Troubleshooting The Air Conditioning System Following Complaints About Cooling Output

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If it is not possible to clearly detect a leak using a leak detector, then only the leak detector additive supplied by SPEKTRONICS may be used. Leak detector additive: Traserline TP 3860 in dissolved form .

This leak detector additive is available from service equipment providers (e.g. Waeco).

For filling this Traser additive, special adapter kits are required, which are also available from service equipment providers (e.g. Waeco).

Information on how to use the air conditioning system and the procedure for filling it can be found in the operating instructions for the adapter kits.

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The troubleshooting steps shown must be used if complaints are received about the cooling output of the air conditioning system.

Status	Specification OK	Specification not OK
1) Check the cooling output, temperature and air flow. Check the air distribution by making adjustments to the air-conditioning control panel. Start the vehicle and check the air conditioning system for the prescribed nominal temperature values. → 870101 FUNCTION CHECK ON AIR CONDITIONING	Specified air flow and temperature is reached. Air distribution is working. Continue with Step 2) .	Insufficient air flow from the exhaust vents. Continue with Step 3) . Required temperature is not reached. Continue with Step 2) .
2) Perform on-board diagnosis on all control units. PIWIS Tester II 9818	No fault memory stored, air flow and temperature complies with specified nominal values. Function OK. No further action required . No fault memory stored and the temperature does not reach the specified nominal values. Continue with Step 4) .	Fault present: Work through fault memory in accordance with "Guided Fault Finding". Continue with Step 1) .
3) Check the following points one after the other. Replace if necessary. Remove activated charcoal/particle filter and check for dirt and dust particles. → 85181900 REMOVING AND INSTALLING PARTICLE FILTER Check fan motor for correct operation and control. Use wiring diagram if necessary.	Fan motor and activated charcoal filter OK. Continue with Step 4) .	Replace activated charcoal/particle filter if necessary. Check mechanical operation (air distribution) of the servo motors/flaps and repair them if necessary, e.g. → 872019 REMOVING AND INSTALLING SERVO MOTOR Following repairs, continue with Step 1) .
4) Connect air-conditioning service device, measure high and low pressure and compare with nominal values. → 870101 FUNCTION CHECK ON AIR CONDITIONING	High and low pressure OK. Function OK. No further action required .	High pressure too high, continue with Step 5) . High pressure too low, continue with Step 6) . Low pressure too high, continue with Step 7) . Low pressure too low, continue with Step 8) .
5) High pressure too high. Check the following points one after the other: Check condenser for dirt/dust particles and damage. Check electrical operation, condenser fan activation. Drain refrigerant, measure and document the amount of refrigerant removed. >> Too much refrigerant. → 87031700 DRAINING AND FILLING REFRIGERANT		Clean the condenser. Repair condenser fan activation mechanism. Use wiring diagram. Fill the air conditioning system with the prescribed amount of refrigerant. → 8X00IN TECHNICAL DATA FOR AIR-CONDITIONING SYSTEM Continue with Step 1) .
6) High pressure too low. Check the following points one after the other: Check electrical operation, air-conditioning compressor activation. Drain refrigerant, measure and document the amount of refrigerant.	>> If the amount of refrigerant is correct, remove the expansion valve and check for foreign bodies (e.g. chips, abrasion). → 87701900 REMOVING AND INSTALLING EXPANSION VALVE → 87031700 DRAINING AND FILLING REFRIGERANT Replace expansion valve if necessary. Continue with Step 1)	Repair air-conditioning compressor activation mechanism. Use wiring diagram. >> If there is not enough refrigerant, fill the air conditioning system according to specifications. → 8X00IN TECHNICAL DATA FOR AIR-CONDITIONING SYSTEM Check refrigerant circuit and connection points using a leak detector. >> Once you have determined the cause of refrigerant loss, replace seal or spare part. Continue with Step 1)
7) Low pressure too high. Check the following points one after the other: Drain refrigerant, measure and document the amount of refrigerant. >> Too much refrigerant. → 87031700 DRAINING AND FILLING REFRIGERANT	If the amount of refrigerant is correct, remove the expansion valve and check for foreign bodies (e.g. chips, abrasion). → 87701900 REMOVING AND INSTALLING EXPANSION VALVE → 87031700 DRAINING AND FILLING REFRIGERANT Replace expansion valve if necessary. Continue with Step 1)	>> If there is too much refrigerant, fill the air conditioning system according to specifications. → 8X00IN TECHNICAL DATA FOR AIR-CONDITIONING SYSTEM Continue with Step 1)
8) Low pressure too low. Check the following points one after the other: Drain refrigerant and measure the amount of refrigerant. >> Not enough refrigerant. → 87031700 DRAINING AND FILLING REFRIGERANT Loosen lines on the air conditioning compressor and check for foreign bodies (e.g. chips, abrasion). → 873419 REMOVING AND INSTALLING AIR CONDITIONING COMPRESSOR	If the amount of refrigerant is correct, remove the expansion valve and check for foreign bodies (e.g. chips, abrasion). → 87701900 REMOVING AND INSTALLING EXPANSION VALVE → 87031700 DRAINING AND FILLING REFRIGERANT Replace expansion valve if necessary. Continue with Step 1)	Fill the air conditioning system with the prescribed amount of refrigerant. → 8X00IN TECHNICAL DATA FOR AIR-CONDITIONING SYSTEM Check refrigerant circuit and connection points using a leak detector. >> Once you have determined the cause of refrigerant loss, replace seal or spare part. Replace air conditioning compressor if necessary. Continue with Step 1)