Usage:
These instructions give the procedure for installation of a cab air conditioner and heater on the above machines. Put refrigerant oil on all air conditioning hose connections before assembly.
NOTE: Use this instruction along with the Parts Book and Service Manual. See FORM SENR7454 (Air Conditioning and Heating) for the correct evacuating and charging procedures.
Necessary Parts Removals
1 Remove the seat assembly, door assembly (1) and filter assemblies (2).
2 Disconnect the electrical wires from resistor (3). Remove the two nuts and washers and remove resistor (3). Remove plate assembly (4). Disconnect the blower motor wires and remove both blower assemblies (5). Also, remove the baffle assembly, which is used when the machine is equipped with a pressurizer or a heater only.
3 Remove panel (6) from the cab (at the rear on the left side). NOTE: The panel is held in position by one nut and washer on the back side. The nut and washer can be removed through the storage compartment door inside the cab. Remove door assembly (7) from the right side of the cab and remove panel (8).
4 Remove bezel (9) and both covers (10). The bezel bolts can be removed through the storage compartment door.
Installation Of Refrigerant Compressor (All)
1 Install 1P9745 Bracket (1) and 7N84 Plate (2) on the right side of the engine with two 1A5964 Bolts (3), one 1D4572 Bolt (4) and a 1D4719 Nut. Install 8N8198 Bracket (5) and 8N8199 Bracket (6) on the compressor with 1A2343 Bolts and 9M1974 Washers. Install 8N9001 Bracket Assembly (7) on the compressor with two S1594 Bolts (8) and 5M2894 Washers. Install the compressor on bracket (1) with one S1587 Bolt (9) and 6H1717 Bolt (10) with 2M849 Washers. Install one 1A2029 Bolt (11) with one 4B4278 Washer, one 5M2894 Washer and one 3K925 Spacer (12). Assemble 1P9742 End (13), 1P2236 Rod Assembly (14), 1P2237 Swivel (15) and two 1D4719 Nuts (16) as shown. Install the assembly with S1587 Bolt (17), 2M849 Washer and 1D4719 Nut (18) and two 5B1226 Washers. Install 1N3743 Vee Belt (19). Tighten the belt to a gauge reading of 534 ± 22 N (120 ± 5 lb.) with a Borroughs BT-33-95 Gauge and tighten all mounting bolts. Connect existing wires (20) to the compressor. Remove the existing cover from the rear of the compressor. Check to make sure the seals are in position. Install 6V877 Fitting (21) and 6V878 Fitting (22) with former cover and an S1748 Bolt and 8M7145 Washer. Turn the fittings away from the engine as far as possible for clearance.
Installation Of Dryer-Receiver And Condenser Coil
1 Cut one length of 5P799 Seal to 220 (8.66") and install on 7V5564 Bracket (1) with adhesive. Install bracket (1) as shown with two 8L7395 Nuts and 5P1075 Washers. Install 9D6888 Dryer-Receiver (2) in bracket (1) with a 9B7237 Bolt, nut and washer.
2 Disconnect wiring harnesses (3) from the fuse panel and remove fuse panel (4). Cut one length of 5P799 Seal at 200 ± 10 (8.7" ± .39") and install it on the bottom of bracket (5). Install 7V5591 Bracket (5) with two 5S7379 Bolts and 5P1075 Washers. Cut a length of 5P892 Seal (6) to 430 (17.0") and install on the frame with the adhesive side toward the frame. Install 2V9682 Condenser Coil (7) as shown with 6J488 Bolts (8), 5S7379 Bolts (9), 8L7395 Nuts and 5P1075 Washers. Install 5P873 Seal at location (B) as needed. Install 7N5933 Switch (10) with 4M5281 Bolts (11), 4L6458 Nuts and 5P4115 Washers. Again, install fuse panel (4) and connect wiring harness (3). Connect existing wires (12) to switch (10), red/black wires at location (C) and orange/white wire at location (D).
Installation Of Fan Motors
1 Cut four lengths of 5P878 Seal to 145 (5.7") and install on four 2V9992 Brackets (1) with adhesive. Install fan blades (2) to motors (3) with the concave side of the blades to the outside. Install the fan motors to brackets (1) with bolts, nuts and lockwashers. Connect motor ground wires (4) as shown. Install the motors and brackets to the former cover with 8L7395 Nuts (5) and 5P1075 Washers. Tighten nuts (5) to a torque of 25 ± 7 N·m (18 ± 5 lb.ft.).
2 Install 7V7700 Guard Assembly (6) with six 8S7395 Nuts (7) and 5P1075 Washers. Make sure the fan blades have clearance.
Installation Of Air Conditioner And Heater Coils.
1 Remove all necessary plugs for installation of the air conditioner and heater coils. Install 3V258 Expansion Valve (1) on air conditioner coil (2). Cut two lengths of 5P799 Seal (3) to 508 ± 25 20" ± 1.0") and install on the bottom side of air conditioner coil (2) and heater coil (4) with the adhesive side toward the fins. Install coils (2) and (4) as shown with 5S7379 Bolts and 5P1075 Washers. Cut two lengths of 5P892 Seal (5) to 508 ± 25 (20" ± 1.0"), two lengths of 5P799 Seal (6) to 80 ± 5 (3.15" ± .20") and two lengths (7) to 40 ± 5 (1.5 ± .20") and install on the top side of the coils with the adhesive side toward the fins.
(2) At location (A), install 5P3928 Coupling (8) with 5P3944 Seal, 5P4107 Lockwasher and 5P4106 Nut. Install 7K3176 Coupling (9) with 1S8947 Seal, 2H3924 Lockwasher and 7K3304 Nut as shown. Install 3V6894 Tube Assembly (10) with a 5L4758 Seal at location (B). Install 3V6898 Tube Assembly (11) with 6H4005 Grommet (12). Install 3V6896 Tube Assembly (13) with 6H4005 Grommet (14) and connect it to the condenser coil with a 6M5062 Seal. Install a 4K8302 Clip (15) on tube assembly (10) and 5K3294 Clip (16) on tube Assembly (13) with one 5S7379 Bolt and 5P1075 Lockwasher. Install 2V86 Hose Assemblies (17) and (18) to the dryer-receiver with 5F9144 Seals. Connect hose (18) to the condenser coil at location (C) with a 5F9144 Seal and connect hose (17) to tube assembly (11) with a 5F9144 Seal as shown. Connect existing wires (19) to switch (20) on the dryer.
(3) Install door assembly (20) and connect existing wire (21) to fan motor wire (22).
(4) Install 3V7558 Fitting and 7F2060 Locknut at location (D) [heater supply] and 5V4236 Fitting and 6K8420 Locknut at location (E) [heater return] as shown. Install 1P6544 Valve (23) on supply hoses (24) and (25) with 5D1026 Clamps. Install the complete assembly as shown. Install return hose (26) as shown with 5D1026 Clamps
Installation Of Thermostat, Wiring And Heater Control
(1) Install 3V6842 Harness Assembly (1) and 2V45 Wire Assembly (2) to 3V253 Thermostat (3) as shown. Put tape on terminal end (4); this is not needed. Install thermostat (3) in control panel (5) with two 2P4339 Nuts and 2V99 Knob (6). Connect harness (1) to the existing harness and connect wires (2) to fan switch (7).
(2) Install heater cable control (8) in control panel (5), through a 6K9555 Grommet at location (A), and install a 6K8179 Clip for support of the cable. Connect the cable to valve (23) [installed earlier] as shown. Install 2V99 Knob (9). Adjust cable (8) at valve (23) with clamp screw (10), so that the valve is at OFF position before knob (9) is at full counterclockwise position. Again, install control panel (5).
(3) Put thermostat capillary tube (11) through the opening at location (B) with 6K9555 Grommet (12). Install 8M2772 Clips at locations (C) and (D) with 8L7395 Nuts and 5P1075 Washers. Install capillary tube (11) in the evaporator coil assembly 175 ± 25 (6.9" ± .10") above the floor. Push the tube through the coil assembly until 15 ± 5 (.60" ± .20") can be seen between the air conditioner and heater coils at location (E). Bend this end of the tube at a 45° angle to the coil assembly. Again install panel (13) that was removed earlier.
Installation Of Air Conditioner Hoses
Connect 2V9985 Hose Assembly (1) to the compressor with a 6M5062 Seal and install 2V9986 Hose Assembly (2) with a 5L4758 Seal as shown. Put the hoses in position along the frame and connect hose (1) at location (A) with a 5P3948 Coupling and 1S8947 Seal. Connect hose (2) at location (B) with a 5P3929 Coupling and a 5P3944 Seal. Install three 4D5371 Clips (3) and one 5D718 Clip (4) as shown.
Connect 3V6714 Hose Assembly (5) to the compressor with a 6M5062 Seal and install 3V6715 Hose Assembly (6) with a 5L4758 Seal as shown. Put the hoses in position along the frame and connect hose (5) at location (C) with a 5P3948 Coupling and 1S8947 Seal. Connect hose (6) at location (D) with a 5P3929 Coupling and 5P3944 Seal. Install 6D1641 Clip (7) with a 5P1075 Washer and a 1D4717 Nut as shown.
Installation Of Heater Hoses
Drain the coolant. Remove the plug at location (A) and install an 8B2664 Bushing, 26453 Elbow and 6V3866 Valve. Remove the plug at location (B) and install a 6B1628 Bushing and 1V6585 Valve. Connect 5P765 Hose (1) 2360 ± 25 (92.90" ± 1.0") in length at locations (A) and (C) with 5D1026 Clamps. Connect 5P767 Hose (2) 1665 ± 25 (65.5" ± 1.0") in length at locations (B) and (D) with 5D1026 Clamps. Install 6D1641 Clip (3) and 9M4972 Clip (4). Install 6N2283 Bracket (5) and 6D1641 Clip (6) with a T102 Bolt, 1D4717 Nut and 3B4506 Lockwasher. Again, install the coolant.
Drain the coolant. Remove the plug at location (F) and install an 8B2664 Bushing, 26453 Elbow and 6V3866 Valve. Remove the plug at location (G) and install a 6B1628 Bushing and 8F8151 Cock. Connect 5P765 Hose (7), 2030 ± 20 (80" ± .80") in length, at locations (F) and (H) with 5D1026 Clamps. Connect 5P767 Hose (8) 1500 ± 13 (60" ± .50") in length at location (G) and (J) with 5D1026 Clamps. Install two 7D7735 Clips (9) with existing bolt and 5M2894 Washer. Install 5H6321 Clip (10) and 4S1962 Clip (11) with L1351 Bolt, 5M2894 Washer and 1D4717 Nut. Again install the coolant.
Check all connections for leaks. Install the fan blowers, covers, air filters, seat assembly and all other parts removed earlier to get access for installation of the air conditioner and heater coils.