Roof Mounted Package (LD8-i Reheat) Type

BUS AIR CONDITIONING

INSTALLATION MANUAL
Issued : April 2011

Applicable Product :
Model Type Part Number Remarks
LD8-440-50-EE-A 441000-440# Compressor Type 6C500
LD8-440-62-EE-A 441000-440# Compressor Type 6C620

00A00646E
© 2011 DENSO CORPORATION
All rights reserved. This material may not be reproduced
or copied, in whole or in part, without the written
permission of DENSO Corporation.
 Table of Contents

Table of Contents

Operation Section

1. GENERAL INFORMATION
1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 PRECAUTIONS DURING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.4 PRECAUTIONS FOR WORK SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.5 WORK SAFETY HIGH ABOVE THE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.6 PRECAUTIONS FOR SAFETY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.7 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

2. COMPONENT LAYOUT FOR INSTALLATION

2.1 MAIN COMPONENTS AND THE LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
2.2 COMPONENT CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
2.3 COMPONENT LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

3. BUS AIR CONDITIONING PACKAGE UNIT

3.1 COMPONENT LAYOUT AND DIMENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
3.2 PIPING POSITION AND DIMENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

4. INSTALLATION PROCEDURE
4.1 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

5. HEAT INSULATION OF BUS BODY

5.1 HEAT INSULATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

6. CONSTRUCTION AIR INLETS AND OUTLETS

6.1 CONSTRUCTION THE OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27

7. INSTALLATION PREPARATION
7.1 PREPARATION OF THE FLANGE, PACKING AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
7.2 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
7.3 MEASUREMENT OF THE BUS BODY FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
7.4 CALCULATION SHEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
7.5 CONSTRUCTION OF THE FLANGE, PACKING AND FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

8. BUS AIR CONDITIONING UNIT INSTALLATION

8.1 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
8.2 INSTALLATION FLANGE FOR THE A/C UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
8.3 INSTALLATION PACKING FOR A/C UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
8.4 INSTALLATION FRAME FOR THE A/C UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
8.5 INSTALLATION A/C UNIT AND DRAIN HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
 Table of Contents

9. COMPRESSOR
9.1 COMPRESSOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
9.2 COMPRESSOR ROTATION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-56
9.3 PULLEY ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-57
9.4 COMPRESSOR MOUNTING SLANT ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
9.5 COMPRESSOR BELT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-58
9.6 COMPRESSOR DIMENSION AND SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-62
9.7 SERVICE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-63

10. PIPING
10.1 PIPING LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-64
10.2 PIPING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-66
10.3 DISCHARGE AND SUCTION HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71
10.4 JOINT BRAZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-76

11. HOT WATER CYCLE (FOR REHEAT TYPE)

11.1 PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
11.2 PIPING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-77
11.3 WATER PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-78
11.4 STRAINER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-79
11.5 WATER MAGNET VALVE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
11.6 WATER SUPPLY METHOD FOR HOT WATER CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-80
11.7 ATTENTION ITEMS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83
11.8 REQUIRED HOT WATER FLOW VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-84

12. CONTROL PANEL

12.1 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-85

13. WIRING
13.1 WIRING LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-86
13.2 WIRING IN THE A/C UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-87
13.3 WIRING HARNESS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-88

14. AIR DUCT CONSTRUCTION

14.1 AIR DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91

15. AIR INLET FILTER INSTALLATION

15.1 AIR INLET GRILL / FILTER LAYOUT AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-95

16. CHARGING REFRIGERANT (HFC-134a)

16.1 CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-98
16.2 CHARGING AMOUNT (REFRIGERANT IN USE HFC-134a). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-99

17. INSTALLATION AND OPERATION CHECK

17.1 INSTALLATION CONDITION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-100
17.2 OPERATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111
17.3 MEASURING AIR VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-115
 Table of Contents

17.4 MOIST AIR GRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-117

Circuit diagram / Wiring diagram (A3)

1. ELECTRICAL CIRCUIT AND WIRING DIAGRAM

1.1 EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119
1.2 ELECTRICAL CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120
1.3 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
Table of Contents
 Operation Section
1– 1

1. GENERAL INFORMATION

1.1 FOREWORD
z This manual has been published to explain the basic procedure of Bus air conditioning installation.
Before installing the Bus air conditioning, please read this manual carefully.

1.2 INTRODUCTION
Important Notice
z This manual has been published for technicians who are qualified and educated in the proper procedures
of Bus body manufacturing; experienced in installation of Bus air conditioning or who are able to carry out
installation procedures when given instructions by an experienced technician in a supervisory capacity; and
are certified to handling refrigerant.
• Take special care to ensure that clearance between air conditioning components and other components
such as brake parts, fuel system and electric wires are as specified in this manual.
• If a problem with the Bus air conditioning is found to be caused by installation, refer back to the manual
to correct the problem(s).

Product Liability (PL) Signal Word Explanation

Symbol Meaning
Indicates a possibility that "improper handling by the user may result in
death or serious injury*1."
Indicates a possibility that "improper handling by the user may result in
injury*2 and/or material loss*3."

*1 : Serious injury is defined herein as those injuries such as vision loss, burns (high temperature, low
temperature), electric shock, broken bones, and poisoning. The subsequent effects and treatment
of the aforementioned injuries require hospitalization and/or long-term outpatient hospital visitation.
*2 : Injury is defined herein as wounds, burns, and electric shock. The treatment of the aforementioned
injuries does not require hospitalization or long-term outpatient hospital visitation.
*3 : Material loss is defined herein as extensive losses in regards to residence, household articles, live-
stock, and pets. Material loss also includes damage that impacts the environment.
Non-Product Liability (PL) Signal Word Explanation
Symbol Meaning
Indicates items for which failing to follow the written instructions may
lead to product breakage, abnormal product operation, and/or loss of
performance.

Indicates additional information provided to deepen product knowledge.

Indicates useful information for product handling, operation, and/or

maintenance.
 Operation Section
1– 2

1.3 PRECAUTIONS DURING INSTALLATION

< ATTENTION >
• The contents given in "WARNING" and "CAUTION" in this manual must be adhered to during instal-
lation. If they are ignored, not only are the functions of the bus air conditioning hindered, but per-
sonal injury or damage to the vehicle may also result. Always carry out the installation in
accordance with the "WARNING" and "CAUTION" notes.
• Safety Precautions
9 If installation is carried out by more than two persons, always pay attention to the co-worker's
safety.
9 When the engine is running, make sure that sufficient ventilation is provided.
9 Take special care when working with heated, rotating, sliding, or moving parts, to prevent bodily
injury.
 Operation Section
1– 3

1.4 PRECAUTIONS FOR WORK SAFETY

z Be sure to read this section before beginning work.
z Descriptions are classified as "WARNING" and "CAUTION" items. "WARNING" items refer to improper han-
dling which may lead to severe injury when working. However, be aware that some items explained in "CAU-
TION" may also cause critical accidents.
z Be sure to follow these safety rules.

CAUTION WHEN WORKING

z Refer to the following.

WARNING
Check that tools, measuring instruments and other parts are not
left on the movable, rotating and current-flow sections before
starting the engine and air conditioning. Don't leave
1 things behind

Warn workers using the horn, etc. and safety check before starting
the engine.

T o remove or install a part in the fuel system, work in an area

that is well ventilated, using a fan when necessary.
In particular, when replacing a fuel filter, keep away from any
3 potential sources of sparks or fire, to prevent the leaked fuel from
igniting and causing a fire.
No sparks
(Never work in an area near sources of sparks or fire, such as or fire
welders or stoves.)

To prevent fire, do not bring flammable items into the room.

Smoking is prohibited.

U008584
 Operation Section
1– 4

WARNING
Turn the air conditioning OFF to prevent injury.
Do not touch the engine belt, fan or drive shaft.

5
Don't
touch

To prevent fire or heat injury, keep flammable items away from

the air conditioning and do not touch the engine or exhaust pipe,
both during operation and just after the air conditioning is turned off. Don't
6
touch

7 Do not apply water, oil, etc. to the fan V-belt or fan motor in order to prevent fire.

Do not allow non qualified workers to disassemble or repair the unit in order to prevent electric shock,
8 fire, etc.

When checking the electric circuit, be careful not to touch the current
flowing section of the terminal, resistor, etc. or it may short circuit
with the body or other parts.
9

Be sure to attach the connectors to the air conditioning harnesses

and vehicle, in order to prevent fire.
NG

10

Make sure the connectors are

securely connected.

11 Use the specified fuse to prevent the electrical system from burning up.

Be careful of the current flowing sections of the vehicle and air conditioning when handling the drill
12 to prevent electric shock, overheating and fire.

13 To prevent electric shock, fire, etc., do not modify the unit.

14 Do not place the refrigerant gas can on the engine or radiator as it may result in a severe accident.

Do not store the refrigerant gas can in direct sunlight, humid conditions or temperatures of over 40 °C
15 in order to prevent severe accidents. Store the refrigerant gas can in a cool, dry place.
Store the refrigerant gas can out of reach of children, and in a place where it will not be exposed to
16 any strong impacts (eg. striking with a hammer) in order to prevent severe accidents.
Be sure to wear protective glasses when handling the refrigerant gas in order to prevent injury.
17 If refrigerant gas enters the eyes, immediately wash out eyes with water.

U008798
 Operation Section
1– 5

CAUTION
2) Release lock
Observe the following precautions when handling connectors:

(1) To disconnect a connector with a lock, push the connector

in the direction of the joining to enable the locking tab to
move freely. Then, release the lock.
(2) When disconnecting a connector, hold the connector and 1) Push towards
not the wiring harness. joining
(3) Before connecting a connector, inspect it for any deformation
1 or damage to its terminals.
(4) When connecting a connector with a lock, push it firmly
until it clicks into place.

Before working on the electrical system, disconnect the negative

terminal from the battery to prevent damage that can be caused
by a short circuit. Loosen
[REFERENCE]
Verify the settings of the clock, radio, or diagnosis system
2 beforehand as they will be erased from memory once the
battery terminal is disconnected.

Be careful when handling the hose, tube, pipe, etc. in order to prevent gas leaks.
Be careful not to get dust on the hose, tube, pipe and inside pipe connections in order to prevent gas
leaks and operation failure.
3

U008586
 Operation Section
1– 6

1.5 WORK SAFETY HIGH ABOVE THE GROUND

(1) Working High Above the Ground - Dangers and Precautions

Dangers While Working High Above the Ground

• When a person is on the ground, loss of balance rarely leads to grave injury. However, when working high
above the ground, a slight loss of balance could cause a person to fall fatally. If a person is working at a
height of 2 meters or more, the extent of injury magnifies, and at a height of 5 meters or more, the fatality
rate increases considerably. To prevent this type of disaster, appropriate facility measures, such as pro-
viding footing or lift equipment, must be taken. At the same time, the use of protective equipment and the
implementation of operations standards must be rigidly enforced, and proper work instructions must be
provided.

Dangers of Workers Falling

• The risk of falling is an inherent danger when working high above the ground. Thus, proper precautions
must be taken to prevent exposure to dangerous situations.

Causes of Falling
• Lack of knowledge or skill in working high above the ground.
• Failure to use protective equipment (safety helmet, safety belt, safety shoes, etc.), or the use of defective
equipment.
• Improper or defective footing or lift equipment.

(2) Directions for Safety While Working High Above the Ground (Awareness and Actions)
Direction
• Those who work high above the ground are urged to strictly observe the following precautions in order to
ensure safe working conditions:

Before Work:
• Inspect installation tools, parts, and protective equipment (safety helmet, safety belt, safety shoes, etc.)
to make sure they are up to standard, and work in proper clothing.
• Secure the vehicle to prevent it from moving.
• Secure the ladder.

During Work:
• Two persons must work together when removing or installing large parts such as a unit case cover.
• Use a suspended bag to hand tools or parts to workers.

After Work:
• Make sure that no tools or parts are left on the roof.
 Operation Section
1– 7

(3) Preparations for Working High Above the Ground

Preparation
• To ensure safe work high above the ground, perform the following preparations before working:

WARNING
[ Clothes and Equipment ]

Be sure to wear a work uniform, safety helmet and safety shoes during work.
1 Check that there are no cracks or internal damage, or that there are no broken
straps on the protectors.

[ Vehicle ]

Be sure to engage the side brake and use wheel chocks during work
to prevent accidents.
2

[ Wearing a Safety Belt ]

Be sure to wear safety belt for high lift work on the roof mounted type air conditioning unit, in order
to prevent critical injury.

< Check before Wearing >

(1) No damage on rope or belt? Buckle Rope

(2) No deformation or damage on hook or buckle? D-ring

< Caution for Wearing > Hook

Belt
(1) Wear the belt around your lower waist.
(2) Properly pass the belt through the buckle and secure the end.
3 (3) Install the D-ring so that it runs from the side to the rear.

< Attachable Items and Positions >

(1) Attach the safety belt to an item from which the rope or the hook
cannot detach, and which can withstand the impact of a fall.
(2) If the item to which the rope is attached has a sharp corner,
attach it so that the rope does not come in contact with the
sharp corner (eg. by placing a patch over the corner).
(3) Attach the rope as high as possible without obstructing
work, at a height that will not allow the person to come
in contact with the ground in the event of a fall. Use as
short a rope as possible (1.5 meters maximum).
(4) Attach the rope so that the person will not come in contact
with any object while swinging in the event of a fall.

U008799
 Operation Section
1– 8

(4) Installing a Ladder

Direction
• A ladder is used to climb onto the roof of the bus. Properly secure the ladder by observing the precautions
listed below, and exercise utmost caution while climbing up or down the ladder.

Ladder
• The ladder must be solidly constructed and free of significant damage or rust.
• The bottom of the ladder must have non-slip pads.
• The width of the ladder must be 30 cm or more, with a uniform space of 25 to 30 cm between the rungs.

Securing the Ladder

• The area at the top of the ladder, which comes in contact with the bus body, must be wrapped with rubber
or sponge sheet to secure the ladder in place, thus preventing it from shifting or sliding, as well as from
damaging the bus body.
• When leaning the ladder against the bus, the angle of the ladder to the ground must be between 60 to 75
degrees.
• Use two suction lifters and secure the ladder with a rope.

Wrap sponge sheet on the area of the ladder that comes in contact with the vehicle,
thus preventing the ladder from shifting.
(Approximately 10 mm thick material wrapped in layers, to a width of 30 to 40 mm)

:
gs
re un
mo e nr
or e
c m b etwm
30 e c
ac 0
ing Sp to 3
t e nd re 2 5
x o
re rm Suction Lifter *1
d de m o
l a c
of f 60
r tion roo
Pobove
a

Free Secured
°
75 *1: Suction lifters are designed to transport glass,
6 0°~ but are used in an auxiliary capacity during bus A/C
repair to support the ladder. However be aware that
suction lifters are not capable of supporting body weight.
Non Slip Pads
Use two suction lifters and
secure the ladder with a rope.
U010492

< ATTENTION >

• Before climbing up or down the ladder, make sure there is someone on the ground holding the lad-
der.
• Do not climb up or down the ladder while holding tools or parts. (Use a suspended bag).
• Never climb up or down the ladder alone.
 Operation Section
1– 9

(5) Precautions While Working High Above the Ground

Precaution
• Thoroughly observe the precautions listed below while working high above the ground.

WARNING
Perform work high above the ground only after taking the
appropriate fall prevention measures.

Two people must work together when carrying the upper cover
of the unit case. If this operation is performed by only one people,
it could result in a serious accident such as a fall.

Use a suspended bag to hand tools or parts to the worker (they must never be thrown).
After completing the operation on top of the roof, make sure not to leave any tools behind.

Don't leave
things behind

Use a suspended bag

While working on top of the roof, position yourself in an area of the roof under which reinforcement
4 material is located, in order to prevent the roof of the bus being dented.

U008815
 Operation Section
1– 10

WARNING
While working on the roof, attach the safety belt hook to one of the hook points.
There are three hook point installation locations on the package unit.

Hook Point (Local Arrangement)

ø 20
ø 41 ø 25 ø8

21
4

18
1.5
M10x25

Hook Point
Installation Locations

Hook Point
(Local Arrangement)

Hook

Hook Point

U010160
 Operation Section
1– 11

WARNING
Do not work on the condenser fan motor, blower motor assy, etc.
Work on the air conditioning unit case or component parts could damage them.

Workers should generally walk on the lined section. Walking in any place except those described
above could cause damage to component parts and the unit case.
< Cover Installed > < Cover Removed >

< ATTENTION >

Do not walk
on this part.

Lined section
is walking area.

< ATTENTION >

Do not walk on this evaporator.

U010161
 Operation Section
1– 12

1.6 PRECAUTIONS FOR SAFETY INSTALLATION

1) Never carry out installation with battery cables con-
Always disconnect nected.
the negative
cable first. [ REFERENCE ]
• If installation is carried out with the power connect-
ed, a short-circuit may result.
• Always disconnect the negative cable first.
• When re-connecting the cables, be sure to connect

U003850
them to the correct terminal of the battery.

2) The bolt where specified must be torqued to the prop-

Torque Wrench
er specification. If the torque is not specified, refer to
the TIGHTENING TORQUE TABLE.

U003851

3) When installing the A/C harnesses, route them prop-

NG erly to avoid interference with surrounding parts.

U003852

4) Do not pull on vehicle wires and/or wire harnesses. To

Lock Type Connector
uncouple electrical connectors, pull only on the con-
nector itself so as not to cause damage.

NG Click [ REFERENCE ]
In the case of lock type connectors, make sure that
the connectors are unlocked before disconnecting.
When re-connecting the connectors, insert them
until a clicking noise is heard. After they are con-
U003853
nected, hold and pull them gently to check that they
are connected properly.
 Operation Section
1– 13

5) Check that an O-ring is correctly installed before the

O-ring mating point.

6) Check that no dust is on the O-ring mating parts. Do

not touch the O-rings with gloves on.

Thread Dust, Duct

U003854

7) Do not apply excessive force to pipes. Do not deform

NG pipes.

8) Arrange hoses well. For example, bending or twisting

engine mounted hoses is not permitted.

[ REFERENCE ]
Reason: Resin inside the hoses may be bent or
scratched, and this may lower the permeation-

U003855 proof function.

9) Remove a shipping cap just before the connecting

pipes to keep O-rings or O-ring seals free of dust.

10) Considering installation and vehicle part deviations,

Shipping Cap confirm there is no interference between the pipes
and vehicle parts. (Keep proper clearances.)

U003856

11) Always assemble pipes using 2 wrenches.

Anticipated
Position 12) Pipes will rotate from 15° to 20° clockwise when tight-
15° ~20°
ening, so anticipate the displacement caused by rota-
tion, and then mount pipes.

13) When finally tightening pipes, do not rotate the fixed

side (the female side).

Proper Position U003857

 Operation Section
1– 14

14) Before making any hose and piping connections, ap-

ply a few drops of compressor oil to the seat of the O-
ring to prevent refrigerant leakage.

Compressor Oil

U003858

15) When removing an O-ring from a pipe, use a wooden

or nylon awl to avoid damaging the pipe.

[ REFERENCE ]
Always replace the existing O-rings with new ones
specified for refrigerant HFC-134a.

U003859

Over Torquing
16) When tightening or loosening fittings, use two
wrenches to prevent the piping from twisting. After
loosening the fittings, tighten them to the specified
torque.

Loosening

U003860

17) When handling refrigerant, always wear proper eye

protection and do not allow the refrigerant to come in
contact with skin.

U003861
 Operation Section
1– 15

18) Do not expose refrigerant to an open flame.

U003862

19) Use the proper refrigerant HFC-134a (R134a).

R134a [ REFERENCE ]
A/C System
The very different characteristics of refrigerants
HFC-134a (R134a) and CFC-12 (R12) have deter-
Trouble
mined the design of their respective air conditioning
systems. Under no circumstances allow CFC-12
R12
A/C System
(R12) to enter an HFC-134a (R134a) system, or
vice versa, because serious damage could occur.
U003863

20) Use the proper compressor oil.

[ REFERENCE ]
Compressor oil used in conventional CFC-12 (R12)
air conditioning systems cannot be used in HFC-
134a (R134a) air conditioning systems. For HFC-
134a air conditioning: ND - OIL 8

U003864

21) Use a HFC-134a (R134a) gas leak detector.

[ REFERENCE ]
The CFC-12 (R12) leak detector is not sensitive
enough to detect HFC-134a (R134a).

U003865
 Operation Section
1– 16

Screwdriver
22) When recovering refrigerant, use the necessary spe-
Special Service etc. cial service tools.
Tool
[ REFERENCE ]
Shaft • Support the service valve by hand to prevent the
Spring piping from bending when connecting the charging
hose.
Service
Valve • Using a general tool like a screwdriver may cause
refrigerant to leak by damaging the service valves.
U003866

23) After installing the drive belt, check the belt tension
using a belt tension gauge DENSO BTG-20 or BOR-
ROUGHS BT-33-73F.

[ REFERENCE ]
• The belt tension must be measured at the center of
2 pulleys.
• The drive belt requires accurate tension adjust-
ment; a slack belt is likely to cause the belt to
U003867
whine, while excessive tension may result in dam-
age to the bearings or the idle pulley bracket.

24) After installing the drive belt, make sure it is properly

<V-belt Type>
seated in the grooves of the pulley.

25) Be sure to use a belt which is suitable for the pulley

OK NG NG shape.

<V-ribbed Belt Type>

OK NG NG
U003868
 Operation Section
1– 17

1.7 TIGHTENING TORQUE

z Where tightening torque is specified, always tighten to the specified torque.
z Where tightening torque is not specified, refer to the tightening torque table.
z Nuts must be fastened to the tightening torque specified for the related bolts.

TIGHTENING TORQUE TABLE FOR BOLTS

[ Unit: N·m ]
Diam. Pitch
4T 5T 6T 7T 8T 10T
(mm) (mm)
5.4 6.4 7.8 10.8
6 1.00 - -
(4.4 - 6.4) (5.3 - 7.5) (6.4 - 9.2) (8.9 - 12.7)
12.7 15.7 19.1 25.5 29.4 38.2
8 1.25
(10.2 - 15.2) (12.8 - 18.6) (15.7 - 22.5) (19.6 - 31.4) (23.5 - 35.3) (30.8 - 45.6)
25.5 32.4 39.2 52.0 60.8 78.5
10 1.25
(20.6 - 30.4) (26.1 - 38.7) (31.4 - 47.0) (41.8 - 62.2) (49.0 - 72.6) (62.9 - 94.1)
47.1 58.8 71.6 95.1 1107.9 142.2
12 1.25
(37.8 - 56.4) (47.1 - 70.5) (57.4 - 85.8) (76.5 - 113.7) (86.4 - 129.4) (113.9 - 170.5)
74.5 91.2 107.9 147.1
14 1.50 - -
(59.8 - 89.2) (73.1 - 109.3) (86.3 - 129.5) (117.7 - 176.5)
112.8 137.3 171.6 225.6
16 1.50 - -
(90.3 - 135.3) (109.8 - 164.8) (137.3 - 205.9) (180.5 - 270.7)

[ Unit: kgf·cm ]
Diam. Pitch
4T 5T 6T 7T 8T 10T
(mm) (mm)
55 65 80 110
6 1.00 - -
(45 - 65) (55 - 75) (65 - 95) (90 - 130)
130 160 195 260 300 390
8 1.25
(105 - 155) (130 - 190) (160 - 230) (210 - 310) (240 - 360) (315 - 465)
260 330 400 530 620 800
10 1.25
(210 - 310) (265 - 395) (320 - 480) (425 - 635) (500 - 740) (640 - 960)
480 600 730 970 1100 1450
12 1.25
(385 - 575) (480 - 720) (585 - 875) (780 - 1160) (880 - 1320) (1160 - 1740)
760 930 1100 1500
14 1.50 - -
(610 - 910) (745 - 1115) (880 - 1320) (1200 - 1800)
1150 1400 1750 2300
16 1.50 - -
(920 - 1380) (1120 - 1680) (1400 - 2100) (1840 - 2760)

Identification of Bolt Strength (Bolt Sizes)

No Mark = 4T
4 = 4T Nominal Nominal
6 = 6T Diameter (M) Diameter (M)
8 = 8T
Length
A number is stamped Length Under Bolt Head (L)
or embossed on the (L)
head of the bolt.
U003869
 Operation Section
1– 18

TIGHTENING TORQUE TABLE FOR PIPING < O-ring type >

JOINT TYPE OUTSIDE DIAMETER N·m kgf·cm
D3/8 17.0 (14.8 - 19.6) 175 (150 - 200)
D1/2 22.0 (19.7 - 24.5) 225 (200 - 250)
NUT
D5/8 32.0 (29.5 - 34.3) 325 (300 - 350)
D3/4 42.0 (39.3 - 44.1) 425 (400 - 450)
FLANGE (BOLT) M10 22.0 (17.7 - 25.5) 220 (180 - 260)
 Operation Section
1– 19

2. COMPONENT LAYOUT FOR INSTALLATION

2.1 MAIN COMPONENTS AND THE LAYOUT

Ventilation
Air Inlet Grill Air Filter
Package Unit Sight-Glass Compressor
and Drive Belt

Outlet Grill
Air Conditioning Duct

Control Panel
Blower Fan
and Motor

Water Pump

Strainer

U010478

[ REFERENCE ]
• The installation position (front, middle, rear) for the A/C unit should be decided based on the bus body
structure.
• The installation position of the compressor differs according to the engine position.
• The installation position of the piping differs according to the bus body structure.
 Operation Section
1– 20

2.2 COMPONENT CYCLE

REFRIGERATION CYCLE
z The condenser pressure switch and the pressure relief valve are installed on the receiver tank inlet pipe,
and the low pressure switch and the high pressure switch are installed on the compressor.

Stop Valve Expansion Valve High-Pressure

High Pressure Sensor
Low Pressure
Compressor
Condenser and
Supercooler Air Outlet

Dryer
Evaporator
Reheat Core

Sight-Glass Fresh
Air Inlet Air
Inlet

Low-Pressure Sensor

Evaporator

Reheat Core
Air Outlet
Condenser and
Supercooler Water Pump
Water Magnet
Valve
Bypass Valve Stop Valve
(Magnet Valve)
Stop
Receiver Valve Strainer

: Refrigeration Cycle
: Hot Water Cycle Room
Engine
Heater
U010162
 Operation Section
1– 21

2.3 COMPONENT LIST

Local
No. Component Denso Arrangement Qty Remarks

1 Air Conditioning Unit 1

2 Compressor w/Mag. Clutch 1 6C500 or 6C620
3 Control Panel 1
4 Hose Suction 1
5 Hose Discharge 1
6 Piping —
7 Service Parts Kit —
(Water Pump, Water Magnet Valve, Strainer, etc.)
8 Electrical Parts — Electrical Wire Harness
9 Air Filter — Part Number 140671-0420 or
equivalent part.
10 Air Inlet Grill —
11 Discharge and Suction Pipe — • C1220T-0
• Discharge Pipe: D3/4
• Suction Pipe: 35
12 Harness — Electrical Wire Harness
13 Compressor Belt —
14 Packing (Air Inlet, Air Outlet) — EPDM or CR
15 Packing (Front) — EPDM or CR
16 Flange (Air Inlet, Air Outlet) — SPCC-SD or SPHC
17 A/C Unit Fixing Frame 2 SPCC-SD or SPHC
18 Fixing Bolts for A/C Unit 10 • SPCC-SD or SPHC • M10
19 Drain Hose — • Diameter D24 X D16
• Rubber (EPDM)
• Reinforcing material (nylon 66)
20 Hot Water Pipe (Discharge and Suction) — • C1220T-0
• D3/4
• For Hot Water Cycle
21 Water Hose — • Diameter D24 X D16
• Rubber (EPDM)
• Reinforcing material (nylon 66)
• For Hot Water Cycle
22 Bracket (For Lifting A/C Unit) 4 SPCC-SD or SPHC
23 Hook Point 4
24 Seal Bond —

1 2 3
4 5

6 7 8 9 10 11

13
12

14 15 16

18
17
20 21 22 23 24
19

U010163
 Operation Section
1– 22

3. BUS AIR CONDITIONING PACKAGE UNIT

3.1 COMPONENT LAYOUT AND DIMENSION

1550 (Drain Port)

84
245.4
270

157
1997
160 1504 160
955 ± 2
342 (Air Inlet)
700 ± 2

1812 (Drain Port)

1854 (Air Outlet)

1170 (Air Inlet)

700 ± 2
3720

227
206
490 ± 2

8 x 20 x 15
(Fixing Hole)
780 ± 2
2 x Ø 15
320

U010164
 Operation Section
1– 23

3.2 PIPING POSITION AND DIMENSION

780 ± 2 490 ± 2 123

119 78
8

405
327
409

124.6

100 8

U010165
 Operation Section
1– 24

4. INSTALLATION PROCEDURE

4.1 PROCEDURE
1 Process Work on Bus Body
(a) Perform heat insulation of bus body
(b) Construct air inlets and outlets

2 Installation of Bus Air Conditioning Components

(a) Prepare for bus air conditioning unit installation
• Measure the bus body form (on the bus roof)
• Calculate the height of the frame and packing
• Construct flange, packing and frame
(b) Install bus air conditioning unit
• Install flange, packing and frame
• Install package unit
• Install drain hose
(c) Install compressor
(d) Piping
(e) Wiring
(f) Construct air duct of bus body
(g) Install air inlet filter

3 Work After Installation

(a) Charge gas
(b) Check installation condition
(c) Operation check
(d) Performance test (measure air volume)
The installation procedure depends on the setting of the bus body. Be sure to follow
these steps on a case by case basis.

U003875
 Operation Section
1– 25

5. HEAT INSULATION OF BUS BODY

5.1 HEAT INSULATION

z Good heat insulation of the bus body will increase cooling performance. DENSO recommends using the
following heat insulation on the respective parts of the bus body.

1) Roof and Side of Bus Body

Exterior
Steel Plate
Aluminum (Ceiling)
Thin Film Material Urethane foam
Thickness 50 mm or more
Density 30 kg/m3

Urethane foam
(50 mm or more) [ REFERENCE ]
Hardboard An air layer should be provided on the inside of the
Air (5 ~ 10 mm)
Interior inner panel. It's thickness must be 5 ~ 10 mm.
U003876

2) Window Glass
Exterior Side Window Glass
Interior
Recommend Material Tinted glass
Hardboard
Aluminum
Thin Film Urethane foam
(50 mm or more)
Air (5 ~ 10 mm)

Steel Plate
(Side Body Plate) Floor Board
(20 mm or more) U003877

3) Floor

Upper Heat Insulator Recommend Material Plywood

Thickness 20 mm or more

Floor Board
(20 mm or more)
U003878
 Operation Section
1– 26

4) Main Engine Compartment

Interior Exterior
Floor Mat for
Heat Insulation Material Urethane foam
Thickness 50 mm or more
Urethane foam
(50 mm or more) Density 30 kg/m3

Steel Plate
(0.8 ~ 1.0 mm) [ REFERENCE ]
or Aluminum Glass wool should be supported with steel or alumi-
Main Engine
Side Body
Plate num plate.
U003879

5) Fender (Tire Apron)

Steel Plate
Undercoating (Foaming)
Thickness 5 mm or more

Undercoating
(5 mm or more)
Floor Board
U003880

6) Entrance Step

Steel Plate Undercoating (Foaming)

Thickness 5 mm or more

Undercoating
(5 mm or more)

U003881

7) Structure of Main Door and Emergency Exit

Sealing
[ REFERENCE ]
• Cool air leakage through the main door and emer-
gency exit will reduce cooling efficiency. It is impor-
tant to ensure that this leakage is kept to a
Sealing
minimum. The use of tinted glass for side windows
will increase the benefit gained from the air condi-
tioning.
U003882
• Ensure that all gaps are effectively sealed.
 Operation Section
1– 27

6. CONSTRUCTION AIR INLETS AND OUTLETS

6.1 CONSTRUCTION THE OPENING

Pre-examination of opening
z The air outlet area is positioned where the A/C unit piping connection part and the vehicle frame will not
interfere with each other.

< ATTENTION >

If the A/C unit piping connection part interferes with the vehicle frame, the A/C unit cannot be in-
stalled to the vehicle.

Dimensions of air inlets and outlets

z Construct openings for the air inlets and outlets on the bus roof, according to the dimensions below.

205 730 730 205

Rear
Air Outlet Air Inlet
Air Outlet
< ATTENTION > < ATTENTION >
Make sure the A/C unit Make sure the A/C unit
piping connection part does piping connection part does
)
(445

not interfere with the vehicle not interfere with the vehicle
frame. frame.
188
0

1305
188

460
130

205 730 730 205

Center
Front
U008822
 Operation Section
1– 28

7. INSTALLATION PREPARATION

7.1 PREPARATION OF THE FLANGE, PACKING AND FRAME

z The flange, packing and frame are prepared before installing the A/C unit. Because the measurements for
these parts change according to the shape of the bus roof, they must be constructed individually for each
bus.

< Flange > < Packing > < Frame >

OR OR OR

U003884

7.2 PROCEDURE
1 Measurement of the bus body form

2 Determination of the flange, packing and frame height

3 Construction of the flange, packing and frame

U003885
 Operation Section
1– 29

7.3 MEASUREMENT OF THE BUS BODY FORM

z Measure the height of the following points (A - E) on the bus roof.

998
972
717
517
Bus Roof
242

Datum of Bus Roof

C D E Center
B of Bus
A
Dimension E:
Dimension B & C: For Inlet packing
For outlet packing Installation Point
Dimension A:
Installation Point Dimension D:
For Side of Unit Case
For Frame Installation Point
[ REFERENCE ]

The dimensions (B, C and E) from center are the measurements when the packing
thickness is 25 mm.

U008864
 Operation Section
1– 30

7.4 CALCULATION SHEET

z The measurement values (for points A - E) are input into the calculation sheet to calculate the height of the
frame and packing.

(1/4)
< Fig 1 >

Unit Undersurface
Unit Case for Fixing Packing (Air Inlet)
Center
115

26
43
Air

12

89
Outlet
Datum of Unit
(Unit Undersurface
Air
for Fixing Flame)
Inlet
Unit Undersurface
for Fixing Packing (Air Outlet) Center of
Side of Unit Case Unit Case

U010166
 Operation Section
1– 31

(2/4)
< Fig 2 >

( 20mm or more)
Gap for Side of Unit Case
Unit Case

(H1) mm
Gap for Center of

(h3) mm
Gap : 10 mm or more

(h2) mm
Unit Case

(h1) mm
(10 ~ 25 mm)
Gap : 10 mm or more
(10 ~ 25 mm)

G2
G1

Center
Bus Roof

< Fig 3 >

Center
998
972
717

517
Air 242
Outlet Bus Roof
Datum of Unit
H
G2
Datum of Bus Roof
G1
D E Air
C Inlet
A B

Dimension B & C : Dimension E :

For outlet packing For Inlet packing
Installation Point Installation Point

Dimension D :
Dimension A :
For Frame Installation Point
For Side of Unit Case

[ REFERENCE ]
The dimensions (B, C and E) from center are the measurements
when the packing thickness is 25 mm.

U010167
 Operation Section
1– 32

1) Method for calculating the height of the frame and packing (3/4)
1.1 Measure the dimension of points A - E.
1.2 Judge the roof form (flat or rounded) of the bus based on measurement value 'A'.
1.3 Examine the conditions (the gap and frame height conditions).
1.4 Taking the gap into consideration, calculate the frame height conditions.
1.5 Select the frame component that suits the conditions, and measure the actual frame height.
1.6 Use the determined frame height to calculate the packing height.

2) Input data for roof profile

2.1 Dimension at A from datum mm (Refer to fig 3)
2.2 Dimension at B from datum mm (Refer to fig 3)
2.3 Dimension at C from datum mm (Refer to fig 3)
2.4 Dimension at D from datum mm (Refer to fig 3)
2.5 Dimension at E from datum mm (Refer to fig 3)

3) Determining the gap and frame height

3.1 Determine the bus roof shape.
1) When the dimension at A is less than 89 mm (A 89) , go to 3.2.
2) When the dimension at A is 89 mm or more (A 89) , go to 3.3.

3.2 When the dimension at A is less than 89 mm (A 89)

( Use the unit with extended case edge. )
1) The gap (G1) at the side of the unit case is 10 mm or more.
(G1) (= A + H - 115) 10 mm
2) The frame height is 36 + D mm or more.
(H1) (= H + D) 36 + D mm
3) Calculate the frame height from conditions 1) and 2) above.
H = 125 - A 36 mm
Frame height (H1)
(H1) = H + D = mm ( or more ) a)

3.3 When the dimension at A is 89 mm or more (A 89) .

( Use the unit with extended case edge. )
1) The gap (G2) at the center of the unit case is 10 mm or more.
(G2) (= H - 26) 10 mm
2) The frame height is 36+D mm or more.
(H1) (= H + D) 36+D mm
3) Calculate the frame height from conditions 1) and 2) above.
H = 36 mm
Frame height (H1)
(H1) = H + D = 36 + D = mm ( or more ) b)

U010168
 Operation Section
1– 33

(4/4)
3.4 Select the frame component to suit the conditions based on the result of a) or b),
and the actual frame height measurement.
Measure the actual frame height.
Frame height (H1) = mm (at location D)

3.5 Reference
< Frame >
1) Frame angle ( ) = 90 + (180 / 3.142) x (atan (C - D / 200)) 70
= ° 30
[ REFERENCE ]
This angle is reference value. (H1)
Create the frame (right, left) angle so that the A/C unit attachment side flat.

2) Gap at the side of the unit case: (G1) = A + H - 77 = A + (H1) - D - 77 = mm

3) Gap at the center of the unit case: (G2) = H - 26 = (H1) - D - 26 = mm

4) Determination of the packing height

4.1 Outlet packing height (h1) = (H1) - D + B + 10 (Compression allowance) - 42
= mm (at location B)
4.2 Outlet packing height (h2) = (H1) - D + C + 10 (Compression allowance) - 42
= mm (at location C)
4.3 Inlet packing height (h3) = (H1) - D + E + 10 (Compression allowance) - 12
= mm (at location E)
[ REFERENCE ]
Construction methods for the packing and flange differ according to whether
the packing height is less than 60 mm, or 60 mm and over.

U010169

[ REFERENCE ]
Refer to the "Z Frame Type" or the "Division Frame Type" according to the material shape.

7.5 CONSTRUCTION OF THE FLANGE, PACKING AND FRAME

Fixing packing and flange
z Stability may deteriorate if the calculated packing height is 60 mm or more, so change the shape of the
flange.

[ REFERENCE ]

OK NG OK
Packing Packing
Packing
Less than 60 mm or 60 mm or
60 mm more more Flange
Flange
Flange

U008874
 Operation Section
1– 34

(1) Construction flange

• The flange is constructed according to the following dimensions.

When the packing height is less than 60 mm.

< Flange (Outlet) > < Flange (Inlet) >
80

05
18

13
d

205 460

[ REFERENCE ]
Flange height (d) is 15 mm or more.
Make sure the flange dose not interfere with the A/C unit case.

When the packing height is 60 mm or more.

The flange height is calculated based on the packing height (h1 ~ h3) calculated in the "Calculation sheet ".
< Flange (Outlet) > < Flange (Inlet) >
80

05
18

13
d'1

d'2

d'3

205 460 25 mm or more

Flange Height = Packing Height - (Packing Standard Thickness)

d'1 = h1 - (Packing Standard Thickness)
d'2 = h2 - (Packing Standard Thickness)
d'3 = h3 - (Packing Standard Thickness)
[ REFERENCE ]
Flange height (d'1 ~ d'3) is 15 mm or more.

U008867
 Operation Section
1– 35

(2) Construction packing

• The packing is constructed according to the following dimensions.

When the packing height is less than 60 mm.

< Packing (Outlet) > < Packing (Inlet) >

25 mm or more
+

+
80

05
18

13
25 mm or more

h3
h2
h1

460 +
205 +
= 2 (Thickness of Flange Board)

When the packing height is 60 mm or more.

< Packing (Outlet) > < Packing (Inlet) >

25 mm or more
80

05
18

13

25 mm or more
h'

h'

h'

205 460

h' = Packing standard Thickness (25 mm)

U003892

[ MATERIAL SPECIFICATIONS ]
Packing material Ethylene propylene rubber (EPDM) or chloroprene rubber (CR).
Density Approx. 0.15
Compression percentage 30 - 50 %
Hardness (25 % compressed) Approx. 0.6 kgf/cm2
 Operation Section
1– 36

• When the packing side surface is not waterproofing, apply sealing compound right around the packing
side surface.

NG OK

Waterproofing

Waterproofing Seal

Packing Side Surface

OK

Seal

U003893
 Operation Section
1– 37

(3) Construction frame (right, left)

• The frame (right and left) are constructed according to the following dimensions.

< ATTENTION >

Use the "Z Frame Type" necessary when there is a distortion in the bus roof.

[ REFERENCE ]
Refer to the "Z Frame Type" or the "Division Frame Type" according to the material shape.

Z Frame Type
< Frame (Left) > < Frame (Right) >
Front Front
80

80
M10 M10
780 ± 2

780 ± 2
Nut/Bolt [ REFERENCE ] Nut/Bolt
35 mm or more
60

60
M10 M10
H1
490 ± 2

Nut/Bolt Nut/Bolt
2760 ± 8

2760 ± 8

490 ± 2
40

40
700 ± 2

700 ± 2

M10 M10
Nut/Bolt Nut/Bolt
1490 ± 4

1490 ± 4

700 ± 2
700 ± 2

M10 M10
Nut/Bolt Nut/Bolt
50

50

M10 M10
70 70
Nut/Bolt Nut/Bolt
3 ~ 4.5
3 ~ 4.5

[ REFERENCE ]
30 30
1. The frame height (H1) should
be calculated using the frame
H1 ( 40 or more )

height calculation sheet.

H1 (40 or more)

2. The frame angle ( ) is

M10 reference value. Create the M10
frame angle so that the A/C
unit attachment side flat.
3. The whole surface of the frame
is painted for rust prevention.
U008868
 Operation Section
1– 38

< ATTENTION >

It is necessary to confirm there is no gap (gap that shifts the direction of height and is right and left)
in the unit installation position of the frame when the "Division Frame Type" is used. When the unit
is installed with there a gap in the unit installation position, the unit might be damaged.

Division Frame Type

< Frame (Left) > < Frame (Right) >
Front Front
80

80
M10 M10
(780 ± 2)

(780 ± 2)
Nut/Bolt Nut/Bolt
60

60
M10 M10

(490 ± 2)
(490 ± 2)

(2760 ± 8)

(2760 ± 8)
Nut/Bolt Nut/Bolt
40

40
700 ± 2

700 ± 2

M10 M10
Nut/Bolt Nut/Bolt
1490 ± 4

1490 ± 4

700 ± 2
700 ± 2

M10 M10
Nut/Bolt Nut/Bolt
50

50

M10 M10
70 70
Nut/Bolt Nut/Bolt
3 ~ 4.5
3 ~ 4.5

[ REFERENCE ]
30 30
1. The frame height (H1) should
be calculated using the frame
H1 ( 20 or more )

H1 ( 20 or more )

height calculation sheet.

2. The frame angle ( ) is
M10 reference value. Create the M10
frame angle so that the A/C unit
attachment side flat.
3. The whole surface of the frame
is painted for rust prevention.
U008869
 Operation Section
1– 39

8. BUS AIR CONDITIONING UNIT INSTALLATION

8.1 PROCEDURE
1 Install flange for the A/C unit

2 Install packing for the A/C unit

3 Install frame and bracket for A/C unit

4 Install A/C unit and drain hose

U003896
 Operation Section
1– 40

8.2 INSTALLATION FLANGE FOR THE A/C UNIT

z The flange is welded to the bus body.

< ATTENTION >

Installing the flange using a bolt or rivet will result in water infiltration.

When the packing height is less than 60 mm.

Rear

Flange (Outlet)
Flange (Outlet)
Flange (Inlet)

18
1305

80
460
205 205
130

730 730
Center

Front

When the packing height is 60 mm or more.

Rear

Flange (Outlet)
Flange (Outlet)
Flange (Inlet)
18
13 0 5

80

460
205 205
130

730 730
Center

Front
U003897
 Operation Section
1– 41

z Apply sealing compound right around the flange to prevent water entering.

< Air Inlet >

When the packing height is When the packing height is
less than 60 mm. 60 mm or more.
Flange Flange
Seal Seal Seal Seal
Seal Seal

< Air Outlet >

When the packing height is When the packing height is
less than 60 mm. 60 mm or more.
Flange Flange
Seal Seal Seal Seal

Seal Seal U007445

8.3 INSTALLATION PACKING FOR A/C UNIT

z Install the packing to the bus body.

Rear

Packing (Inlet)
Packing (Outlet)
Packing (Outlet)

Center
Front

(Duct) (Duct) (Duct)

NG OK OK U003899
 Operation Section
1– 42

z Apply sealing compound right around the packing to prevent water entering.

[ REFERENCE ]
• The joint seal must be insulated and weatherproof.
• Roof profiles will vary according to the design of the bus, so fitters should use their own discretion in making
connecting ducts to specifications, taking care to provide insulation and weatherproof seals where neces-
sary.
• Check that water sealing compound is applied right around the flange and packing.

When the packing height is less than 60 mm.

Inlet Air Duct
342 X 1170
10 mm Compression Width Unit Section Area
Seal

Bus Roof
15 mm
Seal or more
Flange
Packing
460 X 1305
Packing Body Section Area Heat Insulator
Outlet Air Duct
10 mm Compression Width Packing 160 X 1854
Seal Unit section area

15 mm Bus Roof
Seal or more
Flange
Packing

205 X 1880 Heat Insulator

Heat Insulator Body Section Area

When the packing height is 60 mm or more.

Inlet Air Duct
342 X 1170
10 mm Compression Width Unit Section Area
Seal
25 mm Bus Roof
Seal
15 mm
or more Flange
Packing
460 X 1305
Packing Body Section Area Heat Insulator
Outlet Air Duct
10 mm Compression Width Packing 160 X 1854
Seal Unit section area

25 mm
Bus Roof
Seal
15 mm
or more Flange
Packing

205 X 1880 Heat Insulator

Heat Insulator Body Section Area
U003900
 Operation Section
1– 43

8.4 INSTALLATION FRAME FOR THE A/C UNIT

z The frame is welled to the bus body.
z Install the packing (front) to the bus body.

< ATTENTION >

• Installing the frame using a bolt or rivet will result in water infiltration.
• Frame flatness should be within 1 mm and be of suitable strength.

832.5 832.5
477.5 477.5

Frame (Right)
Frame (Left)
Rear

73
0
Packing (Front)
30
10

710

1160

32
0

Unit Case
477.5 477.5

Center
Front

Packing (Front)

e
or
(h3) + 12

m
or
25 900

U003901
 Operation Section
1– 44

z After installing the frame, verify the packing height measurement based on the unit installation surface of
the frame.

Unit Installation Surface

Packing (Front)

Center

10 ± 5
33 ± 5

2±5
Packing (Outlet)

Air
Outlet
Air
Packing (Inlet) Inlet

Frame

U008823

Packing Height Measurement Based on the Unit Installation Surface

Packing Standard Measurement (Height) Actual Measurement
Packing (Inlet) 2±5
Packing (Outlet) 33 ± 5
Packing (Front) 10 ± 5
 Operation Section
1– 45

8.5 INSTALLATION A/C UNIT AND DRAIN HOSE

(1) PREPARATION BEFORE A/C UNIT INSTALLATION

• Construction lifting jig and bracket (Reference)

< Lifting Jig >

t = 5 mm
2000

0
180
300

< Bracket >

15MAX

3.2 100

20
(Material: SPCC-SD or SPHC)

U010170
 Operation Section
1– 46

(2) PRECAUTIONS FOR A/C UNIT INSTALLATION

< ATTENTION >

Do not stand on the A/C unit unless the wood supports for unit conveyance are in position.

• When lifting

< ATTENTION >

• Lift the unit at a lifting point.
• Be sure to set the bracket for lifting to the lifting point (cutting lack part) of the unit.
• When lifting the unit, make sure the four wires are the same length so that the unit will be horizontal.
• Do not place the unit directly on the ground. (This will damage the discharge or hot water pipe.)

Lift Up
< ATTENTION > < ATTENTION >
Discharge Pipe
Lifting Jig

Cover the discharge pipe

with cloth

< ATTENTION > < Lifting Point >

Hot Water Pipe

Bracket

Cover the hot water pipe < ATTENTION >

with cloth
U010171
 Operation Section
1– 47

• When lifting by hand

• Lift between lifting points (A) and (B). • Do not lift from the end or center of the frame.

Lifting Point (B)

OK NG NG
Lifting Point (A) Lifting Point (B)

NG
Lifting Point (A)
U008825

• When lifting with a forklift

• Insert the fork to the center of the unit frame for lifting. • Do not lift the fork when the unit is positioned
• Do not damage the FRP case or pipe with the fork. to one side.

Fork 1.2 Fork

OK m
or
mo
NG
re

View A
View A
< View A > OK < View A > NG

< ATTENTION >

Pipe

1.2 m or more
Fork Fork Fork
U010172
 Operation Section
1– 48

(3) INSTALLATION A/C UNIT

• Remove the 16 bolts then remove the cooling unit cover by the lifting point.

< ATTENTION >

Always lift the cooling unit cover from the lifting point (center).

Bolt (M8 L20)

Lifting Point

Cooling Unit Cover

Lifting Point

U008827
 Operation Section
1– 49

• Remove the 11 bolts then remove the condenser cover.

Bolt (M8 L20)

Condenser Cover

U009644

< ATTENTION >

When attaching the cover, tighten the bolts to the following tightening torque. Excessive tightening
will damage the cover.

Tightening Torque
12.5 N·m (10.0 - 15.0 N·m)
M8 Bolt
{128 kgf·cm (102 - 153 kgf·cm)}
 Operation Section
1– 50

• Hang unit over roof.

< ATTENTION >

• When lifting the A/C unit by hand, hold the (A) section of the unit.
• Be sure to set the bracket for lifting to the lifting point (cutting lack part) of the unit.
• When lifting the A/C unit using a fork lift, take care that the fork dose not damage the discharge pipe
or the bolt on the bottom of the FRP case.
• When lifting the unit, make sure the four wires are the same length so that the unit will be horizontal.
• The discharge pipe protrude from the base of the A/C unit.
• Do not place the unit directly on the ground. (This will damage the discharge or hot water pipe)
• Do not damage the roof of bus with the discharge pipe.
• Cover the discharge pipe with cloth once the A/C Unit is installed in the bus.

Lift Up
< ATTENTION > < ATTENTION >
Discharge Pipe
Lifting Jig

)
(A

Cover the discharge pipe

with cloth

< ATTENTION > < Lifting Point >

)

Hot Water Pipe

(A

Bracket

Cover the hot water pipe < ATTENTION >

with cloth
U010173
 Operation Section
1– 51

< ATTENTION >

When placing the unit on the frame, ensure that is no gap from front to back or left to right. This
may cause the condenser and drain pipe to be damaged when the unit is sifted.

< When the A/C unit is shifted to the front >

Drain Pipe Drain Pipe

NG OK

Condenser Frame Condenser Frame

< When the A/C unit is shifted to the rear > < Unit Underside >

Drain Pipe
NG

Condenser

Condenser Frame Drain Pipe

U003997
 Operation Section
1– 52

• Fix 10 places on the bottom of the case with M10 bolts (nuts) to install the unit.

< ATTENTION >

• When the M10 bolt is used to secure the air conditioning unit, it should not interfere with the bus
roof. Be sure to use correct length bolts.
• Contact between the fixing the frame and bus air conditioning unit must be on the same plane at
all points.
• Make sure the bolts are inserted at right angles (not on a slant) when installing the unit cover.
• Bolts and Nuts should be fastened to within the specified torque.

< Fixing Point >

Position of bolts U010174

Tightening Torque
26.0 N·m (20.8 - 31.2 N·m)
M10 Bolt (Nut)
{256 kgf·cm (212 - 318 kgf·cm)}
 Operation Section
1– 53

[ REFERENCE ]
• Use flat washers with an outer diameter of 21 mm on the bolt head (nut).
• Use LOCTITE or self-locking nuts with nylon inserts to prevent nuts from vibrating loose.
• After tightening the 10 bolts (Nuts) on the bottom of the case, apply sealing compound around all of them.

< Frame (Right, Left) >

M10 Bolt
A/C Unit
Washer (Outer Dia. ø 21 mm)

25~30 mm
Frame

U003947

• Cross section of unit

Air Inlet
Frame Frame
Air Outlet Air Outlet
U003910

(4) DRAIN HOSE

• Lay the drain installed to the left and right outlet ports using rubber hose or vinyl tube with an outer diam-
eter of 24 mm and an inner diameter of 16 mm and discharge it via the nearest pillar. Be sure to lay out
the hose without any traps. If metal pipe is used for the drain, insulate it from heat to prevent condensation
from dripping into the room.

[ REFERENCE ]
The drain hose should be properly clamped to the identical vibrating body at the connection or to a non-
vibrating part of the vehicle body. It should not be able to be pulled out easily.

< ATTENTION >

• Undrained water in the A/C unit to be sucked and sprinkled by the blower motor.
• Undrained water in the A/C unit to create unnecessary condensation on the surface of the A/C unit
that will leak into room via the duct.
 Operation Section
1– 54

LAYOUT (REFERENCE)
(1) Most Recommended Layout Drain Hose

Unit
OK

Eliminate Traps.
Trap
Drain Hose
Unit NG
OK NG
Trap

[ REFERENCE ]
Draining from the unit drain port directly
Drain Port
OK
underneath is the best. It is also possible to
extend the drain hose from the unit drain
port to either the back or front for draining. Drain Hose

(2) Joint Layout (Center Drain) Hose Laid at Lowest

Joint
Point in Duct
Unit
Drain Port
OK
Drain Hose

[ REFERENCE ]
Layout (1) is highly recommended. However joint is used
in vehicles where draining is only possible from one place.
There are cases in which, due to the tilt angle of the vehicle,
the joint becomes higher than the position of the unit drain port,
making draining impossible. Install the joint as low as possible.

(3) Joint Layout (Rear Drain) Joint

Unit

NG
Drain Hose
[ REFERENCE ]
When the vehicle nose is tilted down, there are
cases in which draining will not be possible due to
the distance that the drain hose extends to the rear.
(It is similar when extended to the front.) U008870
 Operation Section
1– 55

• The drain port is inserted on the bottom of the drain hose and fixed with the hose clamp, etc. from the
outside to prevent it falling during driving.

Drain Hose

Should be Secured
with a Clamp Drain Pipe

Drain Port

U005860

• After installing the drain, be sure to check the drains from the A/C unit.
(Apply water to the drain pan and check the four drains.)
 Operation Section
1– 56

9. COMPRESSOR

9.1 COMPRESSOR MOUNTING

z The design and manufacture of the compressor mounting and drive kit are to be carried out by the body
builder or chassis manufacturer. Consideration should be given to the following.

Consideration
z As a rule, the compressor should be mounted directly on the engine block by means of a bracket. In situa-
tions where the compressor has to be mounted on the chassis, a belt tension device should be provided.
The installer should assess engine stability and distortion between the engine crank pulley and compressor,
and where possible maximize the belt length.
z Mount the compressor so that the compressor service valves are not obstructed by other components in
the engine compartment, and in such a way that the crankcase oil-level sight-glass is visible.
z The mounting bracket should not obstruct maintenance access to engine parts.
z The compressor and magnetic clutch can be replaced.
z The compressor and bracket bolts can be tightened with pre-set type torque wrench and ordinary wrench.
z Keep reasonable clearance between the compressor and other parts. (Relative movement : 30 mm or more.
No movement : 15 mm or more.)
z No combustible objects within 100 mm above the magnetic clutch.
z Do not mount the compressor near hot spots (e.g. exhaust manifold). (More than 100 mm or less than
80 °C surface temperature.)

9.2 COMPRESSOR ROTATION SPEED

6C500 / 6C620 Type
z Less than 3000 rpm (Below red zone of engine speedometer).
z More than 700 rpm (at idling speed).
 Operation Section
1– 57

9.3 PULLEY ALIGNMENT

z Crank pulley and compressor clutch pulley misalignment should not exceed standard value.

Compressor Mount Type Pulley Misalignment

Mounting on the Engine Type 20’ (0.33°) or less
Mounting on the Chassis Type 0.5° or less

[ REFERENCE ]
As the example, when the distance between the belt pulleys is L = 350 mm, become G = 3 mm or less.

Crank Pulley B B' Crank Pulley

G

A A'
L Clutch Pulley Clutch Pulley
A - A' and B - B' are parallel.

< Pulley Misalignment > < Pulley Misalignment >

(a) Mounting on the engine type (a) Mounting on the engine type
20' (0.33°) 20' (0.33°)
(b) Mounting on the chassis type (b) Mounting on the chassis type
0.5° 0.5°

G tan {(0.5/180) X 3.142} X L

Measure L and G, and verify

that the equation above is satisfied.

U005837
 Operation Section
1– 58

9.4 COMPRESSOR MOUNTING SLANT ANGLE

z The mounting angle of the compressor should be ± 15° or less.
z The mounting bracket on the vehicle side should have a level mounting surface of 0.2 or less.

15° or less

Engine

U003912

z The compressor hose should be installed in a way that it absorbs engine vibration well.

NG
OK Compressor Hose

OK Clamp

Clamp
NG
Compressor Flexible Hose

U003913

9.5 COMPRESSOR BELT

z After installing the drive belt, make sure it is properly seated in the grooves of the pulley.

<V-belt Type> <V-ribbed Belt Type>

OK NG NG OK NG NG

U004584
 Operation Section
1– 59

z Confirm with the belt manufacturer the required tension and durability. Investigate the durability of the belt
when determining the belts.

[ REFERENCE ]
• The belt tension must be measured at the center of 2 pulleys.
• The drive belt requires accurate tension adjustment; a slack belt is likely to cause the belt to whine, while
excessive tension may result in damage to the bearings or the idle pulley bracket.

< Check Point > [REFERENCE] < Belt Tension Gauge >

Check Here

Comp.

Engine

< Belt tension for V-belt type >

BELT TYPE NEW-BELT USED BELT
490 N (392 - 588 N) 343 N (294 - 392 N)
HM {50 kgf (40 - 60 kgf)} {35 kgf (30 -40 kgf)}
490 N (392 - 588 N) 343 N (294 - 392 N)
A {50 kgf (40 - 60 kgf)} {35 kgf (30 - 40 kgf)}
588 N (490 - 686 N) 392 N (343 - 441 N)
B {60 kgf (50 - 70 kgf)} {40 kgf (35 - 45 kgf)}
686 N (588 - 784 N) 490 N (441 - 539 N)
BC {70 kgf (60 - 80 kgf)} {50 kgf (45 - 55 kgf)}

< Belt tension for V-ribbed belt type >

RIB NEW-BELT USED BELT RIB NEW-BELT USED BELT
490 N (392 - 588 N) 343 N (294 - 392 N) 882 N (784 - 980 N) 617 N (568 - 666 N)
3 {50 kgf (40 - 60 kgf)} {35 kgf (30 - 40 kgf)} 7 {90 kgf (80 - 100 kgf)} {63 kgf (58 - 68 kgf)}
588 N (490 - 686 N) 411 N (343 - 441 N) 980 N (882 - 1078 N) 686 N (637 - 735 N)
4 {60 kgf (50 - 70 kgf)} {42 kgf (37 - 47 kgf)} 8 {100 kgf (90 - 110 kgf)} {70 kgf (65 - 75 kgf)}
686 N (588 - 784 N) 480 N (431 - 529 N) 1078 N (980 - 1176 N) 755 N (706 - 804 N)
5 {70 kgf (60 - 80 kgf)} {49 kgf (44 - 54 kgf)} 9 {110 kgf (100 - 120 kgf)} {77 kgf (72 - 82 kgf)}
784 N (686 - 882 N) 549 N (500 - 598 N) 1176 N (1078 - 1274 N) 824 N (775 - 873 N)
6 {80 kgf (70 - 90 kgf)} {56 kgf (51 - 61 kgf)} 10 {120 kgf (110 - 130 kgf)} {83 kgf (78 - 88 kgf)}

U010491
 Operation Section
1– 60

z A V-belt or V-Ribbed belt should be used to drive the compressor. (Depends on the compressor type)

V-Belt B Type V-Belt BC Type

16.1 17.5
15.4±0.3 16.8±0.3

38°± 1° 38°± 1°

R1
.5

R1
.
R1

R1
.5

.
15

5
16
5

R1
.

.5
R1

R1
.

R1
5

.5
Shape of V-groove Shape of V-groove
17.3
18.8

38°
9.5

38°

11
Shape of V-belt Shape of V-belt

V-Ribbed Belt 3.56±0.05

3.1 or more
40° ± 1° .08
±0
.35
R0
R0
.5
0
-0

Shape of groove
.3

24.92
3.56
2.0~2.9
4.3~5.8

40°

Shape of V-Ribbed belt U008831

 Operation Section
1– 61

Reference
z Belt tension is an extremely important maintenance item. A belt that is too tight will wear quickly and reduce
the life of bearings.

Correct Belt Tension

• Apply 10 kg of vertical pressure at the center of the length of the belt and adjust the tension of the belt
according to the amount of deflection at that time.
• The relationship between the amount of deflection and initial tension is shown in the following graph.

< Relationship Between ‘HM’ and ‘A’ Belt Tension and the Amount of Deflection >
10

20
Deflection
10 kg
30
20
40
Deflection Span Length 50 Belt Tension (kg)
(mm)
60

10

Initial Tension is
60 kg or less.

100 200 300 400

Span Length (mm)

< Relationship Between ‘B’, ‘BC’, ‘C’ and ‘CD’ Belt Tension and the Amount of Deflection >

10

20

20 30

40
Deflection 50 Belt Tension (kg)
(mm) 60
70
10 80

100 200 300 400

Span Length (mm)

The DENSO BTG-2 belt tension gauge should be used to allow easy measurement of belt tension.
U003916
 Operation Section
1– 62

9.6 COMPRESSOR DIMENSION AND SPECIFICATION

Dimension
z 6C500C / 6C620C Type

6C500C (447190-096#)
6C620C (447190-098#)

258.6 168.6 - 01 168.6 - 01

257.4 30 58 50 30

4 x 38º ± 1º

148.1
4 x 15.4 ± 0.3

115
142

34.5
414 +- 525

95.8

56
92
ø 170 ± 0.4

298.2
ø 177.6

41
ø 172

115.3
20

20
20 ± 0.3
OIL PLUG 19
27.5 ± 1 125 ± 0.2 ø 20 ø 20
20 ± 0.3
60º 60º
20 ± 0.3 92.5 ± 1 283.6
112 ± 0.15
459.5 220 ± 0.2
260

U010175

Specification
z Compressor

Compressor Type 6C500 6C620

Part Number 443500-3190 443500-7130
Cylinder bore ø 50 ø 52.5
Stroke 42 mm 47 mm
No. of cylinders 6 6
Piston displacement 495 cm3 (cc) 611 cm3 (cc)
Maximum allowable speed 3000 rpm 3000 rpm
Lubricant (ND-OIL8) 1700 ± 100 cm3 (cc) 1700 ± 50 cm3 (cc)
Weight 26.38 kg 26.38 kg

z Magnetic Clutch

Part Number 247300-752#

Effective outside diameter of pulley ø 170
Rated voltage DC 24 V
Transmission torque MIN 211 N·m
Minimum operating current MAX 1.7 A
Power consumption 60 W
V-Belt B type, 4 Belts
Direction of rotation Clockwise
Weight 19.0 kg
 Operation Section
1– 63

9.7 SERVICE VALVE

z Tighten the cap and the stem of the service valve to the specified torque.

< ATTENTION >

If there is condensation on the service valve cap, wipe off the water before installation.

Back Seat Position

Cap

Stem

Front Seat Position

Stroke

U010200

Cap
Tightening Torque
Suction Side 2.94 N·m (0.98 - 4.9 N·m)
Discharge Side {30 kgf·cm (10 - 50 kgf·cm)}

Stem
Tightening Torque
Back Seat Position Front Seat Position
15.5 N·m (14.0 - 17.0 N·m) 25.5 N·m (24.0 - 27.0 N·m)
Suction Side
{158 kgf·cm (143 - 173 kgf·cm)} {260 kgf·cm (245 - 275 kgf·cm)}
Discharge Side 15.5 N·m (14.0 - 17.0 N·m) {158 kgf·cm (143 - 173 kgf·cm)}

Reference (Stem Stroke)

Suction Side 22.3 mm
Discharge Side 11.0 mm
 Operation Section
1– 64

10. PIPING

10.1 PIPING LAYOUT

< Example (441450-742#) >

7
4

8
3 1 5
9 3
7
4
Drain Parts
12 11 10 13 2
8
3 1
9 3 5
15 14
7
4
2

3 8
1
9 3
5

7
2 4

3 8
1
9 3
5
COMPRESSOR
S D 7
2
[Pipe] 6
Suction Pipe ø 35 High-Pressure Sensor
D
Discharge Pipe D 3/4
S
[Hose]
Specification
Symbol Line Part No. Remarks
Diameter 1 Joint Type

S SUC 441420-5480 D1 775 537 180º 90º

Flange Flange 1
180º 90º
D DIS 441410-5030 D 3/4 800 635 Bulge
Bulge
* This figure is reference
U010176
 Operation Section
1– 65

Part Number Table (Reference)

No. Line Part Number Remarks
1 Suction 441770-2710 ø 35 Flange
2 Suction 441770-2700 ø 35 Flange
3 Suction 050019-0100 ø 35 Flange
4 Discharge 441460-2200 D 3/4 Bulge
5 Discharge 441760-5590 D 3/4 Union Half
D 3/4 Bulge, Union Half
6 Discharge 440460-4180
(High-Pressure Sensor)
7 Discharge 949142-0410 D 3/4
8 Suction 949142-0430 ø 35
M10 × 1.25 × L35
9 Suction 91410-10351
Included No.2
10 Drain 146321-1330 ø 17
11 Drain 949351-0860 ø 17
12 Drain 017163-0520 ø 17 3way
13 Suction 90120-10353 M10 × 1.5 × L35
14 Drain 140621-3400
15 Drain 949351-0800

Tightening Torque
Joint Type N·m kgf·cm
D 3/4 O-Ring 41.7 (39.2 - 44.1) 425 (400 - 450)
Flange (Bolt) 21.6 (17.7 - 25.5) 220 (180 - 260)
 Operation Section
1– 66

10.2 PIPING INSTALLATION

CURVED PIPE PROCESSING
z As shown below, there are limiting conditions regarding the joint part dimensions, R bend and straight line
R interval dimensions when processing pipes. Consider these carefully when doing on-board planning.

CURVED PIPE TABLE

Pipe size Pipe bend angle (R) Length A Length B Length C Note
D 3/8 20 15 R + 20 R + 30 Discharge side (Cooling unit part)
D 1/2 25 20 R + 25 R + 35 Discharge side (Ceiling part)
D 5/8 30 25 R + 30 R + 40 Discharge side (Driving-unit part)
D 3/4 30 30 R + 35 R + 50 Suction side (Cooling unit part)
D1 50 100 R + 70 R + 50 Suction side (Ceiling part)
R + 70
ø 28 50 100 Suction side (Driving-unit part)
(Up to the tip of flange)

B C
R

R
A
R

B,C

U003948
 Operation Section
1– 67

PIPING CONNECTIONS
z Before connection, apply "ND-OIL8", oil to the connection surface (O-Ring).
z Align the sealing surfaces and fit by hand.
z Tighten to the specified torque.

Pipe size D 1/2 (12.7 mm) D 5/8 (15.87 mm) D 3/4 (19.05 mm) Flange Bolt (M10)
Standard N·m 22.0 (19.6 - 24.5) 32.0 (29.4 - 34.3) 42.0 (39.2 - 44.1) 22.0 (17.7 - 25.5)
torque kgf·cm 225 (200 - 250) 325 (300 - 350) 425 (400 - 450) 220 (180 - 260)

O-Ring
O-Ring Type Flange Type
Flange
O-Ring

Apply ND-OIL8 Here

(Entire Periphery) Apply ND-OIL8 Here
(Entire Periphery)
U003949

z Inspection hatches should be provided for easy access to piping connections so that they can be easily
checked for leakage and easily tightened.

Inspection Hatch

U003993

CLAMPING THE CONNECTION

z Both ends of the piping connection should be inserted into a rubber sheet or have a nylon coating clamped
within 100 mm. At this time, the pressing direction should be to the outside and burrs should be 0.3 mm or
less.

Clamp

Within 100 Within 100

U003950
 Operation Section
1– 68

SUCTION PIPE CONNECTIONS

z Affix the packing following the procedure shown in the figures below.

(1) Peel off the adhesive paper of the packing (2) While pulling both ends of the packing, affix them
and feed it through the rear side of the connection together as shown in the figure.
as shown in the figure.

< ATTENTION>
Ensure that the
packing is
adhered directly
on to the pipe.

Insulator

(3) Press the packing by hand to ensure (4) Adhered connection.

there are no gaps.

< ATTENTION >

Pipe

Ensure there are no

gaps between the
pipe and the packing

U008871
 Operation Section
1– 69

SUCTION PIPE INSULATOR

z Be sure to install the insulator on the suction pipe.

Suction Pipe Suction Pipe

Insulator Insulator
U003951

PIPING PROTECTION
z Piping laid underneath the vehicle should be protected from flying debris and stones by means of a cover.
z Piping at the lowest point of the vehicle and/or piping in locations that could be easily struck by a flying stone
should be covered with a protective cover, or have some form of protection.
z Grommets should be inserted where there is penetration into the body.

Pipe Pipe Grommet

Cover

U003953

MOUNTING STRENGTH OF THE PIPING

z Confirm the strength of the mounting sections so that the vibration of moving parts and piping is contained
to a maximum of 3G.
 Operation Section
1– 70

STRESS TO THE PIPING

z When connecting piping to the functional parts, be careful of the two stress positions shown in the drawing.
During installation, always confirm the amount of vibration from the idling to high speed ranges. When ab-
solute values are confirmed, measure with a warpage gauge. (There should be no resonance.)
z The design of the functional part mount should prevent the occurrence of warpage in the bracket being ap-
plied as initial stress to the functional part and the base of piping connected to it.

Bends
Flared Neck Areas

U006147

ROUTING OF PIPE IN THE DUCT

z The piping should be routed so as not to interfere with airflow.

NG A/C Unit Duct

Pipe

OK
A/C Unit Duct

Air Outlet Air Flow Pipe

Grill

NG A/C Unit Duct

Air Outlet
Air Flow Grill Air Flow

Pipe

U007702
 Operation Section
1– 71

10.3 DISCHARGE AND SUCTION HOSE INSTALLATION

z Make sure the discharge and suction hoses exceed their positions of 30 mm or more in all directions.
z Hoses should be positioned 100 mm or more from the exhaust pipe and other high temperature areas. If
this cannot be achieved, use a heat barrier plate to keep the temperature of the surface of the hose under
80 °C or less.
z Flexible discharge and suction hoses should be laid in such a way as to absorb engine vibration.

Compressor Hose

U003955

z Do not damage the pressure switch, when the hose is installed in the compressor.

High Pressure
Switch Low Pressure
Switch

U004608

z Do not make severe bends in the hose directly from the edge of the bracket.

[ REFERENCE ]
Do not bend flexible discharge and suction hoses more than specified. Refer to table of minimum radii.

Edge of Bracket
Minimum Hose Bend Angles
D 1/2 R150 or more
D 5/8 R150 or more

D 3/4 R200 or more

D 1~ R200 or more
R

U003956
 Operation Section
1– 72

z Use a hose length of 400 mm or more to enable the hose to absorb vibration.

NG OK
= Less than 400 mm = 400 or more

U003957

z When using a clamp to secure the length of hose, position the clamp 400 mm or more along the hose.

NG OK

= Less than 400 mm = 400 or more

U003958

z Flexible hoses should normally be clamped at the pipe fitting end. If the hose is too long and it is necessary
to clamp it at the rubber section, then gently cushion the hose.
z Do not use a clamp with insufficient diameter. It will deform the hose.

Clamp With Metal Fitting

NG OK
Deformation

COMP

Rubber Bushing
U003959

z The torsion angle of flexible hoses should be less than 15°.

Allowable Torsion Angle

Flexible Hoses

Torsion
Less than 15
U003960
 Operation Section
1– 73

z When installing the hose, always temporarily install both ends before performing final tightening.

NG OK
Final Tightening Final Tightening

Disconnected Connected

U003961

z When sliding the compressor to adjust the V-belt tension, be sure not excessively bend, pull or compress
the hose at the MIN, MAX and intermediate positions.

Straight
R

NG NG

< MIN > < MAX >

U003962

z Do not twist the hose when installing it. (If using a hose with a bending bracket installed, make sure that the
hose bend direction matches.)
z During installation, do not step on the hose or place heavy objects on top of the hose.

Do not step
on the hose.
Twisting

NG

The resin inner surface

will be deformed.
U006148
 Operation Section
1– 74

z When removing or installing parts, do not temporarily suspend parts with the hose still connected as this
may pull or deform the hose.
z Do not even temporarily leave the hose across high temperature parts. (When installed, leave a clearance
of 100 mm or more between the hose and any hot parts. If this is not possible, install a heat resistant cover
over the hose.)

NG
NG
Do not use the hose
for support.

Muffler

U003964
 Operation Section
1– 75

[ REFERENCE ]
Preventing “Torsion” in discharge and suction hoses.

For Compressor

For Piping

Discharge Hose (D3/4)

Suction Hose (D1)

WORK PROCEDURE

1. Pre-tighten the discharge and suction hoses, compressor and pipe by hand.
2. Tighten the compressor side of both hoses to the specified torque.
Hold the fitting port by hand to prevent it rotating.
3. If torsion is applied to the hose from the tightening compressor side, free the piping
side to remove torsion.
4. Securely tighten the piping to the specified tightening torque using a double spanner.
Pipe Size Specified Torque
41.7 N·m (39.2 - 44.1 N·m)
Discharge hose D3/4
{425 kgf·cm (400 - 450 kgf·cm)}
21.6 N·m (17.7 - 25.5 N·m)
Suction hose D1 (Flange Bolt)
{220 kgf·cm (180 - 260 kgf·cm)}

5. Recheck torsion on the hose after completing work.

(If torsion is still present, repeat procedures 3. - 4.)

U010177
 Operation Section
1– 76

10.4 JOINT BRAZING

z The unions and copper pipes supplied shall be subject to flux brazing, rinsed with hydrochloric acid then hot
water, and dried. (They shall be free from moisture.)
z Copper pipes shall undergo non-flux brazing using nitrogen gas. (If flux is used, the same procedure as
above shall be performed.) The inside of the pipe shall be free from moisture, dust and other foreign matter.
z For details, refer to the "Refrigerant Pipe Processing Manual" (Pub. No. Z6ZGS-02A) published in Dec.
2000.

< ATTENTION >

• If pipes need to be brazed in the field, non-flux brazing shall always be carried out using nitrogen
gas. The pipes shall be free from moisture and other foreign matter before brazing.
• Sufficient brazing material shall be applied to the portion to be brazed.

1 Cutting

2 Debarring

3 Air Blow (Removal of foreign substance)

4 Brazing

5 Cooling Pipe

6 Pressure Test

7 Cap Installation (for storage)

U003966
 Operation Section
1– 77

11. HOT WATER CYCLE (FOR REHEAT TYPE)

11.1 PIPING

Package Unit
Reheat Core

Engine Room

Water Magnet Valve

P Water Pump
Stop Valve
Strainer
Stop Valve
E/G
(Water
Room Heater Pump)
P E/G

U006820

11.2 PIPING INSTALLATION

z The floor pipe is a Cu pipe with O-ring.
z The joint part is installed to the insulator.

Package Unit
Duct
Front Rear

Compressor

: Cu Pipe
: Hose
Engine
Insulator Clip

Band
U006818
 Operation Section
1– 78

Piping Connections
1) Connect the hot water pipe to the unit.

[ REFERENCE ]
Install the O-ring to the piping connection.

Joint Type Tightening Torque

D5/8 O-Ring 32.0 N·m (325 kgf·cm)

2) Install the insulator to the pipe joint.

3) Secure the insulator with the band and clip.

[ REFERENCE ]
Insulator
The insulator is secure if there are no surface gaps.

Band

Clip
U006811

11.3 WATER PUMP INSTALLATION

1) The water pump is installed in the engine room.

Engine 2) The water pump is installed behind the stop valve.

Water Pump 3) Do not install in a location where water drips.

Thermostat
Joint
Stop Valve

To Package Unit
U006821

4) The water pump is installed below the engine hot wa-

NG OK ter outlet.

Water Pump

Engine

Engine Water Pump

U006822
 Operation Section
1– 79

5) Face the water pump attachment hole downwards and in-

Water Pump stall it horizontally.

To Package Unit

From Engine

2-Ø10
38

Bracket

Spring Washer
t3.2

Bolt (M8 x L15)

Local Arrangement

U006823

11.4 STRAINER INSTALLATION

1) The strainer is installed vertically.

NG OK 2) Install the strainer in a position where filter replace-

ment and checking is possible.

U006824

3) Check the direction of the hot water flow and install

Bracket
Inlet (Local Arrangement) the strainer in this direction.
Strainer

Outlet

Bolt (M8)
(Local Arrangement) U010203
 Operation Section
1– 80

11.5 WATER MAGNET VALVE INSTALLATION

1) The water magnet valve is installed horizontally.

NG OK

U006826

Bolt (M8) 2) Check the direction of the hot water flow and install
Bracket
(Local Arrangement) (Local Arrangement) the water magnet valve in this direction.
Bracket
(Local Arrangement)

Water Outlet
Magnet Valve

Inlet Bracket
(Local Arrangement)
U006827

11.6 WATER SUPPLY METHOD FOR HOT WATER CYCLE

1) Check the engine is stopped and the hot water cycle
Water Magnet
is connected.
Valve
2) Open the water magnet valve by hand.

[ REFERENCE ]
Inlet
Outlet • Do not apply a strong force when opening the valve.
• Check the stop valve is open.
Open
Valve
Close U006828

3) Open the reheat core air bleed valves and connect the
Vinyl Tube
(Local Arrangement) vinyl tube to the air bleed valve. Set up the container
at the other end.
Reheat Core
4) Start the engine to supply hot water to the cycle.
When enough hot water has flowed from the vinyl
Air Bleed Valve
tube, close the air bleed valve and the water magnet
Case valve by hand.
(Local Arrangement)
U010178
 Operation Section
1– 81

5) If air is not discharged from the air bleed valve, oper-

ate the water pump according to the following meth-
Simultaneously Press
for 3 Seconds or Longer
od.

6) Return the water magnet valve to its initial state

AUTO + CHECK
(closed).

7) Perform check mode control.

Check Mode No.
"0 0" 8) Stop the air conditioning, and press both the AUTO
U006218
and CHECK switches simultaneously for three sec-
onds or longer.

9) Press the TEMP switch either up or down to select the

check mode number "H1" or "H2".

[ REFERENCE ]
TEMP Press the ON/OFF switch to return to the normal
or display and simultaneously stop the air condition-
TEMP
ing.
Check Mode No. Special
Control No.
U010179

10) When enough hot water has flowed from the vinyl
Vinyl Tube
(Local Arrangement) tube, close the air bleed valve.

11) Operate in this state for several minutes to check for

Reheat Core
any abnormalities (water leaks etc.).

Air Bleed Valve

Case
(Local Arrangement)
U010178
 Operation Section
1– 82

Operating Mode Check Table

Blower Motor Condenser Reheat Mode
Check Mode No. Compressor Bypass Valve
(Airflow Volume) Fan Motor (Water Magnet Valve)
C8 16 (HI) ON OFF HI OFF
C7 12 ON OFF HI and LO are OFF
C6 8 ON OFF switched accord- OFF
ing to the high-
C5 4 ON OFF pressure value. OFF

C4 1 (LO) ON ON LO OFF
C3 1 (LO) ON ON LO OFF
C2 1 (LO) ON ON LO OFF
C1 1 (LO) OFF OFF LO OFF
0 1 (LO) OFF OFF OFF OFF
H1 1 (LO) OFF OFF OFF ON
H2 1 (LO) OFF OFF OFF ON
 Operation Section
1– 83

11.7 ATTENTION ITEMS FOR INSTALLATION

(1) Hot Water Piping Installation

• Use piping that is size D1/2 (inside diameter: Ø10.7 mm) or greater. As a general rule, only use straight
piping. If a bend must be used, follow the criteria below:
9 Use as few bends as possible.
9 Make the bend radius as large as possible (at least 15 mm.)
9 Maintain a bend angle of at least 90° or greater.

Bend Radius R = At least 15 mm

Bend Angle = At least 90

U009187

• For the connections to the hot water hoses, use the piping inside the kit (140720-0200) with lips at both
ends.

Lips

U009188

(2) Hot Water Hose Installation

• The following fiber-reinforced hose is recommended to connect functional components inside the piping
kit, such as the water pump and strainer: Inner diameter Ø25 mm x board length t5 mm (outer diameter:
Ø35 mm.)
• Use clamps suited to the hose size. Additionally, check that there are no leaks from any connections
throughout the entire usage range.
• Position all functional components for shortest length of piping layout.
• Do not forcefully bend or twist straight hoses (when in use.)
 Operation Section
1– 84

11.8 REQUIRED HOT WATER FLOW VOLUME

[ REFERENCE ]
To maintain the hot water flow volume between the engine and reheat cores, the position of each part and
layout of the hot water piping must be designed and installed so that flow resistance is minimized to the
greatest extent possible. The following explains general attention items for designing the hot water piping
installation.

z Maintain a flow volume of at least 14 L/min (at least 7 L/min per core) throughout the entire usage range.
z Measure the actual flow volume to determine whether the aforementioned value can be maintained. If the
flow volume cannot be measured, reference the graph below to verify that the reheat system is functioning.

[ REFERENCE ]
The graph below only applies to the air conditioning unit (440100-753#)

40
Difference Between Outlet

35
and Inlet Temp. [ C]

30

25

20

15

10
40 45 50 55 60
Difference between Inlet Water of Reheat Core and Inlet Air Temp. [ C]

(Attention Items When Using the Chart Above)

- Use each air volume line as a guide. If the measured results fall below the line, there is a possibility
that the proper hot water flow volume dose not reached required level.
(The aforementioned assumes that both the air temperature and air volume measurements are correct.)
- Each temperature (hot water inlet, air inlet and outlet) are calculated using the temperature values directly before
and after the heater core. Therefore, measure temperature near the heater core.
- When air volume is measured with a Biram's anemometer, there is a ±10 % measurement error.
Taking this error into account, verify that there are no air leaks at the inlet or outlet before using the chart above.
It is recommended to subtract 10 % from the measurement results for evaluations based on air volume.
The air volume shown in the chart above is the total air volume for the left and right sides.

U010199
 Operation Section
1– 85

12. CONTROL PANEL

12.1 CONTROL PANEL

z Install the control panel near the driving seat where it is easy to operate.

< ATTENTION >

• Do not install the control panel in a place where water intrusion into the unit is likely.
• When installing the control panel, do not touch the unit with cotton gloves covered in oil, etc.

Auto Control type

178
165
45.75
25.75
22.5
56.5
(64)

64
214 46
200 43
182 4 X ø7 39.3
179.7

AUTO DEHUM VENT

47.4
50

30
46

TEMP H
C
AUTO DEHUM
ON/OFF A/C CHECK

U009233
 Operation Section
1– 86

13. WIRING

13.1 WIRING LAYOUT

z Layout the wiring to connect the relay box in the bus air conditioning package unit with the control panel,
compressor and sensors. Refer to the wiring circuit diagram.

Compressor
Package Unit Relay Box (6C500, 6C620 Type)

Air Conditioning Duct

Control Panel

Water Magnet Valve

Water Pump

U010180

[ REFERENCE ]
• Be sure to solder the wiring connections.
• Align the wire diameters and colors.
• Be sure to install the wiring protectors.
• Separate the ground for the magnetic clutch.
 Operation Section
1– 87

13.2 WIRING IN THE A/C UNIT

z The wiring for the relay box is as follows.

Vehicle Wiring Harness

(Battery and Ground Wiring Harness)

U010181
 Operation Section
1– 88

13.3 WIRING HARNESS INSTALLATION

z All grounds must be correctly secured to the vehicle body.
z Remove the coating on the grounding part.
z Ground bolt and nut should be fastened to the specified torque.

Tightening Torque
12.7 N·m (10.2 - 15.2 N·m)
Ground Bolt and Nut
{130 kgf·cm (105 - 155 kgf·cm)}

Bolt and Nut

U006214

z Use grommets where the harness passes through metal panels.

z Grommets should be tight fitting so that they cannot be dislodged when harness is laid.

Grommet

Panel

Harness

Grommet

OK NG U003969

z Use a cover to protect the harness where it is exposed to flying debris.

Cover

Protector
U003970
 Operation Section
1– 89

z Properly support the harness with rubber cushioned clamps to prevent sagging. Secure the wiring harness
despite any pulling.

Rubber Seat Type Coating Type

Clamp Each Corner to be Confirmed

Rubber Seat
U003971

z The harness should be fixed with clamps. The clamps positions are as follows;

Section Clamp position

Straight portion Less than 500 mm
Bend Clamp at both ends of bend
Near junction Clamp at least 30 mm away from junction

About 3 Times Deadweight

Clamp

Less than 500 mm

Deflection; Less than 20 mm

U003972

z When securing the harness, take care not to pinch or crease it. Never fix the clamps to hot areas.

Wire Harness
NG Clamping NG

Clamp

Damaged
U003973
 Operation Section
1– 90

z To determine which type of cable to use, refer to the following table.

Location Cable type

Engine room Heat resistant harness (AEX cable)
Other areas Common harness (AV cable)

Wiring Harness Gap

Minimum Gap
Installation Position
Without Protection With Protection
Common Fixed Flat part More than 2 mm Can be touched
Parts Protruding part More than 5 mm Can be touched
Common Vibrating Flat part More than 15 mm Can be touched
Parts Projection part More than 30 mm More than 5 mm
Rotating Parts More than 15 mm More than 15 mm
Flat part *More than 50 mm *More than 50 mm
High Temperature
Parts Projection part *More than 100 mm *More than 100 mm

* : Surface temperature. AV wire: Less than 80 °C. AEX wire: Less than 120 °C.
Main Supply Fuse
Cooling type 150 A

z Ensure that connections are accessible for maintenance. Installation should conform to industry standards.
 Operation Section
1– 91

14. AIR DUCT CONSTRUCTION

14.1 AIR DUCT

[ REFERENCE ]
We suggest the following recommendations should be considered when fabricating interior ducting in order
to achieve minimum resistance to air flow and maximum efficiency from the air conditioning.

z Total air flow resistance between the inlet (return air) and horizontal air duct in the passenger compartment
should be less than 98 Pa (10 mm Aq) at 1,500 m3/H of the outlet air volume.
z Cross-sectional area of ducting : 0.04 m2 or more.
z The radius of any bends in the ducting should be as large as possible. Fit air guide vanes to reduce air flow
resistance.

Guide Vane

R0
R R

x x1 x x1 x2 x3
a a U003974

z Where the duct narrows or widens, the walls of the duct must curve smoothly in or out, and avoid sharp
transitions.

NG OK OK
Airflow Direction Airflow Direction Airflow Direction

U003975
 Operation Section
1– 92

z Provide guide vanes for the outlet air sockets. Where there are two plenum outlets, there should be an ad-
justable air guide to distribute the airflow proportionally.

Adjustable Guide

Guide Vane
Air Guide Cool Air
(Air Divider)
U003976

z The air duct must be covered with the heat insulator without clearance. Take care with the corners.

(Duct) (Duct) (Duct)

NG OK OK
U003977
 Operation Section
1– 93

z The insulator must stick to the inside of the duct in the flow direction. And if possible, use the insulator cov-
ered with vinyl leather. 5 mm or thicker urethane foam with vinyl leather must be used as the thermal insu-
lator.

Air Flow Air Flow

NG OK

Pressure Plate

Insulator

Duct
Air Flow Air Flow

NG OK

Insulator with Vinyl Leather

Pressure Plate

Air Flow

OK

U003978
 Operation Section
1– 94

z The air flow from the air outlets of the ceiling duct must be distributed to conduct cooling air evenly to all the
seats, and the speed variation must be within ± 15 % of the average air speed. (The temperature distribution
in the room must be 2 °C or less.) The outlet grilles must be positioned so that the cooling air may be set to
blow directly onto the faces of the passengers.

15 % Less
Air Flow Distribution

Average Air
Flow Speed

15 % Less

Front

U003979
 Operation Section
1– 95

15. AIR INLET FILTER INSTALLATION

15.1 AIR INLET GRILL / FILTER LAYOUT AND DIMENSIONS

z Layout

Filter

Do Not Drop Knurled Screw

Air Inlet Grill

Air Inlet Grill

Filter

U003980
 Operation Section
1– 96

z Dimension (Reference)

[ REFERENCE ]

The relay box checked is performed

from the air inlet. Therefore, the rod
holding the filter in place is detachable.
Air Inlet

Relay Box

1383

562.5
A A'

Rod
20 (Filter)

A - A' Cross Section Filter

t 20
45

30

65
19

40
12

[ REFERENCE ]

42 Use a filter comparable to the

0 Bridgestone MOQT-13 (t20, Black).

U010204

Filter (Reference)
Name Part Number Dimension Remarks
Filter 140671-0420 1240 x 420 x t20 Bridgestone NOQT-13 (t20, Black)
 Operation Section
1– 97

z Filter installation cautions

< ATTENTION >

If air not passing through the filter is directly sucked in by the evaporator, foreign material may clog
in the evaporator, reducing the cooling volume.

NG OK Filter

Air Inlet
Air Inlet Air Inlet
Grill

U003982
 Operation Section
1– 98

16. CHARGING REFRIGERANT (HFC-134a)

16.1 CHARGING PROCEDURE

Start Evacuation
CHECK AND CORRECT
Evacuating time: 30 minutes EACH CONNECTION
Evacuating pressure: -0.1 MPa or less
(-750 mmHg)

Stop Evacuation

Leave the system in this

condition for 5 minutes.

Check for Air Leakage

The gauge indicates

Charge Refrigerant abnormal level.

Charge gaseous refrigerant from Hi

pressure side until the Low pressure
gauge indicates 0.098 MPa (1 kgf/cm2).

Check for Gas Leakage

Charge Refrigerant

Operate Bus air conditioning (compressor) and then charge

refrigerant from Low pressure side.

After charging with refrigerant to the rated volume, operate the air
Running-in
conditioning for ten minutes or more at E/G idling speed.

Confirm there are no bubbles

in the sight-glass.

U003983
 Operation Section
1– 99

16.2 CHARGING AMOUNT (REFRIGERANT IN USE HFC-134a)

z The refrigerant charging amount differs according to the compressor type and refrigeration cycle length. The
following are standard charging amounts.

Compressor 6C500, 6C620 type

Charge refrigerant an additional 0.3 kg
Refrigerant charging amount 4.9
+0.2
kg/1 cycle
or after bubbles disappear in the sight-glass.
0

U008834

[ REFERENCE ]
• The engine is run for ten minutes or more at idle speed. (Turning on the compressor at a high rpm after
charging refrigerant is prohibited.)
• The evaporator may frost in winter. Warm up the vehicle by raising the room temperature to 15 °C or more
using the heater.
• Do not charge liquid from the low pressure side. Gas should be charged with the E/G idling.
 Operation Section
1– 100

17. INSTALLATION AND OPERATION CHECK

17.1 INSTALLATION CONDITION CHECK

z Problems such as insufficient cooling may occur if installation is not appropriate. Check the installation con-
dition of the bus air conditioning components using the bus air conditioning installation check sheet.

Customer Confirmation
(Agreement).
Confirmed by
Bus Air Conditioning Installation Check Sheet

Bus
Vehicles Type Reg.# Witnessed by
Parts
A/C Unit Prod.#
Number
Confirmation. Place Date

Immediate repair/improve is necessary because there was a problem about the following item.

No. Problem Item Contents of Treatment. Repaired by Repair Date

U004586
 Operation Section
1– 101

No. Problem Item Contents of Treatment. Repaired by Repair Date

U004587
 Operation Section
1– 102

A/C Installation Check

Must Check All Items

1. Engine Compartment-Related Check Check Sheet No.

No. Check Item Standard Check Point Judge Result, Problem

Removal and Installation Work is possible with two people. Checked by actual
1 of Compressors Parts can be removed from work.
the vehicle without obstacle.
Removal and Installation Clutch can be replaced without Checked by actual
2 of Magnetic Clutch removing compressor. work.
Prevention of Fire No combustible objects within Checked by visual
Hazard from Excessive 100 mm above the magnetic inspection.
3 Heat due to Magnetic clutch.
Clutch Sliding, etc.
Ease of Compressor Bolts can be tightened with Checked by actual
4 and Bracket Bolt pre-set type torque wrench and work.
Tightening ordinary wrench.
Pulley Alignment Mounting on the engine: Confirmed by actual
20 ' (0.33 ) or less measurement.
Mounting on the chassis:
5 0.5 or less

Mounting Angle of 15 or less Confirmed by actual

6 Compressor measurement.
Belt Tension Within specified tension. Confirmed by actual
7 (Depends on the <Belt tension measurement.
for Belt type>)
Idle Pulley Bracket is Alignment should not deviate Confirmation of
Structured such that when tightening bracket. alignment.
8 Alignment does not
Change
Operation of Tightening The bolts can be tightened with Checked by visual
9 Nut on Idle Pulley pre-set type torque wrench and inspection.
Shaft ordinary wrench.
Tension Adjustment The work must be easily Checked by visual
10 and Replacement of accessible without removing inspection.
Compressor Belt other parts from the vehicle.
Preservation of The compressor belt should not Checked by visual
11 Essential Parts when be engaged with any other inspection.
Compressor is Locked functional parts.
Visual Check of Oil Can be confirmed under the Checked by visual
12 Amount through actual bus condition. inspection.
Compressor Sight Glass

<Belt tension for Belt type>

Belt type New Belt Used Belt
HM 490 N (392-588 N) {50 kgf (0-60 kgf)} 343 N (294-392 N) {35 kgf (30-40 kgf)}
A 490 N (392-588 N) {50 kgf (40-60 kgf)} 343 N (294-392 N) {35 kgf (30-40 kgf)}
B 588 N (490-686 N) {60 kgf (50-70 kgf)} 392 N (343-441 N) {40 kgf (35-45 kgf)}
BC 686 N (588-784 N) {70 kgf (60-80 kgf)} 490 N (441-539 N) {50 kgf (45-55 kgf)}

U006833
 Operation Section
1– 103

No. Check Item Standard Check Point Judge Result, Problem

Visual Confirmation of Can be confirmed under actual Checked by visual
13 Compressor Production bus condition. inspection.
Code
Operation of Can be confirmed under actual Checked by visual
14 Compressor Service bus condition. inspection.
Valve

15 Removal and Installation Can be confirmed under actual Checked by visual

of Main Engine Oil Filter bus condition. inspection.
Removal and Installation Can be confirmed under actual Checked by visual
16 of Main Engine Air bus condition. inspection.
Cleaner Element
Removal and Installation Can be confirmed under actual Checked by visual
17 of Main Engine Fuel bus condition. inspection.
Filter
Hose Bending Radius D 1: R200 or more. Confirmed by actual
18 D 3/4: R200 or more. measurement.
D 5/8: R150 or more.
D 1/2: R150 or more.
Hose Twisting Should not be twisted. Checked by visual
19 (Discharge and Suction) (Less than 15 ) inspection.
Routing of Discharge No pulling. Checked by visual
20 and Suction Hose (verify that there is some give inspection.
to absorb vibration.)
Routing of Discharge Fixed (clamped) every 400 mm Checked by visual
21 and Suction Hose or more. inspection.
Routing of Discharge Clamp position is wrapped in Checked by visual
22 and Suction Hose an insulator. inspection.
Routing of Discharge There should be no turning Checked by visual
23 and Suction Hose stress place on the hose inspection.
connection point when adjusting
belt tension.
Compressor Running-in More than 10 minutes at idling Confirmation.
24 speed.
Compressor Rotation Less than 3000 rpm. Confirmed by actual
Speed (6C500/6C620 (Below red zone of engine measurement.
25 Type) speedometer)
More than 700 rpm. Confirmed by actual
(at idling speed) measurement.
Refrigerant Amount Amount must meet regulations. One Cycle
+0.2
4.9 0 kg/1 Cycle
26
High-pressure side liquid Confirmation.
charging.
Low-pressure side gas charging.

U008835
 Operation Section
1– 104

No. Check Item Standard Check Point Judge Result, Problem

Safety gap
1) Spacing of Pulleys S 2 mm. Checked by actual
measurement.

S
2) Compressor More than 100 mm or less Checked by actual
-Exhaust Pipe than 80 C surface temperature. measurement.
3) Compressor Relative movement: Checked by actual
-Vehicle Parts More than 30 mm. measurement.
No movement:
More than 15 mm.
4) Discharge and More than 100 mm or less Checked by actual
Suction Hose than 80 C surface temperature. measurement.
-Exhaust Pipe
5) Discharge and More than 30 mm. Checked by actual
Suction Hose measurement.
-Relative Movement
6) V-belt Direction of Loose side: Checked by actual
Rotation More than 30 mm. measurement.
27
Tight Side Tight side:
More than 20 mm.

Comp. E/G
Loose Side

7) Wiring Harnesses Checked by actual

a) Around Rotating a) Around rotating parts: measurement.
Parts More than 15 mm.

b) Around High b) Around high temperature parts:

Temperature Parts More than 100 mm, or
surface temperature less than
80 C on AV wire.
Less than 120 C on AEX wire.

c) Vehicles Safety c) Around safety parts:

Parts More than 15 mm.
(Check brakes,
accelerator, fuel piping,
steering, gearbox, etc.
for shifting or movement.)

Discharge, Suction Hose Hose should not absorb direct Checked by visual
28 vibration axially. inspection with
engine ON.
Discharge, Suction Hose Hose should not bear weight at Checked by visual
29 hose crimping point. inspection.

U009010
 Operation Section
1– 105

2. Bus Body

No. Check Item Standard Check Point Judge Result, Problem

Heat Insulation of Roof Urethane foam thickness: Confirm with the
1 and Side Body More than 50 mm. body manufacturer.
Heat Insulation of Floor Floor board thickness: Confirm with the
2 More than 20 mm. body manufacturer.
Heat Insulation of Main Urethane foam thickness: Confirm with the
3 Engine Compartment More than 50 mm. body manufacturer.
Heat Insulation of Heat insulation (Urethane Confirm with the
4 Fender (Tire Apron) foam, etc.): body manufacturer.
More than 5 mm.
Heat Insulation of Heat insulation (Urethane Confirm with the
5 Entrance Step foam etc.): body manufacturer.
More than 5 mm.
Window/Door Opening Should be no air leakage. Checked by visual
6 and Closing Area inspection and/or
by hand.
Air Duct Should be no air leakage. Checked by visual
7 inspection and/or
by hand.
Heat Insulation of Urethane foam with vinyl Confirm with the
Air Duct leather thickness: body manufacturer.
more than 5 mm.
8
No gaps, good insulation. Checked by visual
inspection.

U005846
 Operation Section
1– 106

3. Air Conditioning Unit

No. Check Item Standard Check Point Judge Result, Problem

Unit Installation There should be no gap Checked by visual

1 between the unit and the frame. inspection.
Unit should be fixed.
Gap Between Unit Gap: 10 ~ 25 mm Confirmed by actual
2 Case and Bus Roof (Center, Side) measurement.
Securing the Unit The fixed unit bolts should be Checked by actual
3 tightened to the specified work.
torque (26 N m).
Unit Fixing Frame A notch must be cut in the Checked by visual
4 frame so that it does not inspection.
interfere with the condenser.
Air Inlet Inlet should be sealed with Checked by visual
5 packing so that there is no inspection.
gap or air leakage.
Air Inlet Connection points should be Checked by visual
6 sealed with a flange to prevent inspection.
water from intruding the interior Check for water
of the vehicle. leakage as necessary.
Air Outlet Space between duct and unit Checked by visual
7 should be sealed with packing inspection and/or
so that there is no air leakage. by hand.
Air Outlet Connection points should be Checked by visual
sealed with a flange to prevent inspection.
8 water from intruding the interior Check for water
of the vehicle. leakage as necessary.
Air Inlet Filter Should be easily removal and Checked by actual
9 installation. work.

Air Inlet Grill Verify that work on the relay Checked by actual
10 box can be performed from work.
the air inlet.
Routing of Drain Hose No crushing. Drainage condition
11 Hose is routed at a descending is confirmed by the
angle to prevent trapping water. visual observation.
Drain Hose Confirm number of drain hoses Checked by visual
12 and hose diameters. inspection.
Installation of Drain port must be attached Checked by visual
13 Drain Port to the end of the drain hose. inspection.
Clamp of Drain Port Should be secured with a Checked by visual
14 clamp. inspection.

U008836
 Operation Section
1– 107

4. Piping

No. Check Item Standard Check Point Judge Result, Problem

Pipe Connection Space Accessible with actual spanner/ Checked by actual

1 torque wrench to be used. work.
Pipe Interference Must not interfere with other Checked by visual
2 pipes or body parts. inspection.

Pipe Clamping Use rubber coated or silicone Checked by visual

3 coated clamp or insert rubber inspection.
seat.
Pipe Vibration Strike by hand to confirm no It is actually struck
4 vibration. by hand and
checked.
Protection of Pipe at Pipe is to be protected with Checked by visual
5 Penetrations putty, grommet etc. inspection.
Clamping of Pipe along Piping that is not attached to Checked by visual
6 the Body the body should be clamped inspection.
at turning points.
Clamps at Connection Clamp the both sides of the Confirmed by actual
7 Points piping connection within measurement.
100 mm from the connection.
Insulator Pipe should be wrapped in Checked by actual
8 insulation after performing gas work.
leak check.
Removal of other Parts of the vehicle can be Checked by actual
9 Vehicle Parts removed and installed even if work.
air conditioning parts and pipes
aren't removed.

10 Oil for O-Rings ND-OIL8 - R134a Conform with the

body manufacture.
Routing of Pipe in the The piping should be routed so Checked by visual
11 Duct as not to interfere with airflow. inspection.
Protection of Confirm that condensation is Checked by visual
12 Mechanical/Electrical not dripping on electric parts inspection.
Parts from such as the amplifier and
Condensation connectors.

U005848
 Operation Section
1– 108

5. Electrical

No. Check Item Standard Check Point Judge Result, Problem

Protection of Electric Use a fusible link or breaker in Checked by visual

1 Circuit the power supply line. inspection.
Electric Wire Size for Use wire size indicated in the Checked by visual
2 Vehicle drawing (especially, power inspection.
supply line, earth wire).
Prevention of Ground Remove insulation materials and Checked by visual
3 (Earth) Fault paint at the point of body inspection.
grounding.
Ground (Earth) A ground bolt is used, and Confirmed by actual
4 Confirmation grounding is confirmed with a measurement.
megger.
Ground (Earth) Bolt Do not share a ground with a Checked by visual
5 fixed bolt or a pipe clamp (may inspection.
become loose.)
Ground Circuit 1) If there are ground bolts in Checked by visual
more than two places, ground inspection.
in accordance with the
drawings.
6
2) Make adjustments as Checked by visual
necessary to prevent inspection.
exceeding the allowable
current due to a ground fault
in another earth circuit
(floating, open circuit, etc.)
Grounding of A/C Parts Carry out grounding of A/C Checked by visual
7 parts as necessary. inspection.
Check Fuses and Install fuses in one area for Checked by visual
8 Exchange ease of maintenance and inspection.
replacement
Installation of Wiring No biting, damage, or Checked by visual
9 Harness interference. inspection.
Protection of Wiring Install the wiring harness Checked by visual
Harness protector. inspection.
10 (Eg. corrugated tube, spiral
tube, tube)
Wiring Harness Insert grommet securely. Checked by visual
Penetrations (Such as inspection.
11 through the floor, body
or panel/frame.)
Gap Between Rotating No possibility that the wiring Checked by visual
Parts and Wiring harness will be damaged due inspection
Harness to rotating parts such as a
12 pulley, belt, or fan.
Verify proper clamping of the
wiring harness.

U005849
 Operation Section
1– 109

No. Check Item Standard Check Point Judge Result, Problem

Clamping of Wiring Wiring harness should not be Checked by visual

13 Harness to High clamped to high temperature inspection.
Temperature Parts exhaust parts.
Wiring Harness Gap Checked by actual
Minimum Gap measurement.
Installation Position Without With Wiring harness
Protection Protection should be protected
More than Can be with tubing, spiral
Common Flat part tube, etc.
2 mm touched
Fixed Parts Protruding More than Can be
part 5 mm touched
Flat part More than Can be
14 Common 15 mm touched
Vibrating
Parts Projection More than More than
part 30 mm 5 mm
Rotating Parts More than More than
15 mm 15 mm
Flat part * More than * More than
High 50 mm 50 mm
Temperature
Parts Projection * More than * More than
part 100 mm 100 mm
* Surface temperature. AV wire: Less than 80 .
AEX wire: Less than 120 .
Routing of Wiring No damage due to manufacturing Checked by visual
15 Harness processes such as screw inspection.
tightening, welding, and painting.
Routing of Wiring Installation position of wiring Checked by visual
16 Harness harness is such that it will not inspection.
be pinched during removal of
A/C and vehicles part.
Routing of Wiring Water should not accumulate Checked by visual
Harness on the wiring harness terminals inspection.
17 due to dripping (water damage
to the magnetic clutch is
possible.)
Routing of Wiring Routing/installation is such that Checked by visual
Harness there is not repeated stress inspection.
18 added to the wiring harness.
There is slack when stress is
added to the harness.
Wiring Harness Clamp Use plastic clamp with rubber Checked by visual
19 seat or nylon coating. No metal inspection.
clamps.
Clamp Position of Clamp is placed every 500 mm. Checked by visual
20 Wiring Harness Clamping where wiring harness inspection.
turns.
Wiring Harness Clamp Harness should not move even Checked by actual
21 if pulled lightly by hand. work.

U005850
 Operation Section
1– 110

No. Check Item Standard Check Point Judge Result, Problem

Tension Condition of Should not be excessively Checked by visual

Wiring Harness loose or tight. inspection.
22 Push about three times by Checked by actual
hand deadweight deflection: measurement.
5 ~ 20 mm
Clamping of Vibrating There is to be a rubber seat or Checked by visual
23 Portion of the Wiring protective tubing at the clamped inspection.
Harness portion of the harness.
Connectors Inside the Waterproof connector should be Checked by visual
24 Vehicle used if there is a possibility of inspection.
water damage due to washing
the floor.
Connectors Outside Apply waterproofing (such as Checked by visual
25 the Vehicle waterproof connectors, tape.) inspection.
Connector Shape Ensure that connectors in the Checked by visual
26 same area that are of similar inspection.
shape are not misconnected.
Fuel Ignition Connectors are not in a position Checked by visual
27 Prevention where fuel dripping/splashing is inspection.
likely.
Connector Position A connector is not in the Checked by visual
position where oil, refrigerant, inspection.
condensation or LLC are likely
28 to drop/splash from the
compressor, hose connection,
etc.
Other Connections Terminal and wiring number Checked by visual
29 are to be specified. inspection.
Short Circuit + Terminal should not interfere Checked by visual
Prevention with other parts when it is inspection.
30 exposed.
Consider dispersing
connections.
Pressure Switch Connector should not dangle Checked by visual
31 Connector or wave when clamped. inspection.
Pressure Switch Installation position should be Checked by visual
32 Position in a waterproof environment. inspection.
Control Panel Operation of the panel and Confirmed by
Operability confirmation of the display can actual operation.
be performed from the driver's
33 seat.

Control panel operation must

not obstruct vehicle operation.
Removal and Inspect for accessibility and Checked by visual
34 Installation of Control removability. inspection.
Panel Lamps and
Switches

U005851
 Operation Section
1– 111

17.2 OPERATION CHECK

z After installing all components of the bus air conditioning, check the bus air conditioning operation and air
volume.

(1) System Check

• The following is the procedure to verify that the bus A/C system is correctly set.

1) Stop the A/C, and press both the Check and TEMP
(down) switches simultaneously for three seconds or
Simultaneously Press
for 3 Seconds or Longer longer.
Both the ON/OFF and A/C switch LEDs will illuminate,
indicating that the system is in control panel check
CHECK + TEMP
mode.

AUTO DEHUM

TEMP H
C
AUTO DEHUM
ON/OFF A/C

All Items Appear

All LED Light ON

U010182

2) Press and hold both the Blower (up) and TEMP

Simultaneously Press (down) switches simultaneously for three seconds or

for 3 Seconds or Longer
longer. A "1" will appear on the display.

3) ) Press the TEMP switch up or down, and verify

+ TEMP whether the displayed number remains lit or blinks in
accordance with the chart below.

[ REFERENCE ]
Remains Lit or Blinks
U006560 If the relevant number does not remain lit or does
not blink, check the wiring (connector removed,
open circuit, etc.)

4) Press the ON/OFF switch to return to the normal dis-

play.
 Operation Section
1– 112

System Check Chart

Displayed Display Status
Remarks
Number (Remains Lit or Blinks)
1 Remains Lit Blower Motor Drive Recognition
2 Blinks Compressor Type Recognition 1
3 Remains Lit Compressor Type Recognition 2
4 Blinks Bypass/No Bypass Recognition
5 Remains Lit Rotation Sensor/No Rotation Sensor
Recognition
6 Blinks Compressor Quantity Recognition
7 Blinks Evaporator Quantity Recognition
8 Blinks Reheat/No Reheat Recognition
9 Remains Lit Condenser Drive Recognition
10 Remains Lit Vehicle Manufacturer Recognition
11 Blinks Ventilation/No Ventilation Recognition
 Operation Section
1– 113

(2) Fixed Operating Mode Check

• Run the A/C system fixed in each check mode, and perform operational checks for each functional part
(compressor, blower motor, condenser fan motor.)

1) Stop the A/C, and press both the AUTO and CHECK
switches simultaneously for three seconds or longer.
Simultaneously Press
for 3 Seconds or Longer

AUTO + CHECK

Check Mode No.

"0 0"
U006218

2) Press the TEMP switch either up or down to select the

check mode number.

3) Press the ON/OFF switch to return to the normal dis-

TEMP play and simultaneously stop the A/C.
or
TEMP

Check Mode No. Special

Control No.
U006219

Operating Mode Check Table

Blower Motor Condenser Reheat Mode
Check Mode No. Compressor Bypass Valve
(Airflow Volume) Fan Motor (Water Magnet Valve)
C8 16 (HI) ON OFF HI OFF
C7 12 ON OFF HI and LO are OFF
C6 8 ON OFF switched accord- OFF
ing to the high-
C5 4 ON OFF pressure value. OFF

C4 1 (LO) ON ON LO OFF
C3 1 (LO) ON ON LO OFF
C2 1 (LO) ON ON LO OFF
C1 1 (LO) OFF OFF LO OFF
0 1 (LO) OFF OFF OFF OFF
H1 1 (LO) OFF OFF OFF ON
H2 1 (LO) OFF OFF OFF ON

Special Control Number Table

Special Control No. Control Name
0 Without Control
2 Frost-hold Control
 Operation Section
1– 114

(3) Ventilation Mode Check

• Look into the unit inlet and verify ventilation flap operation.
• Press the VENT switch. Each time the VENT switch is pressed, the system switches between recircula-
tion mode and fresh mode.

[ REFERENCE ]
The A/C system goes to auto ventilation mode immediately after system startup.

VENT
< Recirculation Mode > < Fresh Mode >

AUTO AUTO Front

Ventilation Flap

Fresh Air

Fresh
Air

Recirculation Mode Fresh Mode

U007469
 Operation Section
1– 115

17.3 MEASURING AIR VOLUME

z Measuring the cooling air volume in a vehicle is difficult, and there is no ideal method. However, air volume
can be measured using the following method.

Measuring Method
z Refer to the following table.

Measuring Method Measuring Procedure

1. Measure the outlet air Use an air flow meter gauge to measure the air velocity at
volume with an air flow each of the outlet vents. Record the results on the Recording
meter gauge. Paper for Blower Air Distribution.

Use the following formula to find the total air flow volume
V m3/h=v1 m/s n Fb 3600
V : Total air flow volume
v1 : Average air velocity value from each blow-out port
n : Total number of grills
Fb : Biram surface area
NOTE:
Even if the total air volume passes the basic standard, the
variation in average air velocity among each of the outlet
vents should be within ±15%.

2. Using an air flow meter Use the air flow meter gauge to measure the air velocity at
to measure return air each of the body-side return air vents.
velocity.

Use the following formula to find the total air flow volume
V m3/h=v2 m/s Fc 3600
V : Total air flow volume
v2 : Average air velocity
Fc : Area of the mesh section of the suction port
U003986

Target values for air volume are specified in the table below.
z Outlet air volume can be measured using an Air flow meter.

Blower Speed Target Value Tolerance Value

Hi 4400 m3 /h ±10 %

[ REFERENCE ]
Differences will appear in the measurement values between the return air and outlet vent measurements.
 Operation Section
1– 116

Blower Air Distribution

Cooler Device Name Vehicle Model
Blower RPMs Hi: Lo: Battery Voltage Hi: Lo:

6
Air 5
Velocity 4
Right Side

3
m/s 2
1
Lo
Hi
Blow-out
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TOTAL
Port Number

Blow-out
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TOTAL
Port Number
Hi
Left Side

Lo
1
Air 2
Velocity 3
4
Approved m/s 5
6
Hi Lo Remarks
Checked Average Average Value for All Grills
Velocity at
Blow-out Maximum
Grill Maximum and Minimum Values
m/s Minimum Excluding the Highest and Lowest
Written
Blow-out Right-side Duct
Velocity Total Blow-out Velocity BIRAMU
m3/h Left-side Duct Passage Surface Area 3600
U003991
 Operation Section
1– 117

17.4 MOIST AIR GRAPH

U003987
t (c)
g
al/k
i kc
 Operation Section
1– 118
 Circuit diagram / Wiring diagram (A3)
2– 119

1. ELECTRICAL CIRCUIT AND WIRING DIAGRAM

1.1 EXPLANATION
z The electrical circuit and wiring diagram are used to show how the electrical components work, and to troubleshoot the electrical system.

Explanation of Relay in the Electrical Circuit Explanation of Connectors in the Wiring Diagram

A coil section and a contact point in a relay are The connectors in the wiring diagram are shown in the figure below.
separated in a circuit diagram as shown in the figure on Female Connector Male Connector
the right. Contact Point
The contact points of the two relays in the electrical Relay Female Connector Male Connector
circuit are shown as normal. When current flows through (Female Terminal) (Male Terminal)
the coil, a magnetic field is created around the coil,
and the coil works as a magnet. As a result,
the contact is closed for a normally open type,
or or
and open for a normally closed type.
Coil Section

The connecting terminals in the wiring diagram are shown as below.

Circuit Normal Condition Operation Condition

Female Connector
< Normally Open type > Female Connector (Female Terminal)
· Coil section : 1 - 2 · Coil section : 1 - 2
(Female Terminal)
· Contact point : 3 - 4 Open · Contact point : 3 - 4 Closed
1 3
4 3 2 1
1 2 3 4

1 2 3 4 Male Connector
1 2 3 4 (Male Terminal)
2 4

4 3 2 1
< Normally Closed type > · Coil section : 1 - 2 · Coil section : 1 - 2
1 2 3 4
· Contact point : 3 - 4 Closed · Contact point : 3 - 4 Open Male Connector
1 3 (Male Terminal)

2 4
The connectors in the wiring diagram are viewed from the contact part.

< Switching Contact type > · Coil section : 1 - 2 · Coil section : 1 - 2

5 · Contact point : 3 - 4 Open · Contact point : 3 - 4 Closed

3 - 5 Closed 3 - 5 Open
3
4
1 2 3 4
1 2
1 2 3 4
A View

A
U008496
 Circuit diagram / Wiring diagram (A3)
2– 120

1.2 ELECTRICAL CIRCUIT

WIRE COLOR

<A/C ECU>

51 48 47 46 40 30 29 28 26 25 24 23 11 10 7 2 1
63 60 58 56 53 38 37 36 32 18 15 14 13

140302-7240 1/1
U010183
 Circuit diagram / Wiring diagram (A3)
2– 121

1.3 WIRING DIAGRAM

1
2

3
4
5
6
7
8
9

10

11

12

13

14

15

16

17
18
19
20
21
22
23
24
25

26
27

140302-7250 1/4
U010184
 Circuit diagram / Wiring diagram (A3)
2– 122

1
2

3
4
5
6
7
8
9

10

11

12

13

14

15

16

17
18
19
20
21
22
23
24
25

26
27

140302-7250 2/4
U010185
Circuit diagram / Wiring diagram (A3)
2– 123

1
2
3

140302-7250 3/4
U010186
 Circuit diagram / Wiring diagram (A3)
2– 124

1
2
3

140302-7250 4/4
U010187
Service Division DENSO CORPORATION 04N001D
1-1, Showa-cho, Kariya-shi, Aichi-ken, 448-8661, Japan Printed in Japan