Operation and maintenance manual

Section 260-0130
SM 1405 Rev 2 11-04
3
Operators Compartment - Air Conditioning
REMOVAL
Numbers in parentheses refer to Fig. 2, unless
otherwise stated.
WARNINGS
Always wear goggles or glasses to protect
your eyes when working around R-134a.
R-134a boils at sea level temperatures of
-29.8° C (-21.6° F), which means that direct
contact with your skin will produce frostbite.
Exercise extreme care when handling R-134a. If
R-134a contacts your skin, wash immediately
with plenty of warm water. Remove any
contaminated clothing with caution as it may
adhere to the skin. If blistering or continued
irritation occurs obtain immediate medical
attention.
If you get the slightest trace of R-134a in
your eye, flood the eye immediately with cool
water; then treat with mineral oil or clear
petroleum jelly followed by boric acid rinse.
Report to a hospital or doctor as soon as
possible.
The chemicals of R-134a when burned
produce gases that will damage the respiratory
system if inhaled. NEVER SMOKE in an area
where
R-134a is used or stored. Use hot water or an
approved heated charge cylinder as a heat
source if required to force R-134a into the
system. If using water, do not exceed 52° C
(125° F). Never use direct flame or electric
heaters in direct contact with the R-134a
container. High temperatures may result in
raising the pressure to a dangerous level.
To prevent personal injury and property
damage, be sure wheel blocks, blocking
materials and lifting equipment are properly
secured and of adequate capacity to do the job
safely.
1. Position the vehicle in a level work area, apply the
parking brake and switch off the engine. Operate
steering right and left several times to relieve pressure
in the steering system.
2. Block all road wheels and place the battery master
switch in the 'Off' position.
3. Pull on handle (inside cab) to release hood catch
and raise the hood.
4. Discharge the air conditioning system as described
under 'Discharging The System'.
5. Remove screws (2) and lockwashers (3) securing
cover on air conditioner (1) outer box to gain access to
refrigerent hosing.
6. When satisfied that the system is completely
discharged, tag refrigerant hoses (5 & 6) to aid in
installation and carefully disconnect hoses from air
conditioner (1). Cap air conditioner (1) fittings and
refrigerant hoses (5 & 6) to prevent foreign matter
from entering the system.
7. Remove bolts (45, Fig. 3) and lockwashers
(46, Fig. 3) securing front cover and filter assemblies
on air conditioner (1) outer box.
8. Disconnect harness (4, Fig. 3) and unhook control
cable (47, Fig. 3) from water valve (48, Fig. 3).
9. Remove bolts (40, Fig. 3), lockwashers (41, Fig. 3)
and washers (42, Fig. 3) securing air conditioner (1)
outer box to cab assembly and withdraw box.
10. Tag refrigerant hoses (5 & 9) to aid in installation
and carefully disconnect hoses from receiver/drier
(16). Cap receiver/drier (16) fittings and refrigerant
hoses (5 & 9) to prevent foreign matter from entering
the system.
11. Support receiver/drier (16) and remove nuts
securing receiver/drier (16) to mounting bracket (17). If
necessary, remove bolts (13), lockwashers (14) and
mounting bracket (17) from engine block.
12. Tag refrigerant hoses (7, 8, 9 & 10) to aid in
installation and carefully disconnect hoses at radiator
cowl and condenser (11). Cap condenser (11) fittings
and refrigerant hoses to prevent ingress of foreign
matter.
13. If required, support air conditioner condenser (11)
and remove bolts (13), lockwashers (14) and washers
(15) securing condenser (11) to radiator assembly.
Remove condenser (11) from vehicle.
14. Tag refrigerant hoses (6 & 7) to aid in installation
and carefully disconnect hoses from compressor (12).
Cap compressor (12) fittings and refrigerant hoses
(6 & 7) to prevent foreign matter from entering the
system.
15. Disconnect electrical connection from compressor
(12) clutch.