AC Repair Manual PDF

SONGZ Users Manual of Exterior Overhead Air Conditioner
Company Profile
Established in June 2002 with total investment of USD 15.50 million, SHANGHAI SONGZ
AUTOMOBILE AIR CONDITIONING CO., LTD. is a solely foreign-funded enterprise
specialized in the research and development, manufacture and marketing of automobile airconditioning system. The companys headquarter is located in No. 4999, Huanning Road,
Xinzhuang Industrial Zone, Shanghai, covering an area of 110 mu. Now it has more than
2000 employees, among which there are over 300 specialists with middle or high professional
titles. In addition, it holds the shares of Xiamen SONGZ, Anhui SONGZ, Chongqing SONGZ,
Beijing SONGZ, Chengdu SONGZ, and Nanjing Boshilan. It passed ISO/TS 16949:2002
Quality Management System Certification and Automobile Products Certification. In 2007,
it was awarded 'Outstanding Hi-tech Enterprise and Advanced Technical Foreign-funded
Enterprise'. In addition, with complete technical standards system, the company is one of the
key units that are designated to draft the national standards of air-conditioners for passenger
vehicle. Consecutively for many years, it has been crowned 'the Flagship Enterprise of
Air-conditioners for Passenger Vehicle' and 'the Best Manufacturer of Air-conditioners
for Passenger Vehicle' conferred by Urban Vehicle Experts Committee of the Science and
Technology Commission under the Ministry of Construction and BAAV.
In March 2008, SONGZ AUTOMOBILE AIR CONDITIONING CO., LTD was reorganized as
SONGZ AUTOMOBILE AIR CONDITIONING Corporation. Its registered capital amounted
to RMB 180 million controlled by 11 shareholders including Chen Fuquan, BEIJING BASHI
CO., LTD, NANJING ZHONGBEI (GROUP) CO., LTD and SHANGHAI DAZHONG
PUBLIC UTILITIES (GROUP) CO.,LTD, etc. On July 20, 2010, SONGZ was successfully
listed in Shenzhen small and medium-sized market where the stock was abbreviated as SONGZ
SHARE with code number 002454.
Specialized in manufacturing automobile air-conditioner, SONGZ is the largest manufacturer of
air-conditioning system for large and medium-sized passenger vehicles in China. Taking selfbrand operation as the core and being market-oriented, the company independently researches
and develops, designs, and sells a variety of automobile air-conditioner products, which are
widely used in various vehicles including large and medium passenger vehicle, bus, van, light
bus and railcar. The company has filled the blank in air-conditioner production for doubleCreate healthy human living space
decker bus in China, and it also manufactured air-conditioners for Beijing Olympic new energy
bus and BRT bus.
Contents
In the future, SONGZ will seize the opportunity of fast development in automobile airconditioner industry by giving full devotion to its specialization and intensifying investment in
R&D, growing into an industry leader who boasts technology, brand and cost advantages and
give satisfaction to enterprise, staff, client and shareholder. In addition, it will make efforts on
the promotion of environmental and energy-efficient products, and assume social responsibility
to become an honored enterprise.
Notice to users
Chapter I Cautions
Chapter II Product Description
Chapter III Operation and maintenance of air conditioner
Chapter IV Operation and maintenance of contained air conditioning unit 17
Create healthy human living space
Chapter V Fast diagnose and treatment of common faults
25
Common Used Circuit Diagram
34
Notice to users
Chapter I Cautions
Dear users,
1.1 Safety Issues
Thank you very much for purchasing our bus air conditioning unit!
2. Dont touch the driving parts (fan, belt, belt pulley, etc) and high-temperature parts
1. Promptly switch off the air conditioner if fault alarm occurs.

(compressor and high pressure pipeline) of the system during operation or after shutdown of
For your correct usage, maintenance and troubleshooting of the air conditioner, the Manual
the air conditioner.
describes in related details as your reference when necessary. The information included in the
3. The electrical part of the air conditioner shall work in dry.
Manual is applicable to the driver and mechanic who operate SONGZ bus air-conditioner.
4. To avoid accidents, the air conditioner shall only be dismounted by maintenance worker.
5. Following operations are not allowed.
Please hand over the Manual to the driver.
a. Directly inflate the air conditioning system with nitrogen for pressurized leak detection
The Manual is used in conjunction with Product Quality Warranty Manual.
without installation of reducing valve.
Please keep the Manual in vehicle for easy reference.
b. Replace nitrogen with oxygen for pressurized leak detection.

c. Use refrigerant instead of vacuumizing device to evacuate the air inside the system.
The Manual is for your reference only and subject to change without notice.
d. Directly take oxygen weld when the system is yet complete decompressed.
Please feel free to point out the inadequacy in the Manual if any.
e. Let the vehicle operation unchecked after the air conditioning system is pressurized and
during maintenance.
f. Fill R134a air conditioning system with other models of refrigerants such as R12, R407C,
R22.
Your opinions and suggestions on further improvement of the product

would be appreciated.
g. Fill refrigerant oil that is not intended for the compressor of the system.
1.2 Suggestions on Operating Environment
1. Park the air conditioned bus in a shady and well-ventilated environment when stop.
2. During operation of air conditioner, please close the doors, windows and ventilation
equipment of the bus.
SONGZ reserves the right to modify the Manual from time to time without notice.
The Manual shall not be copied or printed in any form without SONGZs approval.
1.3 Rules on Customer Service
1. If any maintenance service is needed, please contact SONGZ customer service department,
service centers or service stations and show the Product Quality Warranty Manual.
2. We are not liable for any problems arising due to incorrect installation and improper use of
SONGZ products.
Chapter II Product Description
Chapter III Operation and

maintenance of air conditioner
3.1 Function of LED Numerical Control Manipulator
Evaporator
Condenser
Typical overhead air-conditioner picture
(Figure 2-1)
2.1 General
(1) The ultra-thin streamline design ensures an elegant appearance of the whole vehicle.
(2) Good component matching inside the product ensures high refrigerating efficiency of
the system.
LED manipulator (Figure 3-1)
(3) The selection of rational fresh air mechanism ensures a comfortable environment for the
clients (providing 10~20% fresh air).
(4) The product only uses green and environment-friendly refrigerant HFC134a in hope of
a minimized environmental pollution.
(5) The product mainly consists of exterior overhead evaporator and condenser assembly,
compressor assembly, pipeline and manipulator, evaporator and condenser are installed
at top.
1. Power Switch
After the power switch of the vehicle is on, press
Press MODE to select the operating mode of the air conditioner, i.e.
ventilation and
2.2 General Layout
to start up the air conditioner and press
again to shut down.

2. Operating Mode
refrigeration,
heating.
When
goes on, the air conditioner is refrigerating and ventilating.
When
goes on, the air conditioner is ventilating.
When
goes on, the air conditioner is heating (invalid for the product without heating
function).
When <AUTO> goes on, both the refrigerating condition of the air conditioner and the
lowest temperature to be reached in vehicle are automatically controlled by manipulator
based on the temperature inside the vehicle.
3. Fresh air
Press <
Fresh Air> to select start-up or shutdown the fresh air device and ozone
generator. During operation, the corresponding green indicating light is on.

(Figure 2-2)

When <
> goes on, fresh air device starts to work with the vent opened for long term.
When <O3> goes on, ozone generator starts to work.

When <AUTO> goes on, fresh air supply is in auto-operation mode.
4.
3.2 How to Switch-on The Air Conditioner on LED Nnumerical Control

Manipulator
Note: the function is invalid for the air conditioner without functions of fresh air supply and
When the engine is started up, press the power button

to activate evaporator fan. Since
manipulator has power-off memory function, the air condition simultaneously turns into the
sterilization.
running status that exists before shutdown, whereupon it is recommended to adjust the running
is a red nixie tube displays the temperature inside vehicle, defrosting temperature
and fault code.
mode of the air conditioner and set its running parameter if required.
5. Air volume control and air speed indication:

is an air speed control key to switch the fan in circulation from low speed to medium
speed to high speed.
Light beam: fan speed is showed by the illuminated LED on light beam.
when select
1. Press MODE to select running mode of the air conditioner, for example,
Refrigeration, the light shows green, and the air conditioner starts to refrigerate. The idle
speed boost will start to work as well if it is equipped in the engine.
2. Press
or
(hold on for more than 2s) to scroll the Defrosting 1 temperature Defrosting
2 temperature - Setting temperature. When red nixie tube displays setting temperature, the
temperature to be reached inside vehicle can be set within 16C~32C. Press
to increase or decrease the setting value by 1C, otherwise, if neither
or
or
once
is pressed
within 5s, it will automatically switch to the temperature inside vehicle display mode.
Note: Since human bodys comfortable temperature is 22C~28C, it is suggested to set
the temperature within this range. Once the temperature inside the vehicle is lower than the
setting value, sensor will promptly transmit the induction signal to manipulator whereby the
air conditioner will stop refrigerating.
3. Press
Low speed
Medium speed
High speed
Air speed indicating light (Figure 3-2)
to adjust the required air speed.
4. If you feel the air inside vehicle is turbid, press

in which fresh air flows into the vehicle. When
to drive the fresh air motor open the vent

shows green, the vent opens for long
time.
If AUTO shows green, fresh vent will open for 3 minutes and close for 27 minutes, and then
6. Browse buttons:
: increase temperature or page up the information;
: decrease temperature or page down the information.
goes in this cycle.

If O3 shows green, the ozone generator is at work.
5. If you want to switch out refrigerating mode to auto-running mode, press MODE till AUTO
7. Fault alarm indication:

: indicates air conditioner fault alarm if red LED flashes.
shows green, and then the refrigerating system will conduct auto-control based on actual invehicle temeprature (During auto-operation, dont press the key on manipulator, otherwise it
Note: MODE, Air Speed,

Fresh Air and temperature setting buttons all
have power-off memory function!
Power-off memory function means that manipulators running mode, fresh air
working condition, in-vehicle setting temperature and air speed keep the same
as those before last shutdown.
After the fan starts up for 30 seconds and then the compressor will be
activated!

will exit the auto-mode.). The temperature set below AUTO mode is a conventional value.
(1) In AUTO mode, if the temperature inside vehicle is higher than 25C and the temperature
outside vehicle exceeds 23C, the air conditioner will turns into refrigerating status
where the conventional setting temperature is 25C, i.e. Tset=25C.
(2) In AUTO mode, if the temperature inside vehicle is within 21C-24C, the system will
operate in low-speed ventilating status.
(3) In AUTO mode, if the temperature inside vehicle is lower than 20C, the air conditioner
will turn into heating status where the conventional setting temperature is 20C, i.e.
Tset=20C.
6. Check the temperature inside vehicle
The temperature inside vehicle is displayed in default mode. When
is switched on, the
nixie tube displays the temperature inside vehicle, which will change with the variation of
refrigerating time and thermal load of carriage.
The display of the temperature inside vehicle ranges from 0.0C to 60.0C (with accuracy
down to 0.5C); Lo is displayed when the temperature inside vehicle is lower than 0.0C,
and Hi is displayed the temperature inside vehiclee is higher than 60.0C.
7. Check defrosting temperature
Press
or
and hold on for more than 2s to scroll Defrosting 1 temperature Defrosting
Table 1 Air Conditioner Fault Codes Comparison

Fault Code
Meaning of Fault Code
Potential Cause
Refrigerant leakage (low pressure

protection)
Fan of condenser malfunction (high
Fault code EP1 is displayed, pressure protection)
indicating unusual pressure System, dryer or expansion valve
electrical or system fault
blockage (low pressure protection)
Pressure switch failure ( protection on
high pressure switch or low pressure
switch)
Fault code E 1 is displayed,
Sensor is damaged
indicating that temperature
Sensor connection is loose
sensor is cut off.
2 temperature.
The display of defrosting temperature ranges from 0.0C to 90.0C (with accuracy down
to 0.5C); Lo is displayed when defrosting temperature is lower than 0.0C, and Hi is
displayed when defrosting temperature is higher than 90.0C.
8. Check fault code
For some faults, we can analyze and determine their causes based on the display, receiving
and feedback commands on numerical control manipulator.
When fault indicating light goes on and the temperature inside vehicle is displayed, press
and the digital window will display fault codes in order of EP1, E
1, E
2, EU1; press
, the digital window will display fault codes in order of EU1, E 2, E 1, EP1; if related
Fault code E 2 is displayed,

indicating the temperature
Sensor is damaged
sensor of evaporator is cut
Sensor connection is loose
off (i.e. defrosting sensor is
disconnected)
Fault code EU1 is displayed,
indicating voltage is too low (the
tested input supply voltage of
manipulator is less than 20V for
consecutive 13 seconds)
Generator speed is too slow

Belt is loose
Regulator fails
Generator stator winding or field
winding fails
alarm code is defaulted when scrolling, the displayed codes will move forward in order. See
Table 1.
Supplementary (notes!):
When (supply) voltage is higher than 32V for consecutive 13 seconds, power supply will
automatically cut off with ventilation, refrigeration and fresh air supply stopped working
while excitation will maintain effective and panel display will keep on.
When (supply) voltage is higher than 45V, power supply will automatically cut off with
ventilation, refrigeration and fresh air supply stopped working while excitation will
maintain effective, but panel display will keep off.
10
11
3.3 Cautions for Use of the Air Conditioner
8. Generally, do not short-circuit the thermal control or defrosting protection (i.e. No forced
from water
9. Under no circumstance should the high/low pressure switch be short-circuited.
1. Please keep the manipulator of air conditioner away
refrigeration).
Correct usage ensures the best refrigerating effect of the air conditioner
with minimum faults and high reliability.
3.3 Maintenance of Air Conditioner
Manipulator is installed on the left side of cab
1. Avoid exposing the air conditioned vehicle in sunshine when parking in summer.
(Figurer 3-3)
Manipulator, an electrical subassembly, may lead to the malfunction of air conditioner if water
flows into it. Please pay special attention to:
Exposure to sunlight will cause rapid increase of thermal load of the vehicle, which will
reduce refrigerating effect and cooling rate during the operation of air conditioner.
2. Check out the intensity of the belt and adjust it if necessary (see the Figure)
After parking the bus, please close the doors and windows on right and left sides of the
The intensity and wear rate of belt should be checked after 48-hour running of new vehicle
cab to prevent rain soaking and damaging the manipulator.
or every month. At present, in China it is common to control belt tension via hand-feel, i.e.
When vehicle is under cleaning, please close the doors and windows on right and left
vertically pressing 10kg (about 98Newton) force onto the belt at center position between two
sides of the cab to prevent water inflow and damage to the manipulator.
belt pulleys with deflection (offset) shown as follows:
In process of driving, drivers teacup should be placed away from the manipulator to
avoid tea water splashing into the manipulator, causing in damage.
ce
2. Air conditioner can only be switched on if engine is started up
nt
If air conditioner is switched on before start of engine, clutch will pull in with the driving
disc of compressor, and the later start of engine will cause much friction between clutch
er
di
sta
nc
deflection per meter of 10mm

center distance
of the clutch. (With regard to the sudden shutdown due to the temperature inside vehicle
reaching set value, the instantaneous wear-down of chuck is normal.)
ex
ter
na
l fo
reaches to the peak. Such operation lasting for a long term will result in early wear-down
rce
chuck and driving disc of the air conditioner because the instantaneous torque of engine
3. Dont use the air conditioner when fault light or under-voltage light goes on.
4. In seasons when it is suitable to use air conditioner, engines idle speed can be appropriately
turned up and kept within 650~850rpm/min. In general, engine is equipped with special idle
(Figure 3 -4)
speed boost for air conditioner. If it is found that the revolving speed of engine fails to greatly
increase after air conditioner starts refrigerating, it is necessary to check idle speed boost or
ECU for normal operation or notify the manufacturer of engine or passenger vehicle.
5. In out-of-service seasons, it is forbidden to remove the compressor and generator
transmission belts of air conditioner.
6. During operation of air conditioner, please close all the doors, windows and the air
interchangers (except fresh air device).
7. Do not close all air outlets of air conditioner and keep at least 1/3 outlets opened.
12
Check the belt for wear rate and promptly replace the unqualified belt. (Note: two belts
should be the same during displacement.)
3. Check out the cleanness of filter screens of both return air grille and evaporator and regularly
clean the filter screens (there are three filter screens at each return air grille)
Generally, it is necessary to clean the city bus once or twice a week, and clean coach once
a week. In dusty area, the interval of cleaning can be shortened as appropriate.
Filter Screen at least cleaned once a month in out-of-service seasons
13
The dual cores should be cleaned at least once a year. The reversed fins found during
cleaning should be corrected with fin comb.
Warning! If the filter screen is not cleaned regularly, the

heat exchange efficiency of evaporator may be seriously
impact for the case in which lots of dust and greasy
dirt enter into evaporator core, resulting in significant
decrease of refrigerating effect, and even causing
filter screen blockage, less air volume, or incomplete
evaporated fluid refrigerant entering into compressor to
give rise to liquid hammer of the compressor.
Condenser
core
(Figure 3 -5)
Detach the return air grille and clean the filler screen
It is every drivers responsibility to regularly clean the filler screen of air

conditioner and keep a clean inside environment of the bus.
5. Check the amount of refrigerant and the dryer condition:
Evaporator
core
Figure 3 - 8
Following cleaning methods are suggested:

Clean the surface of condenser and evaporator cores by high pressure water gun with
cleanser essence.
Blow the surface of condenser and evaporator cores with high pressure air gun.
Note: the high pressure water gun or air gun can be used only after being adjusted
to proper pressure, and the fins should not be beaten down; for specially dirty cores,
especially evaporator core with filter screen not being cleaned for so long that lots of
Low of refrigerant inside Level Glass

Level glass
Dryer
(Figure 3 -6)
(Figure 3 -7)
water for air conditioner

7. Frequently check the compressor for any oil leakage or oil shortage:
Generally, coach air conditioner adopts piston compressor, of which the shaft is sealed via
(1) Check the moisture content of system via level glass of return air grille. If the color of
the sliding seal surface of shaft seal, and the sealing property and lubrication of the shaft
test paper goes green, it means the moisture content is normal. If the color of test paper
seal all depend on refrigeration oil, so a little oil leakage (dropping) is normal. During actual
gradually becomes yellow, it means the moisture content is high and dryer fails where it
application, driver should examine the compressor as necessary, and promptly repair it once
is necessary to replace the dryer.
oil leakage arises due to abnormal shaft seal.
(2) It is possible to judge if the refrigerant is enough by observing the movement of

refrigerant through level glass can help (See Figure 3-6).
No obvious but occasional bubbles in liquid flow means refrigerant is enough, in contrast,
obvious and constant bubbles in liquid flow means refrigerant is not enough.
6. Check the heat exchange fins of evaporator and condenser cores for their cleanness:
14
dust and dirt covered on fins, it is necessary to wash it with special fin leaner diluted with
Examining methods:
(1) The run-in period of compressor is 250 hours. The oil leakage during this period is normal,
and oiling is necessary only when a great deal of oil leakage occurs.
(2) The refrigerant level of compressor can be observed via sight glass: check the refrigerant
level 10-15 minutes after startup. Since the actual installation position of compressor is
Regularly cleaning heat exchanger (of evaporator, condenser) of the air conditioner ensures
different (oblique position), its better to examine the refrigerant level through two sight
the best refrigerating performance of air conditioner and avoids any faults of air conditioner
glasses, at least through one sight glass. (Part of refrigerant flows into overhead section
arising due to excessive dirt on the surface of heat exchanger.
during operation, and it should be verified repeatedly when debugging new vehicle).
15
(3) When the air conditioner is not

running, it is suggested that the
Chapter IV Operation and maintenance of

contained air conditioning unit
Sight glass
oil level of one compressor be not

lower than 1/3 of the sight glass.
8. Inject lubricating grease for belt
4.1 Description of manipulator IIs Functions
pulley bearing and support shaft

sleeve of the air conditioner once
a year to ensure lubrication of the
bearing. (2#lithium base grease is
suggested):
9. Regularly turn on the air conditioner
in winter:
(Figure 3-9)
Regularly turn on the air conditioner in winter to ensure its operation twice a month (running
for 5-10 minutes each time), so as to guarantee the lubrication of mechanism inside the
compressor.
Before start of vehicle, lock the clutch chuck of rotating compressor with hand or monkey
wrench to make the chuck of compress change from being heavy to being light (advisable),
then switch on the air conditioner for about 5 seconds, and switch it off. After this, switch
on the air conditioner once again for about 5-10s and switch it off as before. After above
procedure, the air conditioner can be normally started up.
For the users in north, the abovementioned operation procedure should be followed before
the first startup of air conditioner in spring.
10. Check the pipeline and joint
Frequently check the exposed rigid tube, flexible pipe and pipeline joint in case of any
interference, wear, extrusion and looseness. The broken pipeline and loose joint will cause
refrigerant leakage, resulting in decrease of refrigerating effect of the air conditioner and
even no refrigeration of the air conditioning system. The extruded pipeline will form stopflow of refrigerant, which will impact refrigerating effect of the air conditioner.
11. Check the wiring cluster
Frequently check the exposed wiring cluster and its connector assemblies in case of any
interference, wear and looseness.
Manipulator II (Figure 4-1)
1. Key switch
Key switch is set to start and stop the engine of power unit, and control the operation and
shutdown of air conditioning system specialized generator.
2. Power indicating light
The power indicating light is set for power indication of power unit. When key switch is at
On, the power indicating light illuminates to power on, and at off, the power indicating
light extinguishes to power off.
3. Oil pressure alarm indicating light (see Figure 4-2)
Oil pressure alarm indicating light is set to warn the condition in which the lubricating oil
pressure of engine is too low, controlled by the switch-on/off
of oil-pressure in forced lubrication pipeline of engine. If the
alarm indicating light goes on, turn the key switch to Off to
promptly stop engines operation, avoiding damage of engine,
and check machine oil level of the engine.
Note: During pre-startup of engine phrase, when key

switch is at On, the oil pressure indicating light
showing on is normal, and it will show off about 10s
after start up of engine.
(Figure 4 -2)
4. Water temperature alarm indicating light (see Figure 4-3)

Water temperature alarm indicating light is set to warn the the condition in which water
16
17
temperature is too high, controlled by the switch-on/off of cooling water temperature switch
Note: If the engine fails to start while starting motor
inside engine water cooling pump. If the alarm indicating light goes on, the engine will
has been running for 30 seconds, please re-start
automatically shutdown to avoid engine overheating.
the engine after one minute. If the engine fails to
When water temperature alarm indicating light

goes on, check if the level of engine water tank is
too low, air inlet passage is clear or the belt of water
pump is tensioned.
Note: When normal operation of engine or
after water temperature alarm indicating light
illuminates, please do not open the engine water
tank lid, to prevent operator being injured by the
cooling liquid.
start for three consecutive times, please check the

oil line, air line and electrical system, remove all
related faults if any, and re-start the engine.
(3) Turn key switch clockwise to Start position and
the engine will be started by the driving of starting
motor. (See Figure 4-6).
(4) When engine is started up, release the key switch,
(Figure 4-6)
which will automatically rebound to On position.

(Figure 4-3)
5. See Function description of manipulator I in Chapter IV for other information about

manipulator.
The engine operates at low speed to make preparation for switch-on of air conditioner.
Note: When passenger vehicle air conditioner is running, key switch

should keep at On.
2. Switch on the air conditioner (see How to switch on the air conditioner by manipulator I)
4.2 How to switch on the air conditioner:
3. Introduction to timer function of manipulator
1. Startup of engine
The manipulator has timer function, that is, the accumulative service time of the air
(1) Before startup of engine, make sure the air conditioner is powered off and turn the key
conditioner can be displayed and viewed through simple operation. If the manipulator is
switch clockwise to Warm up position (For the engine with different configuration, the
changed in the midway, record the service time at the time of changing the manipulator. If it
warm-up function probably doesnt work, so the position can be skipped over) to prepare
is necessary to inquire the accumulative service time later, what we have to do is only to sum
the startup of engine. Warm-up time should not be more than 12s each time. (see Figure
the recorded service time and the current displayed service time.
4-4).
Operation method: hold on both <
>and<
>for 5s, nixie tube will display the first 3
digits of service time of the system; within 10s, press <
> to display the last 3 digits of
service time of the system, then press <
>again to display the first 3 digits of service time
of the system; within 10s, there is no <

<in-vehicle> temperature display.
>or<
>pressed, it will automatically return to
The format of accumulative service time of air conditioner is in form of XXX, XXX. The
unit of first 5 digits is 1-hour, and the unit of last digit is 6-minute, with total statistic of 100
or 1000 hours.
4.3 Cautions for usage of air conditioner

(Figure 4 4)
(Figure 4 5)
(2) Turn key switch to On position, then the Power and Oil pressure indicating lights
will illuminate. (see Figure 4-5)
18
1. See Cautions for use of air conditioner in Chapter III for other operations except engine.
2. The adjustment and maintenance are subject to the instruction for usage and related
regulations.
(1) Make sure the storage battery is fully charged, and check the terminals for cleanness and
19
check the connection for reliability.
(4) Re-fill machine oil and clean or replace filter element after vehicle travelling reaches to
(2) Prior to use of new engine, running-in according to regulations is necessary (see the Table
1000 and 3000km.
below), and the engine should not be suddenly accelerated.

(3) Please use the refrigerant that is prepared based on specified ratio and mixed with
antifreeze.
4.3 Maintenance of Air Conditioner

1. Check Engine Machine Oil of Power Unit
(4) The engine without supercharger should use CC class machine oil, while the engine with
Verify the oil level is between the highest and lowest scales of oil dipstick. (see Figure 4-7)
supercharger should use CD class or above machine oil.

(5) The engine with supercharger should idle for 3-5 minutes after startup, and also idle for 3-5
minutes before stop.
(6) Machine oil pressure should be higher than 392KPa when it keeps at normal water
temperature (80~90C) and medium vehicle speed, the normal
(7) The fuel of engine is 0# diesel (10# diesel is preferred in north in winter).
(8) During engine running, it is necessary to promptly shutdown and check malfunction if
any.
(9) Open the radiator cover at first before discharging the water in cooling system (don
t open until water temperature decreases, otherwise the hot water that spouts out would
cause injury), then open the discharging plug screws at left bottom of radiator and left
side of cylinder.
2. Check Cooling Open water tank lid to check the volume of cooling water. The rated volume
of cooling water is 9 liter (full).
Specification on running-in of new engine

Mileage (Km)
Load
Vehicle speed
0 ~ 200
No load
Less than 50% of the rated speed of the engine
> 200 ~ 800
Less than 50% of the rated load Less than 50% of the rated speed of the engine
> 800 ~ 1500
Less than 75% of the rated load Less than 75% of the rated speed of the engine
> 1500 ~ 2500
(Figure 4-7)
Full load
Lower than the rated maximum speed
Cautions for running-in of new engine:

(1) Check the volume of machine oil, water and diesel and make sure the battery is charged,
and eliminate any leakage.
(Figure 4-8)
(2) Use torque wrench to turn engine crankshaft several rounds before starting engine.
(3) After engine is installed in vehicle, running-in should be done on Class 1 or Class 2 road.
No running-in is done on any poor road, especially on sands.
20
3. Check the Air Filter of Engine

(1) Remove air filter element from the filter. (see Figure 4-9)
21
(2) Repeatedly blow with the compressed air.

(3) The replacement period of air filter should be based on the requirement specified in
instruction for use of engine.
Instruction Table for Drivers Routine Operation and Maintenance

Item
Maintenance
interval
Air outlet
Every day
Filter screen of
return air grille
Filter screen of
evaporator core
Condensate pipe
Every week
Every month
Every day
Every week
Transmission belt
Every month
(Figure 4-9)
Compressor oil
level
Every day or
every week
Electromagnetic
clutch
Every day
Every year
Compressor
Fan
Dryer
Status
Contents and requirements
When air conditioner is running, it is necessary to keep 2/3 air

Before and after
outlets opened to guarantee good circulation of airflow; Check if
startup
the volume of air out at two sides is similar.
Wash the filter screen (sponge block) of return air grille with
Before startup
water, and the washing can be earlier if vehicle runs in dusty area.
Wash the filter screen of evaporator core with water, and the
Before startup
washing can be earlier if vehicle operates in dusty area.
After air conditioner has operated for 1 hour, check the
condensate pipe for any discharge of condensate water. In South
After startup
or coastal area with high humidity or in rainy season, there is
large amount of water discharge.
Check the belt for its intensity and wear, and adjust or replace it
Before startup
if necessary. Vertically apply 10kg force (about 98 Newton) with
thumb to the belt between two belt pulley, its deflection should be
Before startup
as follows: the deflection of center distance per meter is 10mm.
Check the compressor for its oil level. The refrigerating machine
oil level of compressor can be observed through sight glass: over
45 30minutes after stop of the air conditioner, and 14~34 in
Before and after
working condition. If the level is lower than above criteria during
startup
250-hour running-in period, it is necessary to replace felt and
add refrigeration oil; if the level is lower than above criteria after
running-in time, the shaft seal should be replaced.
Prior to power-on, check the clutch bearing for any abnormal
Before and after
sound; after power-on, check if the electromagnetic clutch can
startup
promptly pull in /separate, and slip.
Before startup Check the bolt of fixed support of compressor for any looseness.
Every week
After startup
During non-use of compressor, check different components for

normality by operating it once every week, several minutes each
time
Every year
After startup
Check if there is any abnormal sound during operation.
Every year
Socket connector,
Every month
terminal
Replace the dryer (note: if the test paper of sight glass fails to
become yellow, and refrigeration of the system is normal and
After startup
the sight glass is clear and transparent, the dryer may not be
replaced).
Check if the cable of compressor clutch and the terminals of
Before startup
generator are loose.
Check if the master fuse of 150A power supply, the fuse of 50A
Before startup fan, and the 5A, 7.5A, 10A inserting type fuses are intact, and if
the retaining screw at both sides and base are loose.
Fuse
Every month
Transition wheel
Half a year
Before startup Refill lubricating grease (may inject it from grease fitting.)
Support shaft
sleeve
Half a year
Before startup
Refill lubricating grease (may inject it from grease fitting.)

Refill lubricating grease (may inject it from grease fitting
See SONGZ Users Manual of Passenger Vehicle Air Conditioner for the rules on operation and maintenance by
professional technician (Version No.: JS-2010-01& by Zhong Huawei).
If any fault occurs, please inmmediately contact SONGZ service center or service station.
22
23
Instruction table for routine operation and maintenance of JMC engine

1000
km
3000
km
6000 18000 36000

km
km
km
Item
Daily
Dashboard,
manipulator
Check if dashboard/manipulator pointers and display functions are normal.
Pipeline, connector,
seal
Check if there is oil leak, water leak, air leak and electric leak at connectors
and seals.
Belt
Check the transmission belt for its intensity and wear.
Bearing (with
lubricating nipple)
Water tank
Check and promptly fill lubricating grease into belt pulley bearing.
Check if the cooling water is enough.
Air filter
Air valve
Contents
vehicle for reference in order to help the driver rapidly treat the general faults arising and
Wash air filter
accurately report the failure by calling the technician.
Check and adjust the gap of valve inside
Air inlet/exhaust
system
Remove the scale deposit inside the system
Crankcase ventilation
system
Remove the scale deposit inside the system
Air inlet/exhaust
manifold
Check if nuts are loose. The torsion should be evenly distributed when
fastening the nuts of air inlet/exhaust manifold, otherwise air leak would
occur.
Check if the air inlet/exhaust manifold has any crack and void, and if the
gasket is damaged or washed out.
Check the oil pan for any oil leak (when engine running)
Machine oil filter
Replace the machine oil in oil pan
Wash oil tank and its pipeline

Wash fuel filter
Replace diesel filter element (also may advance or delay the maintenance as
appropriate).
Check the oil line for its tightness, and observe if there is any local
overheating and abnormal sound.
Oil pump
Wash the interior filter screen of fuel inlet neck of transfer pump
Check the oil nozzle for its oil level and oil injection pressure, the normal
pressure is 18.1MPa(185kgf/cm2).
Lubrication clutch
release bearing
Storage battery
Generator
Check the storage battery for any crack and electric leak.
Starter
Check the generator for its fastening

Check the generator for its normal operation
Check the fuel injection pump for its oil supply angular advance (16crank
angle in front of top dead center for JX493Q1, and 14crank angle in front of
top dead center for JX493ZQ), oil supply and the uniformity of oil supply of
cylinders, and make adjustment if necessary.
Refill lubricating grease
Various electrical
connectors
inside vehicle, but the setting value should be within 16C~32C. In summer and autumn when
case, driver should not switch on refrigerating function until air temperature rises again. If it
feels stuffy in vehicle, please turn on the Ventilation function of air conditioner or open the
ventilator (skylight) on the vehicle.
Wash or replace the paper element of oil filter
Diesel filter
temperature inside vehicle lower than the setting temperature, we can lower the temperature
inside vehicle is probably less than 16C where the air conditioner will not work. In this
First, it is necessary to check if the setting temperature of manipulator is correct. In case of the
there is big difference of temperature between morning/afternoon and noon, the temperature
Replace machine oil
Oil tank and oil tube
This is a common fault of refrigerating air conditioner, which is caused due to many factors.
Replace the machine oil filter element (also may advance or delay the
maintenance as appropriate).
Check if the oil amount of machine oil pool is enough.
Machine oil pool
1. No refrigeration:
Wash machine oil filter
Replace the machine oil filter element
The Chapter abstracts following typical fault cases of SONGZ air conditioner for passenger
Check the air filter and blow it with compressed air to make it clean.
Replace filter element (air filter element of paper filter element
Chapter V Fast diagnose and treatment of

common faults
Other factors:
No refrigeration due to loose belt: in such case, we would hear the belt slip in engine chamber
when air conditioner is switched on, then refrigeration indicating light shows off at once, the
engine speed significantly decreases at the same time and engine stops running. We can analyze
and know the reason based on the principle of air conditioner: compressor, as the heart of
refrigerating system is driven by engine, with power transmitted by belt. If the belt is loose, it
will cause belt slip, and generator fails to keep synchronous operation with engine, resulting
in sudden decrease of engine speed that directly leads to too low current transferred to clutch
coil. Since the current is excessively low, the pull-in between clutch chuck and driving disc is
Remove and wash the starter
insufficient, and friction and slipping arise, resulting in compressors failure in running and no
Check or tighten the socket connectors, relays, fuses, and terminals to ensure
good connection.
refrigeration of air conditioner. On this occasion, what should be done is only to appropriately
The items involved in each phase of maintenance include all the items involved last phase of maintenance.
adjust the belt.
JMC maintenance items are subject to Users Manual of JMC Engine, and the maintenance of Fukuda Aoling 4JB1
series of engines is subject to Fukuda Users Manual. During maintenance, if any fault occurs, please immediately
contact SONGZ service center or service station.
No refrigeration due to fuse burnout of compressor (clutch coil): first, check if the inserting
24
type fuse in control box is burnt out. After replacing the fuse, make sure the fuse is firmly
25
secured, and check if the socket connectors of manipulator and compressor coil are properly
The connection of generator is loose
connected, because poor connection will cause high current, resulting in fuse heating and
or broken, causing no air supply
burnout.
of air conditioner. In this case, it is
No refrigeration due to the loose socket connector of engine clutch coil: it is generally
necessary to check the connection
caused by excessively tightened wiring harness or poor connection of socket connector. Please
of output, grounding and excitation
re-insert the socket connector and secure firmly the two ends of wiring harness.
of generator terminals in the air
No refrigeration due to refrigerant leak: in this case, the fault light of manipulator flashes
conditioner. To solute such problems,
red. At this moment, the Refrigeration should be switched off promptly. Check the engine
please re-connect or crimp the
chamber, flexible pipe and copper pipe inside air passage for any leakage. In case of slight
terminals.
leakage, there is refrigerant stain at connector or weld; in case of fast leakage, we can hear the
No air supply is caused by fuse
Fuse of
evaporator fan
Control box of return air inlet
sound of leakage. Report the check results to SONGZ service center, where the professional
burnout, generally due to the damaged fuse of main power source 150A or evaporator fan. In
technician will treat the problem.
general, 150A main power supply is equipped with spare fuse that can be used to solve the
problem on spot. If the fuse of fan is damaged, the problem can only be solved by SONGZ
2. Poor refrigerating effect of air conditioner
service station.
Closing most of air outlets will cause poor
The broken speed regulation resistance of evaporator causes less air volume on both sides or
refrigerating effect and less air volume. Sine
on one side. On this occasion, please contact the SONGZ service station.
the temperature of front part of the vehicle is
4. Less air volume and significant decrease of refrigerating effect
higher than that of rear part due to direct solar

radiation, sometimes the driver would adjust
If it happens during normal running of air conditioning system, it is often due to extremely
the temperature inside vehicle according to own
dirty filter screen of air conditioner. Especially, for the air conditioner that was used last
feeling, resulting in some passengers feeling too
summer and re-used next spring and summer, the refrigerating effect of the air conditioner
cold and closing the air outlets. However, the
is obviously worse than the previous year. What should be done is to dismantle the filter
more air outlets closed, the less air supplied. If
Air outlet
screen of return air grille and filter screen of evaporator, and wash them. For preventing
the defrosting sensor fails, it will even cause evaporator core icing, lead to short circuit of
such problem, it is necessary to regularly wash filter screen of the air conditioner according
in-vehicle return air inlet and circulating air flow, resulting in fault of poor refrigerating
to users manual. See aforesaid Item 4 of 3.3 for detailed requirements.
effect of the air conditioner. To solute such problems, please set the temperature inside
vehicle at the value for passengers comfort, and open all air outlets.
Poor refrigerating effect due to bad carriage seal. The solution is: close all doors and
The fault is often related with bearing and behaviors as follows: when the engine starts up
windows.
while air conditioner is shutdown, the clutch makes abnormal sound, and after switch-on of
Poor refrigerating effect due to shortage of refrigerant. In order to determine this case,
air conditioner, the abnormal sound disappears. Before pull-in of clutch, the bearing is in full
the first is to check via sight glass if the refrigerant is enough (see Item 5 of 3.3 for
working condition when the load is the maximum. When the problem arises for the first
related standard), and notify SONGZ service center to solve the problem.
time, please contact SONGZ service center as soon as possible.
3. Less air volume or no air supply from the air conditioner

26
5. Abnormal sound of clutch
6. See Users Manual for common troubleshooting of engine.

27
Appendix: Fault analysis table of air conditioner for passenger vehicle
Fault analysis table: power-down of air conditioner

Fault
Symptom
Potential Cause
Fault analysis table: no air supply or less air volume

Measure
Fault
Symptom
No power input at Pin D+

Check vehicle key switch
on the manipulator of the air for the introduced power
conditioner
supply
Replace the fuse after
10A fuse of manipulator
removing short circuit
No air supply, no refrigeration, damaged
and poor contact
and no panel display
Master fuse of power supply
burnt out, resulting in dead
Same as
power supply of electrical
load.
Powerdown of air
conditioner
28
Manipulator failure
Replace manipulator
No air supply and no

refrigeration
Generator failure (inside

regulator and generator)
Replace manipulator or
generator
Ineffective refrigerating output,

ineffective ventilating output,
effective excitation, ineffective
fresh air/ sterilization/heating,
and on the panel, only the lowspeed light keeps on.
(Supply) voltage higher than

+32VDC for consecutive
Check and replace
13s, resulting in too high
regulator or generator
voltage of vehicle generator.
Ineffective refrigerating
output, ineffective ventilating
output, ineffective excitation,
ineffective fresh air/ sterilization/heating, no display on the
panel, and noisy fan
The interior part of vehicle

generator or regulator
damaged when higher than
+45VDC
Check and replace

regulator or generator
Evaporator fan fails
Potential Cause
Measure
Poor grounding of fan
Check circuit
Loose socket connectors
Re-connect and fix
Broken fuse
Replace fuse
Broken relay
Replace relay
Broken speed regulation

resistance
Replace speed regulation

resistance
Broken evaporator fan
Replace evaporator fan
Extremely dirty filter screen

Wash filter screen
of evaporator
No air supply or Less air volume of air
less air volume outlet
Air pipe fallen off, causing Check the tightness of air

air leakage
pipe
Electric brush of evaporator Replace carbon brush or
fan seriously worn down
evaporator fan
Air volume has no change

when adjusting air volume Manipulator failure
level
The ventilation of
air conditioner is not
controlled by manipulator:
after switch-off of the air
conditioner, there is still air
supply from the air outlet.
Check and replace

manipulator
Relay of the fan burnt out

with pins 30, 87 closed
Note: the fault always
Check and replace relay
occurs on the vehicle where
air conditioner and vehicle
share one generator.
29
Fault analysis table: no refrigeration

Fault
Symptom
Potential Cause
Fault analysis table: insufficient cooling air

Measure
Carriage temperature is too

It is normal, with no need of
high or too low, i.e. higher
Compressor and condenser fan than 60C or lower than 16C repair
fail
The output voltage of
Find the reason of low
generator lower than 20V
pressure and treat the fault
Compressor and condenser fan
fail, fault light shows red, and Refrigerant in extremely low
high/low pressure is on the
volume
low side.
Check air leakage position and

add right amount of refrigerant

fail, fault light shows red, and
Refrigerant fully leaked
its difficult to set high/low
pressure
Check air leakage position and

add right amount of refrigerant

fail, fault light shows red, low
Receiver dryer blockage (by
pressure is unusually low, and
dirt)
filter pipe of receiver dryer is
condensed.
Dismantle and check the

component
Return air temperature sensor Replace the sensors after

(temperature sensor) breakage verifying the sensor is
(open circuit)
defective.
Compressor and condenser fan Defrosting sensor breakage
No refrigeration, only fail, and fault light shows red (open circuit)
natural wind supply
Pressure switch defection
Compressor and condenser
Condenser fan breakage
fan fail, fault light shows red,
and high pressure is unusually Fuse of condenser fan burnt
high.
out
Loosen socket connector of
electromagnetic clutch
Same as above
Replace the pressure switch
after verifying the switch is
defective
Repair or replace the
condenser fan
Replace the fuse of condenser
fan
Re-connect the cable of
compressor
Fuse of electromagnetic clutch Remove the reason of fuse

burnt out
burnt out and replace the fuse
Compressor fails
Control relay of
breakage
Replace the relay
Electromagnetic clutch
breakage
Repair or replace
Overly wider air gap of

Adjust air gap or replace the

clutch
Interior parts of compressor

damaged
Replace compressor
Loosen or broken transmission

Adjust or replace the belt
belt
30
Fault
Symptom
Potential Cause
Loose wire terminals of
intermittent
refrigeration
of air
conditioner
(cooling air
is just blown
out every
now and
then)
No pull-in of clutch
sometimes
Defective Sensor (return air

temperature sensor and defrosting
sensor)
Defective pressure switch that starts
to work under abnormal pressure
No closing of relay
Relay of electromagnetic clutch
sometimes
breakage
The sensitivity of return air
temperature sensor or defrosting
sensor decreases or they installed in
incorrect position.
Low pressure is unusually The air flow passage in evaporator
low, or evaporator frosting blockage
and air inlet of compressor Filter screen of return air grille of
frosting may occur at the
evaporator blockage by dust or dirt.
same time.
Dirt in evaporator core
Exhaust pressure is
Dirt in condenser core, causing
unusually high, and
blockage of air flow passage in
compressor is unusually
condenser
heating.
The exhaust pressure
and suction pressure at
Condenser fan failure
compressor side is high
The revolving speed of
Carbon brush seriously damaged
condenser fan is slow, and
exhaust/suction pressure is Poor grounding of condenser fan
high.
High/low pressure is on
Refrigerant leakage
low side, refrigerant is
Leakage of system pipeline
not enough, and there are
Insufficient obvious bubbles in sight

cooling air glass.
Insufficient filling-up of refrigerant
High/low pressure is on
high side, there are bubbles
in sight glass, compressor
is noisy, and compressor is
unusually heating
Compressor is noisy
High pressure is low while
low pressure is high,
high/low pressure rapidly
keeps balanced after closing
refrigeration, compressor
is noisy and compressor is
unusually heating.
Incondensable gas in the system: air,

hydrogen, nitrogen, etc. All the gases
circulate in system with refrigerant,
and dont condense with refrigerant,
and dont produce refrigerating
effect. Generally it is because of
incomplete vacuation, with some air
left in system.
The refrigerant oil is too much in the
system (note: refrigerant oil involves
in the circulation, but is not used as
heat exchange medium).
Compressor valve damaged and
existsing displacing valve leakage
(blowing between high and low
pressure cylinders)
Sealing gasket of valve plate
breakage (blowing between high and
low pressure cylinders)
Measure
Reconnect the wire, and replace
the electromagnetic clutch after
verifying the clutch is defective.
Replace the sensor after verifying
the sensor is defective.
Replace the pressure switch after
verifying the switch is defective.
Replace the replay
Adjust installation position of the
sensor; replace the sensor.
Remove the blocking
Wash filter screen and remove the
blocking
Remove the dirt on evaporator core
Wash out and remove the dirt on
condenser with compressed air or
water
Remove the fault causing the fan
doesnt work
Replace carbon brush or fan
Re-grounding
Repair position with refrigerant
leakage, and then fill refrigerant till
to specified amount.
Fill refrigerant
Exhaust the incondensable gases,

and completely vacuate prior to
filling-up of refrigerant.
Check and adjust oil level of the

compressor
Replace valve plate or compressor
Replace sealing gasket
31

Fault
Symptom
Potential Cause
Overly large friction loss
between the parts inside
High/low pressure difference is
compressor, resulting in actual
reduced
air displacement much less than
theoretical one.
Receiver dryer inlet blockage
Low pressure is too low, and
The displacing valve of
obvious temperature difference
compressor breakage with
exists between the pipelines at
both sides, with drop of water on fragments entered into high
pressure end, resulting in slight
the pipelines.
blocking.
The water entering the system
Suction pressure is unusually
iced at expansion valve nozzle,
low, expansion valve frosts, the
stopping the circulation, but when
low-pressure side sometimes
the ice is melted, the system
becomes vacuum, refrigeration
recovers its normal operation.
is intermittent or there is no
Generally, the problem arises
refrigeration at times, and pointer
from the dryer in saturate status
of pressure gage jitters.
and system moisture out of limit.
Damage or breakage in the
Suction pressure is unusually low,
refrigerant pipeline between
expansion valve frosts, and air
thermal bulb of expansion valve
inlet of compressor frosts.
and the expansion valve
Low pressure is high, or at the
same time, evaporator frosts, air
Expansion valve overly opened.
inlet of compressor frosts and
compressor becomes noisy.
Expansion valve overly closed:
Insufficient The pressure on low pressure side interior balance pipe (thermal
cooling air is low
bulb) breakage; dirty interior of
the valve.
The pressure of low pressure pipe
is unusually high, evaporator
Expansion valve failure with
frosts, compressor frosts, and
acicular corrosion or breakage.
compressor become noisy.
The air flow of air outlets and
return air inlet shorted.
Cooling air is not enough
Poor seal of evaporator box.
Fault
32
Overly low speed of engine
Symptom
Repair or replace compressor
Remove the fragments
After switch-on of air

Noise of actuating conditioner, abnormal
device
noise comes out of
actuating part.
Clean or replace component, and

the dryer should be replaced.
Replace the thermal bulb or

expansion valve; wash the
expansion valve.
Measure
Sound from clutch bearing
Replace clutch or bearing
Engine surges: Overly low

idle speed
Increase the idle speed of

engine
Loose support screw of

compressor
Adjust screw torsion
Belt slipped due to being

loose
Adjust belt intensity
High/low pressure
is unusually high,
Discharge right amount of
compressor is
Too much refrigerant filled in
refrigerant
unusually heating, and
compressor is noisy.
Check and replace expansion

valve and pipeline
Check if thermal bulb is fit with
outlet pipe of evaporator, and if
the installation position is correct.
Replace it as necessary.
Potential Cause
Sound from transition wheel Replace the transition

or tense bearing
wheel or bearing
Wash or replace drying filter
Refrigerant oil is too

much
Abnormal noise of
compressor
Compressor is
unusually noisy
Replace the expansion valve
Too much refrigerant oil in

the system
Reduce the level of

compressor refrigerant oil
and make adjustment
Liquid refrigerant flowed into See Fault analysis table:

the compressor
cooling air is not enough
Interior of compressor
damaged
Replace compressor
Excessive gap of clutch
Block the air outlets on both sides

of return air inlet
Increase the speed of engine to

appropriate range
Polluted interior of system caused Replace refrigerant and refrigerant
by impure refrigerant
oil
Misuse: stop refrigeration before
The temperature inside vehicle is
human comfortable temperature Re-set temperature
set too high.
is reached.
Problems due to unreasonable air
Air outlets are too few, and the air
passage structure with insufficient Increase the number of air outlets
supply in carriage is too less.
air supply area.
Metal floor without installation
Heat insulation of platform floor
of plastic board or PVC artificial Install floor leather
is poor
leather.
There is no heat preservation
Poor seal of air supply pipe.
paste heat preservation
pasted in air passage.
Air pipe fallen off or the hot
Check and take appropriate
Air leakage exists in air passage. airflow from outside entered into
sealing measure
the air passage.
Fault analysis table: abnormal noise
Measure
Sound of fan
Clutch slips on friction

Overly low voltage of
surface
generator
See Fault analysis table:

No refrigeration, but
normal ventilation
Fan makes sound
Replace the fan
Sound from Fan bearing
33
Common Used Circuit Diagram

1. The circuit diagrams in the Manual that represent part of products typical circuit diagrams.
2. Instruction for usage of circuit diagrams:
The circuit diagram SZC provided below is applicable to the maintenance of CPP, BBP, LUX
series. The so-called circuit difference between SZC-II, II/F, III, III/F, IV, IV/F, V, V/F, VI
series is just due to the variation of coil quantity of relay, evaporator fan, condenser fan and
compressor with same control principles.
34
35
35
36
37
38
39

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SONGZ Users Manual of Exterior Overhead Air Conditioner

SONGZ Users Manual of Exterior Overhead Air Conditioner

SONGZ Users Manual of Exterior Overhead Air Conditioner

Chapter II Product Description

Chapter III Operation and maintenance of air conditioner

Chapter IV Operation and maintenance of contained air conditioning unit 17

Create healthy human living space

Chapter V Fast diagnose and treatment of common faults

Common Used Circuit Diagram

Create healthy human living space

SONGZ Users Manual of Exterior Overhead Air Conditioner

SONGZ Users Manual of Exterior Overhead Air Conditioner

1.1 Safety Issues

1. Promptly switch off the air conditioner if fault alarm occurs.

the air conditioner.

3. The electrical part of the air conditioner shall work in dry.

Please hand over the Manual to the driver.

The Manual is used in conjunction with Product Quality Warranty Manual.

without installation of reducing valve.

Please keep the Manual in vehicle for easy reference.

b. Replace nitrogen with oxygen for pressurized leak detection.

Your opinions and suggestions on further improvement of the product

1.2 Suggestions on Operating Environment

1.3 Rules on Customer Service

Create healthy human living space

Create healthy human living space

SONGZ Users Manual of Exterior Overhead Air Conditioner

SONGZ Users Manual of Exterior Overhead Air Conditioner

Chapter II Product Description

Chapter III Operation and

LED manipulator (Figure 3-1)

2.2 General Layout

to start up the air conditioner and press

again to shut down.

goes on, the air conditioner is refrigerating and ventilating.

goes on, the air conditioner is ventilating.

generator. During operation, the corresponding green indicating light is on.

Create healthy human living space

Create healthy human living space

SONGZ Users Manual of Exterior Overhead Air Conditioner

When <O3> goes on, ozone generator starts to work.

SONGZ Users Manual of Exterior Overhead Air Conditioner

3.2 How to Switch-on The Air Conditioner on LED Nnumerical Control

When the engine is started up, press the power button

5. Air volume control and air speed indication:

Air speed indicating light (Figure 3-2)

to adjust the required air speed.

4. If you feel the air inside vehicle is turbid, press

to drive the fresh air motor open the vent

goes in this cycle.

7. Fault alarm indication:

Note: MODE, Air Speed,

Create healthy human living space

Create healthy human living space

SONGZ Users Manual of Exterior Overhead Air Conditioner

SONGZ Users Manual of Exterior Overhead Air Conditioner

and hold on for more than 2s to scroll Defrosting 1 temperature Defrosting

Table 1 Air Conditioner Fault Codes Comparison

Meaning of Fault Code

Refrigerant leakage (low pressure

Fault code E 2 is displayed,

Generator speed is too slow