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HJ Air-con Troubleshooting
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Conoregan87 Offline
#1 Posted : Friday, 16 December 2022 10:07:48 PM(UTC)
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[img]null[/img]Hi Gents

I have a HJ Holden with air-con fitted. Since owning the air con hasn’t worked. I have had the system regassed and replaced the fuse. I believe I have a few issues.

Firstly the fan doesn’t work on settings 1-3, only setting 4. From research I believe this may be a problem with the resistor, I have bought a spare and plan to swap out.

Secondly even with the fan on setting 4 it will only come on when the middle switch is in either two of the far right positions (above the switch in this position is a red line and below is an up and down triangle) if i move away from these 2 positions the fan stops. It doesn’t matter what position the bottom switch is in (left blue or right red).

Any recommendations?

This is the switch I have:

https://images.app.goo.gl/g2w8o1QZmA3aK6Vu9

Thanks,
Conor

Edited by user Friday, 16 December 2022 10:27:40 PM(UTC)  | Reason: Not specified
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wbute Offline
#2 Posted : Saturday, 17 December 2022 3:31:15 PM(UTC)
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Try another fan altogether or replace the resistor. . It does sound like there is a bad contact in the dash control switch as well. The fan should work on all positions on the top mode selector (except off position). I reckon the dash control could be causing the ac not to work as well. I assume when you say it isn’t working, there is no power turning the AC compressor on?
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Conoregan87 on 23/12/2022(UTC)
Conoregan87 Offline
#3 Posted : Tuesday, 20 December 2022 10:08:03 PM(UTC)
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Hi Guys

So I have done some more diagnosing.

Fan speed: I have swapped the resistor out with 2 x spares and tested, the fan still only operates on setting 4.

Air-con: I have removed the fan controller the master switch measures 0 resistance when the middle lever is in the far left position (off), once it’s moved off the far left it reads 1.2 ohm resistance. The computer switch measures 1.2 ohm in the far left (off) position as well as on the 2 x air con positions, the switch measures 0 resistance when I move to the 2 x heat settings on the right.

So sounds like everything is ok with the resistor and micro switches - what should I try next?
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Conoregan87 Offline
#4 Posted : Tuesday, 20 December 2022 10:13:26 PM(UTC)
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Looking at the diagram on the below website if the master switch, fan switch and compressor switch seem to be ok would the next thing to check be the relay? Seems a bit unusual as when the fan control is on setting 4 the fan starts but on this setting power is through the relay?

http://wbholdenclub.com/Aircon.pdf
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Conoregan87 Offline
#5 Posted : Tuesday, 20 December 2022 10:58:53 PM(UTC)
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Or, even though the master switch is testing ok, if the master switch is faulty it could explain why I’m not getting power to the fan switch for setting 1-3 AND not getting power to the compressor? Not sure why I am still getting the fan on speed 4 though.
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202tonner Offline
#6 Posted : Wednesday, 21 December 2022 7:41:14 AM(UTC)
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Not familiar with aircon wiring so this is the best I can offer.

First thing is to get the fan working on all 4 speeds. I'm assuming the fan should always run on any setting regardless of the aircon status.
Since it will run on 4 you would assume there is power to the switch, But if it hasn't worked since you first got it the wiring may be wrong. Check the wire colours at the fan switch connector. Do they match the colours in the pdf? Also do they correspond to the appropriate wire at the other end?
If that all looks good then run power to each wire in the connector to see if the fan will run at other speeds if the power doesn't come through the switch (make sure you fuse this wire).
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wbute Offline
#7 Posted : Wednesday, 21 December 2022 8:42:48 AM(UTC)
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Have you used a test light to see if there is power going to fan and AC compressor?
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Conoregan87 Offline
#8 Posted : Thursday, 22 December 2022 9:49:02 PM(UTC)
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Hi Guys

I have done a few more tests.

Ran a temporary wire straight to compressor, clutch engages so compressor is ok. When I disconnect temporary wire and return to normal I measure for power at the compressor, nothing - so it’s not receiving power.

When I test the resistor, the resistor has power (on all 4 pins even though the fan is on setting 4?) but still doesn’t work on settings 1-3, only 4 when the resistor is bypassed.

I have found a second relay, looks like the compressor and aftermarket thermofan are wired into the relay. Presumably when compressor is turned on the thermo fans turns on.

I replaced the 2 x relays, the original and the second for the thermofan.

Where to from here?
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Conoregan87 Offline
#9 Posted : Thursday, 22 December 2022 9:55:19 PM(UTC)
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Well this is embarrassing.

Found a single aftermarket brown wire running from aftermarket relay through firewall, traced through into cab, went to pull at it, the air con fan, thermo fan and compressor clutch all engaged - must have been a loose wire!
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Conoregan87 Offline
#10 Posted : Thursday, 22 December 2022 10:19:03 PM(UTC)
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There was an aftermarket switch installed on the dash to turn on the thermofan which ran to the second relay, by having the dash apart the 2 wire connected to this switch accidentally came into contact and everything fired up.
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wbute Offline
#11 Posted : Friday, 23 December 2022 6:03:57 AM(UTC)
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It definitely sounded like a wiring issue. Good to get it sorted! Now find an AC place that understands the system and it will keep working well.
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Conoregan87 Offline
#12 Posted : Sunday, 25 December 2022 4:35:14 PM(UTC)
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Hi Guys

Still having issues - not getting cold air.

System has been regassed, fan works on all settings, compressor clutch engages, fan on the condenser is working. Externally everything seems to be working. What should I be looking at next? The whole system in the engine bay is hot, nothing is cooling.
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Smitty2 Offline
#13 Posted : Sunday, 25 December 2022 8:43:08 PM(UTC)
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Originally Posted by: Conoregan87 Go to Quoted Post
Hi Guys

Still having issues - not getting cold air.

System has been regassed, fan works on all settings, compressor clutch engages, fan on the condenser is working. Externally everything seems to be working. What should I be looking at next? The whole system in the engine bay is hot, nothing is cooling.



the system has been regassed? a HJ aircon system regassed without a compressor rebuild?
you cannot use the current allowed refrigerant gas R134 on an old compressor/air con system
designed for R12 refrigerant. Well you can.. but you kill the compressor and system sensors
TX valves will not be happy either. Their 'heat' function is impared or will not work.


Club circuit racing...the best fun you can have with your pants on
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wbute Offline
#14 Posted : Sunday, 25 December 2022 9:09:11 PM(UTC)
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If it’s not cooling and it has gas, the compressor is no good. Usually caused by the thermostat being set too cold.
We ran old Chamberlain tractors on the new gas for years(they used the same Delco style compressor). Never had any issues with them.
Just don’t use that propane based refrigerant in them. Minus 30 I think is one brand.
Or the clutch could be no good on the compressor.
It’s par for the course to replace the receiver drier when ever the system has been regassed as well. (Big silver canister on the heater box).
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