TXV.

• Outlet temperature of the evaporator determines

the position of the TXV and the amount of
refrigerant going in to the evaporator.

• The evaporator should never become flooded as

the TXV controls the evaporator input.
TXV

The TXV regulates the pressure into the evaporator but will adjust according to
the temperature coming out of the evaporator.
TXV
Evaporator

The evaporator receives low

pressure, low temperature
refrigerant from the TXV.
When the warm air passes over
the evaporator it causes a
change in state as the warm air
changes the low pressure
refrigerant liquid into a low
pressure vapour.
 TXV
&
Water Valve

Condenser
HVAC Unit

Receiver/Drier

Compressor
Pressure Switches

Left: The high pressure switch monitors the

pressure in the high side of the AC system
(compressor to condenser). Switch operates from
40 to 406 PSI (2.8 to 28 Bar).

Right: The low pressure switch monitors the

pressure in the low side of the AC system
(evaporator to compressor). Switch operates
from 5 to 15 PSI (0.3 to 1.0 Bar).
Manual HVAC - Component Locations
AC Button: Switches the
compressor on/off. The
Resistor Pack: Controls the fan speed on Manual compressor will then only switch
HVAC systems once the operator has set it on the off if the evaporator probe shows
panel that the evaporator is frozen.

Fan Speed: So the operator

can adjust the fan speed.

Temperature control: Controls

the amount of engine coolant
going through the water valve.
Manual HVAC - Component Locations

Right: The HVAC evaporator

probe will cycle the compressor
clutch as it monitors the
evaporator temperature. If the
evaporator drops below
33⁰F/0.5⁰C then the
compressor will switch off until
Above: TXV and water valve on a Manual system. it returns to its normal state.
These components can be found in the same
location on a Deluxe system but the water valve
is controlled by the ECU but on a Manual system
it is controlled by a cable by the operator.
Deluxe HVAC - Component Locations
Display Information

Inside Temp Decrease:

Lowest evaporator
temp achieved when
set to 15 ⁰ C (60⁰F).

Inside Temp Increase

Duct Output: Allows the

operator to direct the air
towards the windscreen,
the operators upper and
lower body or all three.

Above: The fan speed is controlled by the HVAC ECU which is

located under the fan. On top of the fan cover is a temperature Fan Speed: Sends a signal to
sensor which monitors the output temperature of the fan. the HVAC ECU to control the
fan motor speed.
Deluxe HVAC - Component Locations

Deluxe Water Valve: The

deluxe water valve is
regulated by the HVAC ECU
and will adjust depending on
the inside temperature
sensor, blower output
temperature to try and
maintain the control panel
settings.
Inside Temp Sensor: The cab temperature sensor monitors the
inside temperature so that it remains at the operator
requested temperature that is set on the control panel.
Air Con Troubleshooting - Electrical

Error codes for the Deluxe HVAC

system can be seen by;
• Having the control panel on
• Press the outside temperature
button three times.
• If there are multiple errors with the
system then keep pressing the
outside temp button to scroll
through the active errors
Air Con Troubleshooting - Electrical
Entering Advanced Diagnostics Functions

With the control panel on, go into the error code reading screen of the HVAC panel and then press and hold the outside
temperature button again for 5 seconds to view real time diagnostics. The text ‘CAB’ will be displayed and after a few
seconds the cab temperature will be shown. Press the outside temperature button again to scroll through the available
diagnostic information.

• CAB Cab Air Temperature

• DUCT Duct Air Temperature

• EUAP Evaporator Core Temperature

• A-C A-C Clutch Request (on/off)

• HEAT Water Valve Position (0 to 100% open)

• PRES Pressure Cut Out Switch (on/off, off=pressure limit exceeded)

• SUN Sun Load Value (0 to 100, 100=max sun load detected)

• FAN Blower Fan Duty Cycle (0 to 100, 100=maximum speed)

• DOOR Mode Door Actuator Feedback Position (0 to 100% of travel)

In order to measure the pressures in AC systems two gauges need to be used.

Compound Gauge Pressure Gauge

Compound Gauge – Indicates pressure or vacuum values within the system (low
side).
Pressure Gauge – Indicates pressure in the system (high side)
Air Con Troubleshooting
Gauge Readings
Low side – normal
High side - normal

Other Symptoms
• Discharge air – slightly cool but may not cool well during hot part of the day.
• Low side gauge does not fluctuate with switch ‘on’ and ‘off’ cycle.

Diagnosis
• Some air and moisture in the system.

Correction
1. Leak test system. Leak test the compressor seal area and self sealing couplings very carefully.
2. Remove refrigerant from the system
3. Repair leaks as located
4. Replace receiver – drier as it is probably saturated with moisture.
5. Check the PAG oil level in the compressor.
6. Evacuate the system for at least 30 minutes
7. Charge with R-134a
8. Operate the system and check the performance.
Air Con Troubleshooting
Gauge Readings
Low side – normal
High side - normal
Other Symptoms
• Discharge air – becomes warm as low side cycles into vacuum. As moisture is
released by saturated desiccant, it becomes trapped and freezes at the
expansion valve, blocking refrigerant flow to evaporator.
• Discharge air – becomes warm all the time during the hot part of the day.
Warmer ambient temperatures cause more moisture to be released from
saturated desiccant and blocks refrigerant from entering evaporator..

Diagnosis
• Excessive moisture in the system.

Correction
1. Leak test the system. Leak test the compressor seal area and self sealing couplings very carefully.
2. Remove refrigerant from system.
3. Repair leaks as located.
4. Replace receiver – drier. The drier is probably saturated with moisture.
5. Check the oil level in the compressor.
6. Evacuate the system for at least 30 minutes.
7. Charge the system with R-134a.
8. Operate the system and check the performance.
Air Con Troubleshooting

Gauge Readings
Low side – normal
High side - normal

Other Symptoms
• Compressor – cycles ‘on’ and ‘off’ too fast.
• Low side gauge – not enough range shown on low side gauge.

Diagnosis
• Defective temperature control system.

Correction
1. Stop the engine and turn the air conditioner off.
2. Check the electrical components of the air conditioning system and repair defective components.
3. Operate the system and check performance.
Air Con Troubleshooting
Gauge Readings
Low side – low or vacuum
High side - low

Other Symptoms
• Discharge air – slightly cool.

Diagnosis
• System slightly low on R-134a.

Correction
1. Leak test the system.
2. Discharge refrigerant from the system if necessary to replace units or lines.
3. Repair leaks as located.
4. Check the oil level in the compressor. System may have lost oil due to leakage.
5. Evacuate the system using the vacuum pump.
6. Charge the system with R-134a.
7. Operate the system and check the performance.
Air Con Troubleshooting
Gauge Readings
Low side – low or vacuum
High side - low

Other Symptoms
• Discharge air – warm.

Diagnosis
• System very low on R-134a.
• Possible leak in system.

Correction
1. Leak test the system.
2. Leak test the compressor seal very carefully.
3. Discharge refrigerant from the system if necessary to replace units or lines.
4. Repair leaks as located.
5. Check the oil level in the compressor. System may have lost oil due to leakage.
6. Evacuate the system using the vacuum pump.
7. Charge the system with R-134a.
8. Operate the system and check the performance.
Air Con Troubleshooting
Gauge Readings
Low side – low
High side – low to vacuum

Other Symptoms
• Discharge air – slightly cool.
• Expansion valve – sweating or frost build up.

Diagnosis
• Expansion valve stuck closed.
• Expansion valve inlet blocked.
• Temperature sensing malfunction.

Correction
1. Clean out expansion valve or replace.
2. Evacuate the system using a vacuum pump
3. Charge the system with R-134a
4. Operate the system and check performance
Air Con Troubleshooting
Gauge Readings
Low side – low
High side - low

Other Symptoms
• Discharge air – slightly cool
• High side lines – cool and also shows sweating or frost. Frost will build up after
the point ofrestriction.

Diagnosis
• Restriction in the high side of the system.
• Receiver-drier malfunction.

Correction
1. Discharge the system.
2. Remove and replace the receiver-drier, liquid lines or other defective components.
3. Evacuate the system using the vacuum pump.
4. Charge the system with R-134a.
5. Operate the system and check performance.
Air Con Troubleshooting
Gauge Readings
Low side – high
High side - low

Other Symptoms
• Compressor noisy (if the compressor is not noisy with these gauge readings, the
problem may be a loose or torn drive belt).
• Discharge air – slightly cool.

Diagnosis
• Compressor malfunction.

Correction
1. Discharge the system.
2. Remove, repair or replace the compressor.
3. Check the compressor oil level.
4. Replace the receiver-drier if:
• The system has been previously opened
• The system has operated for two or more seasons with the current unit
• Compressor inspection reveals desiccant particles inside (very fine golden or brown particles)
5. Evacuate the system using the vacuum pump
6. Charge the system with R-134a
7. Operate the system and check performance
Air Con Troubleshooting
Gauge Readings
Low side – high
High side - high

Other Symptoms
• Discharge air – warm
• High side lines – very hot.

Diagnosis
• Malfunctioning condenser or over charge
• High/Low pressure safety cut-out switch in operation

Correction
1. Inspect the condenser for blocked air passages, bent or damaged fins, or other obstructions.
2. Check the tractor engine radiator is not restricted.
3. Carry out an inspection of the tractors engine cooling system.
4. Operate the system now and check the performance (if gauge readings still high continue to step 5).
5. Discharge the system
6. Remove and inspect the condenser to ensure free passage of refrigerant or replace the condenser.
7. Replace the receiver-drier
8. Evacuate the system using the vacuum pump.
9. Charge the system with R-134a.
10. Operate the system and check performance.
Air Con Troubleshooting
Gauge Readings
Low side – high
High side - high

Other Symptoms
• Discharge air – slightly cool.

Diagnosis
• Large amount of air and moisture.

Correction
1. Discharge the refrigerant from the system.
2. Replace the receiver-drier which may be saturated with moisture.
3. Evacuate the system using the vacuum pump.
4. Charge the system with R-134a.
5. Operate the system and check performance.
Air Con Troubleshooting
Gauge Readings
Low side – high
High side – normal to high

Other Symptoms
• Discharge air – warm.
• Evaporator – normal to high.

Diagnosis
• Expansion valve stuck open.

Correction
1. Discharge the refrigerant from the system.
2. Replace the expansion valve.
3. Evacuate the system using the vacuum pump.
4. Charge the system with R-134a.
5. Operate the system and check performance.
Air Con Troubleshooting
Gauge Readings
Low side – very low or zero
High side – very low or zero

Other Symptoms
• Discharge air – warm.
• Evaporator – very low or zero.

Diagnosis
• High/Low pressure safety cut-out switch in operation
• Loss of refrigerant.

Correction
1. Leak test the system.
2. Discharge the refrigerant from the system if necessary to replace units or lines.
3. Repair leaks.
4. Evacuate the system using the vacuum pump.
5. Charge the system with R-134a.
6. Operate the system and check performance.