ZEST BOLT Service Manual

AIR CONDITIONING 4 11.3 DIAGNOSIS DIAGNOSIS TIPS FOR AIR CONDITIONING The most basic and important element of effective trouble shooting is safety The basic steps are: 1. Switch off the engine before you open the bonnet while looking for fault identification. 2. Use gloves and safety glasses when handling refrigerants and compressor oil. 3. Keep our environment safe by practicing proper recovery, evacuation and charging procedures. 4. Never use oxygen for pressure testing a system. It may explode in presence of oil. Instead use Nitrogen from a cylinder equipped with proper pressure regulator. Many times the problems overlap. For example, a malfunctioning of relay or contact may make compressor cycle on / off too frequently and damage compressor Although the problem is electrical, it results into mechanical failure. Proceed in a logical manner to rectify the defect. Ensure following minimum equipment are available at service point. 1. Safety equipment ( Gloves, Glasses ) 2. Manifold gauges 3. Vacuum pump 4. Contact thermometer digital 5. Leak detection equipment 6. Weighing scale 7. Refrigerant recovery unit 8. Recovery cylinder 9. Sealed lubricant container 10. Container for recovered lubricant 11. Refrigerant (R134a) in sufficient quantity and of proper quality 12. Multimeter Procedure STEP 1 - Collect as much information from customers possible. It could give vital clues. STEP 2 - Conduct preliminary checks - engine off SR NO a b c d e f g h i j k l m n o PROBLEM Dirty condenser / Radiator coil / fins Dashboard grill vanes operation Loose belts/belt noise when AC on Damaged-loose inter connecting piping Idler pulley loose Oil / Dirt patches oil Refrigerant leak Indications burn out hose Wiring Electric harness connection loose loose Condenser / Radiator / EBA / Clutch / Pressure witch Control Cables Loose / stuck All AC fuses Radiator fan rotation direction Compressor clutch working with AC ON / OFF button Blower Fan operation Compressor ground to be checked Check FR/RECIRC push button working ok SOLUTION Clean Repair/Replace Adjust belt tension Replace Align / tighten Locate and Replace joints indicating Replace Refix Repair/Replace Check/Replace Correct Check Check IF loose tighten RECIRC noise little high Fresh noise is more