Great Wall V200. Instruction - part 23

 

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Great Wall V200. Instruction - part 23

 

 

CD Player and Air Conditioning System-3

(Figure 7-2) cable position of 2-pin connector socket

                                               

Pos.  No. 

Color 

Function 

Pos.  No. 

Color 

Function 

White 

Send the data (TX) 

11 

Shielded cable 

Earthing of data cable 

Red 

Receive the data (RX) 

12 

— 

— 

Brown 

Telephone mute (TEL) 

13 

Blue 

Automatic antenna (ANT ) 

Orange 

Lighting (LAMP) 

14 

Red 

Ignition power supply (ACC) 

— 

— 15 

 

Grounding 

wire 

— 

— 

16 

Yellow 

Memory power supply B+ 

White and 

black 

Front left speak (-FL-) 

17 

Green and black 

Rear left speak (-RL-) 

White 

Front left speak (+FL+) 

18 

Green 

Rear left speak (+RL+) 

Gray and 

black 

Front right speak (-FR-) 

19 

Violet and black 

Rear right speak (-RR-) 

10 

Gray 

Front right speak (-FR+) 

20 

Violet 

{

Rear right speak (+RR+) 

     

 

 

 

 

 

Possible Troubles of CD Player, Inspection and Analysis 

 

Trouble Descriptions 

Possible causes, inspection and solutions 

No programs received for AM and FM 

Check if the antenna is pulled out and socket becomes 

loosened. 

Impurity of sound after radio auto-searching 

Tune to the correct radio station with instruction tuning method 

No sound of one speaker 

Check the speaker and the socket or adjust the balance(front, 

back, left and right) 

Refuse to work 

Check the power supply, or disconnect and connect the power 

supply and restart the player. 

No power supply 

Check if the plug-in fuse and output plug is loosened and if the 

fuse is burned down. 

Single channel when played 

Check if the speaker is in open-circuit and examine its plug   

Not read CD 

Check the CD type and if it is placed in reverse or scratched.   

Display screen displaying bad 

Check the connecting wire of display screen or adjust the 

brightness level higher 

Air conditioner refuses to start 

Inspect the ECU of air conditioner and air conditioning system 

Button failure of air conditioner   

Inspect the ECU of air conditioner and air conditioning system 

   

A-side View

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CD Player and Air Conditioning System-4

Air Conditioning System

Composition of Air Conditioning System

Air conditioning system mainly consists of air conditioner control unit, display unit, sensors and executor elements.

fresh air damper executor

mode damper executor

emperature damper executor

integrated display screen

CD Player

outside temperature sensor

inside temperature sensor

temperature sensor

of the evaporator

 of the air conditioner

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CD Player and Air Conditioning System-5

1. integrated display screen    2. CD player    3. Air conditioner ECU    4. Temperature sensor the evaporator   5. Outside

temperature sensor

6. Outside temperature sensor    7. Speed-adjusting module    8. Temperature damper executor    9. Mode damper executor

10. Fresh air damper executor

    Definition of each button on CD player of air conditioner panel

[1] Button to increase the temperature   [7] wind conveying mode button

[2] Button to decrease the temperature

[8] button to start air conditioner

[3] automatic operation button

[9] button to decrease the wind amount

[4] front-defrost button

[10] power-off button of air conditioner

[5] rear-defrost button

[11] button to increase the wind amount

[6] external circulation button

    Definition of each button in air conditioning display zone of the integrated display screen

[1] display of inside temperature setting of air conditioner

[5] switch button of outside temperature display

[2] display of automatic operation of air conditioner

[6] display zone of outside temperature

[3] display zone of wind conveying mode of air conditioner

[7] clock display zone

[4] display zone of wind amount of air conditioner

Control and display unit:Control and display unit of the air conditioner mainly consists of:

Air conditioner ECU: The CC6460K model is designed with the individual air conditioner ECU to control the overall operation

of air conditioning system; Air conditioner ECU is installed under the bottom of CD player.The control panel of air conditioner

is designed with an integrated pattern with the control panel of CD player: to regulate, control and set the operation of the air

conditioning system.

Integrated display screen: display the working condition of air conditioning system of the car; relevant functions of air

conditioning system can be found to be displayed in different zone in the integrated display screen.

The sensor

Sensors of CC6460K Model automatic air conditioning system include: inside temperature sensor, outside temperature

sensor, temperature sensor executor of the evaporator.

Executor components include: mode selection executor motor, cold & hot executor motor, internal & external circulation

executor motor.

Trouble Diagnosis and Repair of Automatic Air Conditioning System

1. Self-diagnosis of the system

CC6460K air conditioning system is designed with the system self-diagnosis function. When the air conditioning system fails to

work, the self-diagnosis function designed for the car can be activated for the initial trouble diagnosis.

    

Operating directions:

At first, start the engine (turn the ignition switch from OFF to ON) and press OFF,

 A U TO, RR and MODE successively and the

pressing of MODE switch shall last at least 2 seconds. The button must be pressed down within 10 seconds when the engine is

started (the ignition switch is turned to ON position).If the system is supposed to be released, then press A U TO switch or turn

off the ignition switch (OFF) .If one step is supposed to switch to another step, then press TEMP (HOT) or TEMP (COLD)

switch based on the needs.

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CD Player and Air Conditioning System-6

Turn the ignition switch from OFF to ON

The display symbols all light up

failure of the switch or display tune

NO

Press down “Temp+”  switch

Enter into self-diagnosis procedur1?

NO

“ Temp +” switch failure

Step 1: Display “01”

(set the temperature zone)

all other display symbols turn off

Press down “Temp+” switch

Step 2: Display “02”(set  the
temperature zone)

The inspection procedures

During the period of 10 seconds after the engine is started(turn the ignition switch from OFF to ON), press OF F, A U TO,
RR and MODE once more, and the pressing of MODE switch shall last at least 2 seconds .

All sensors are good.

Display “000”(outsidetemperature)

 

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CD Player and Air Conditioning System-7

Code of failure

Sensor failure

100

Open circuit of outside temperature sensor

200

Short circuit of outside temperature sensor

010

Open circuit of inside temperature sensor

020

short circuit of inside temperature sensor

001

Open circuit of temperature sensor of the evaporator

002

Short circuit of temperature sensor of the evaporator

Step 3: Display “03”(set the temperature zone)

Display the outside temperature value

Press down “Temp+” switch

Step 4: Display “04”(set the temperature zone)

Sensor failure

The code of the sensor with failure
is showed on   the display screen.

Press down “Temp+” switch

Press down “Temp+” switch

Step 5: Display “05”

(set the temperature zone)

          

Display the inside temperature value

Display the temperature value of the evaporator

Press down “Temp+” switch

 

 

 

 

 

 

 

 

 

 

 

 

 

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CD Player and Air Conditioning System-8

Step 6: Display “06”(set the temperature zone)

Press down “Temp+” switch

Display the detection code of mode/
temperature damper executor

Press down “Temp+” switch

Step 7: display “07”(set the temperature zone)

Action of the executor mechanism:
Mode damper: wind to the person
Circulation damper: internal circulation
Temperature damper: cold end
Wind amount: the maximum
Compressor: enabled

Note: X is a digital number without specific meaning; the code
number is displayed in the outside temperature display zone.

 display “08”

C

 

Code number 

Code Meaning 

0x0 

Temperature damper executor works normally 

0x1 

Detection for temperature damper executor is in progress. 

0x2 

Temperature damper executor failure 

00x 

Mode damper executor works normally 

01x 

Detection for mode damper executor is in progress. 

02x 

Mode damper executor failure 

 

 

 

 

 

 

 

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CD Player and Air Conditioning System-9

Step 9: display “09”

Action of the executor mechanism:
Mode damper: wind to the person and the fee
Circulation damper: internal circulation
Temperature damper: in the middle
Wind amount: bigger
Compressor: enabled

Action of the executor mechanism:
Mode damper: wind to the feet and defrost
Circulation damper: external circulation
Temperature damper: in the middle Wind amount: small
Compressor: off

display “10”(set the temperature zone)

Action of the executor mechanism:
Mode damper: wind to the person and the feet
Circulation damper: external circulation
Temperature damper: hot end
Wind amount: medium
Compressor: enabled

Press down “Temp+” switch

Press down “Temp+” switch

 

 

 

 

 

 

 

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CD Player and Air Conditioning System-10

Refrigeration of air conditioner failed

Trouble

Descriptions

Analysis of the Cause

1.No pick-up of compressor

1. fuse burned down, compressor’ s relay damaged

2. pressure switch contact disconnected, short circuit or open circuit of the

routing

3. open circuit of clutch’s winding

4. switch burned down

5. master relay burned down

6. slide of the clutch

7. belt of the compressor broke or too loose

8. compressor failure

9. sensor failure(judged by reading the failure code)

10. insufficient cold media, lower systempressure(< 0.97MPa)

11. system pressure above 1.37MPa

12. water temperature of the engine too high

13.V oltage of the clutch below 7V

2. Pick-up of Compressor

1. normally-open contact of the compressor’ s relay stuck and serious leakage

of system cold media, systemrunning short of cold media

2. no wind fromthe blower

Refrigeration

of

air

conditioning

system failed

3. no wind from the blower

1. fuse burned down

2. motor brush of the blower damaged

3. switch of the blower damaged

4. coming off of distribution wire connectors or circuit disconnected

5. speed-adjusting module damaged

6. no wind fromthe blower when at high speed, high-speed relay damaged

Press down “Temp+” switch

Step 11: display “11”(set the temperature zone)

Action of the executor mechanism:
Mode damper: defrost
Circulation damper: external circulation
Temperature damper: cold end
Wind amount: the minimum
Compressor: off

Attention: during the inspection period from step 7 to step 11, the controller will forcibly transit the output signal based on

the code number displayed on the integrated display screen to the functioned executor; the inspection must be done with

such methods as visual inspection, listening to abnormal sound or touching the air vent by hand so as to judge whether

there is any improper operation.

Trouble Diagnosis and Troubleshooting of A i r Conditioning System
Air cooling system

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CD Player and Air Conditioning System-11

b .Insufficient refrigeration output

T rouble

Descriptions

Analysis of the Cause

Inadequate

refrigeration

1. wind amount

is normal

1. compressor works normally

(1) low-level pressure at high-pressure and low-pressure sides

a. block of expansion valve

b. openness of expansion valve too narrow

(2) high-level pressure at high-pressure and low-pressure sides

a. failure to high-voltage pipeline, flow not smooth

b. malfunction of thermo resistor

c. openness of expansion valve too wide

d. too much refrigeration oil

e. too much refrigerant

f. poor heat dissipation of the condenser

(3) pressure at high-voltage side too low

a. low-pressure pipeline damaged

b. block of low-pressure pipeline

(4)pressure at low-pressure side too low

a. the evaporator frosted

b. block of expansion valve

c. low-pressure pipeline not smooth

d. malfunction of thermo resistor

(5)pressure at low-pressure side sometime normal, sometimes with negative pressure,

moisture and ice block in air cooling system

(6)negative pressure at low-pressure side, pressure at high-pressure side too low, block of air

cooling system

(7)pressure at low-pressure side too low, pressure at high-pressure side too high

a. internal block of drier of fluid reservoir

b. block of high-pressure pipeline

(8)pressure at low-pressure side too high, pressure at high-pressure side too low

a. leakage of the compressor

b. damaged valve of compressor

(9)poor heat radiation of condenser due to small wind amount fromthe condensing blower

2. compressor works improperly

(1)internal malfunction of compressor

(2)belt of compressor too loose or sliding

(3)failure of electromagnetic clutch

a. low voltage of power supply

b. mutual interference of the stator and rotor

c. malfunction of amplifier stabilizing the idle speed

d. circuit disconnected, coming off of the joints

e. poor operation of the switch and relay

f. short circuit and open circuit of the routing

g. poor earthing

3. other causes

bad sealing of wagon

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CD Player and Air Conditioning System-12

e . Precautions for the overhaul of air cooling system

When the air cooling system encounters the trouble, the cause for such trouble shall be analyzed inlightof trouble varieties,

followed with the examination and report work.

c.

T he cooling system sometimes works while sometimes refuses to work.

T rouble

Descriptions

Analysis of the Cause

1. compressor works normally

1. ice block in the cooling system
2. failure of thermal resistor or temperature sensing bulb
3. poor contact of A/C switch
4. condensing blower damaged

T he

cooling

system

sometimes

produces

refrigeration

effect

while

sometimes not.

compressor works improperly

1. slide of the clutch
2. coming off of the clutch’ s winding
3. poor earthing of clutch’ s winding

d.

Noise of the air cooling system

T rouble

Descriptions

A nalysis of the Cause

Noise of the air cooling system too
loud

Noise too loud

(1) belt too loose or worn too much
(2) fastening screw of mounting holder of the compressor

loosened

(3) mounting holder of the compressor damaged
(4) internal parts of the compressor damaged
(5) too much refrigeration oil or none
(6). slide of the clutch
(7). B earing of the clutch running short of oil or damaged
(8). motor bearing of the blower damaged
(9) holder of the blower broken or loosened
(10) blade of the blower broken or loosened
(11). Friction of the blower’ s blade with other components

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CD Player and Air Conditioning System-13

1. CC6460K air conditioning system is designed with SD7V16 compressor, whose refrigeration oil type as

specified is SP-10PAG; hence application of other type of refrigeration oil may damage the parts and compo
nents of the compressor. When the air conditioning system goes through maintenance and replacement of
parts, it should be added with new refrigeration oil, whose volume is listed as follows: the evaporator and
condenser: 30ml; the drier: 20ml; the pipeline: 10ml.

     Addition of refrigeration oil can be available with two methods: The direct addition and the vacuum suction

2. Direct addition method

a. remove the oil filler plug and fill with the specified SP-10PAG refrigeration oil.

b. observe through the hole of oil filter plug and rotate front plate of clutch to make the piston connecting rod right position in the

    center of the hole of oil filter plug.

c. insert the dipstick along the right side of piston connecting rod till the top of dipstick touches the case of the compresso r

d. pull out the dipstick and examine the graduations (grooves) of refrigeration oil, the readings shall be within the range of 4-6

    scales.

e. screw firmly the oil filter plug with the fastening torque of 14.7± 4.9N. m

3. Vacuum suction method:

Firstly pump out the refrigerating system to the vacuum of 0.2x105Pa, and then fill with the specified 0.2x10

 5

 Pa refrigeration oil;

the detailed steps are as follows:

a. switch off the high-pressure instruction valve and the auxiliary valve.

b. dismantle the high-pressure side hose from the manifold pressure gauge and insert it into the oil cup

c. open the auxiliary valve and have the refrigeration oil sucked into the refrigerating system from the oil cup.

d. when the refrigeration oil in the oil cup is almost pumped out to the vacuum, then immediately turn off the auxiliary valve to

    prevent the air from being sucked into the system.

e. secure the hose adapter at high-pressure side to the manifold pressure gauge, start the vacuum pump and turn on the high-

   pressure instruction valve, then turn on the auxiliary valve to pump the system to the vacuum state of 0.2x10

5

Pa, keep such state

   for 15mins so as to discharge out the air flowing into the system along with the oil.

Volume of Refrigeration Oil Addition and its Methods

2.air heating system

T rouble

C auses of the trouble

Heating not supplied or
not sufficiently supplied

1. blower of air conditioner failure 2. relay of the blower damaged
3. heating water pipe blocked

4. cooling water pipe blocked

5. cold/hot damper executor damaged 6. insufficient cooling liquid

No rotation of blower

1. fuse burned down or poor contact of the switch
2. motor of the blower burned down
3. open circuit of high-speed relay of the blower
4. speed-adjusting module damaged
5. short circuit

leakage of water

W ater pipe of air heating aged, insecure joint

Overheat

1. speed-adjusting resistor of the fan damaged
2. cold/hot damper executor damaged

Insufficient hot air
volume for defrosting

1. mode executor damaged
2. falling off of the drive rod
3. damper not in position
4. air vent blocked
5. inadequate heating supply
6. installation of wind tunnel not fit
7. circuit disconnected

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CD Player and Air Conditioning System-14

Pumping Out of A i r Conditioning System to the Vacuum and Addition of Refrigeration Oil

Connect the manifold pressure gauge with the pipe of air conditioner (compressor) and the multi-purpose adapter of the vacuum

pump for the purpose of pumping out of the system to the vacuum state.

Before pumping out to the vacuum, turn on the high-pressure and low-pressure valve of the manifold pressure gauge and the end valve

(if provided) of the vacuum pump, then press the button ON to start the vacuum pump, the duration shall be more than 20 minutes.

When the reading of manifold pressure gauge is -760mmHg or below, turn off the high-pressure and low-pressure valve (if opened),

and press the switch to turn off the vacuum pump

.

1. check the air tightness

Continue to check the pressure reading of the manifold pressure gauge after turning off the vacuum pump.

If the pressure reading remains unchanged within 20 minutes after the vacuum pump stops running, then it indicates that th e

refrigerating system has no leakage, the operator can proceed with next work; while change of the reading indicates that the

system has the leakage. Launch the examination and pump out to the vacuum after the leakage is fixed.

2. Injection of the refrigerant

When the air tightness of the system is verified correct, connect the refrigerant reservoir (or gas bottle) with one end of the yellow

air-charging hose, while other end of yellow air-charging hose is connected with the liquid injection port in the middle of the

manifold pressure gauge. Ensure that the refrigerant reservoir is connected firmly with the nut of air-charging hose, then turn on
the valve of refrigerant reservoir; at this time, the high-pressure and low-pressure is closed, use a tip screw driver or other similar
tools and press the by-pass valve spool for 1~ 2 seconds to discharge out the air in the air-charging hose and the manifold
pressure gauge.

low pressure

high pressure

manifold pressure gauge

quick coupler

low-pressure pump

high-pressure pipe

quick coupler

quick

 coupler

red

blue

vacuum pump

manifold pressure gauge

low pressure gauge

high pressure gauge

Red

blue

yellow

yellow

4. Attention:

a. when a new compressor is used to substitute for the old one, the oil must be released to some extent that its oil volume  is the

 same as that of old compressor so as to avoid the influence over the refrigeration effect due to too much oil.

 b. when an old or repaired compressor is employed, the volume of the refrigeration oil in the compressor must be kept the same

as that of the replaced compressor.

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CD Player and Air Conditioning System-15

Turn on the high-pressure valve on the manifold pressure gauge and inject the refrigerant to the system from high-pressure pipeline.

At this time, the attention shall be given to the readings of high-pressure meter and low-pressure meter, and make sure that these two

pressure all go up. If the refrigerant is being injected while the pressure does not go up, then the joints of the pipeline may be loosened

or the seals damaged, inject the refrigerant once more after finding out the cause and the fixing. When the increase of pressure stops,

turn off the high-pressure valve of the manifold pressure gauge and then start the engine

.

Operate the switch in a way as follows:

     Turn the switch of air conditioner to “ON”

Regulate the temperature controller to the coolest position,

Enable the air conveying to the maximum,

Select the internal air circulation between the internal/external air circulation,

During this process, the door and windows will be all opened.

Adjust the engine’s speed to the specified free running speed.

Erect the refrigerant reservoir or gas bottle (have the refrigerant injected into the refrigerating system in a gas state), turn on the

low-pressure valve of the manifold pressure gauge.

When the compressor is at work, please do not turn on the high-pressure valve.

Before checking the refrigeration level, please confirm the injection volume of the refrigerant specified for air conditioning system.

When injecting the refrigerant, carefully observe the high-pressure side of the manifold pressure gauge and the flow condition of

the refrigerant (clear, foaming or turbid), all these could be viewed through the inspection window, by which the moment of stop

injecting the refrigerant can be reasonably judged(turning off the low-pressure valve).

air washing

off

off

tip screw driver

red

yellow

blue

refrigerant reservoir

high-pressure

low-pressure

off

low-pressure pipe

high-pressure pipe

refrigerant reservoir

yellow

red

blue

on

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CD Player and Air Conditioning System-16

refrigerant reservoir

high-pressure pipe

low pressure

high pressure

yellow

red

blue

on

on

low-pressure pipe

When judging the injection volume of the refrigerant, please make the settings based on the following working conditions:

Water tank temperature of the engine: stable

Speed of the engine: normal free running speed

 Switch of air conditioner: ON

Switch of the fan: “High” gear

Temperature controller: air return temperature inside the car is between 25

 and 30

.

Fresh air control: internal circulation

Door: all opened

Window: all opened

Repair and replacement of pipeline

a. Before installation of parts and components, the negative pole of the accumulator must be disconnected.

 cut off

b. When the air entries of the refrigerating system, water tank of the engine and the air conditioner are opened, please make sure that

all openings are capped to prevent the penetration of the dust, foreign matters or water.

                                p

rotective cap                                                             protective cap

protective cap must be installed.

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CD Player and Air Conditioning System-17

Daily Maintenance of Air Conditioning System

In order to ensure normal operation of air conditioning system, maintenance and care services shall be frequently performed for the

air conditioning system. The daily maintenance of air conditioning system is illustrated as follows:

1. Inspect, wash and clean the condenser of air conditioning system, requiring that radiator pins are clean and there is no dirt

between the pins. After the car runs in the rain or on the muddy road, the fan of the condenser should be inspected to find

whether it bears the earth, sand, stone and etc, and remove them if any.

2. Check the quantity of the working media of the refrigerating system; when the compressor set works normally, observe the

liquid viewing glass, under the normal circumstance, there shall be not air bubbles in the glass.

3. Inspect the drive belt. The belt between the compressor and the engine should be tensioned.

4. Check if there is any abnormal noise or odor in the air conditioning system.

5. Check if the temperature difference between the air inlet and outlet of the compressor is normal.

6. Check if the hose of the refrigerating system is in an apparent good condition and connections of all joints are secure.

7. Check if the pipeline of the refrigerating system collides with other parts and components, and if there is any oil leakage trace

left at each joint.

8. Check if the circuit connection of the refrigerating system is secure and if there is an occurrence of short circuit and falling off

9. Check if fastening bolts of the compressor are firmly secured or broken.

d. When connecting the pipe, apply little compressor oil to the O-ring and fasten the nut with two wrenches. Attention: never

spatter the compressor oil to the painted parts or the plastic components to avoid the corrosion. If these components are

spattered with the oil, please clean it immediately.

e. When connecting the pipe, please follow the torque listed in the following table to fasten the screws or the nuts:

Diameter of Pipe 

Fastening Torque (N·m) 

¢8mm 12-15 

¢16mm 30-35 

30-35 

     

 

At ends of each pipe the protective caps should be installed till the pipe is connected to the refrigerating system.

                                  compressor oil                                 fasten it by using two wrenches at the same time

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Safety airbag-1

Chapter 12

Safety airbag

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