CAB HEATER/AIR

CONDITIONING
(AFTER SEPTEMBER, 2017)

PART NO. 4215267 0100 SRM 2107

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow
instructions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet or
exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
Series Code / Model Designation Reference Table ................................................................................................ 1
Description and Operation ......................................................................................................................................1
Heater System ..................................................................................................................................................... 2
General .............................................................................................................................................................2
Air Conditioning .................................................................................................................................................. 3
General .............................................................................................................................................................3
Dryer ................................................................................................................................................................ 3
Compressor Lubrication ..................................................................................................................................4
Control Systems, Sensors, and Switches ........................................................................................................4
Climate Control ................................................................................................................................................... 5
Description .......................................................................................................................................................5
Service Menu ................................................................................................................................................... 6
Set Up ...........................................................................................................................................................6
View 1 and View 2 ....................................................................................................................................... 6
Error List ..................................................................................................................................................... 7
Statistics .......................................................................................................................................................7
Exit ............................................................................................................................................................... 8
Temperature Sensors ...................................................................................................................................... 8
Troubleshooting ........................................................................................................................................... 8
Water Valve ..................................................................................................................................................... 8
Troubleshooting ........................................................................................................................................... 8
Troubleshooting .....................................................................................................................................................11
Insufficient or no cooling ...................................................................................................................................11
Preliminary Checks ....................................................................................................................................... 11
Checking System Air Output ........................................................................................................................11
Check The Sight Glass for Bubbles .............................................................................................................. 11
Remove and Replace ..............................................................................................................................................14
Standard Heater Assembly ...............................................................................................................................14
Access ............................................................................................................................................................. 14
Remove ........................................................................................................................................................... 14
Install ............................................................................................................................................................. 15
Standard Heater Parts ......................................................................................................................................16
Heater Core ....................................................................................................................................................16
Remove ....................................................................................................................................................... 16
Install ......................................................................................................................................................... 17
Blower ............................................................................................................................................................ 18
Remove ....................................................................................................................................................... 18
Install ......................................................................................................................................................... 18
Water Valve ................................................................................................................................................... 19
Remove ....................................................................................................................................................... 19
Install ......................................................................................................................................................... 20
Push/Pull Cable ................................................................................................................................................. 20
Water Valve Cable .........................................................................................................................................20
Remove ....................................................................................................................................................... 20
Install ......................................................................................................................................................... 21
Heater/Air Conditioner Assembly ................................................................................................................ 21
Remove ....................................................................................................................................................... 21
Install ......................................................................................................................................................... 22
Heater/Air Conditioner Parts ........................................................................................................................... 23
Vent Door ....................................................................................................................................................... 23
Remove ....................................................................................................................................................... 23
Install ......................................................................................................................................................... 24

©2017 HYSTER COMPANY i

Table of Contents

TABLE OF CONTENTS (Continued)

Heater Core ....................................................................................................................................................24
Remove ....................................................................................................................................................... 24
Install ......................................................................................................................................................... 25
Evaporator Core .............................................................................................................................................25
Remove ....................................................................................................................................................... 25
Install ......................................................................................................................................................... 27
Blower ............................................................................................................................................................ 27
Remove ....................................................................................................................................................... 27
Install ......................................................................................................................................................... 28
Thermostat .....................................................................................................................................................28
Remove ....................................................................................................................................................... 28
Install ......................................................................................................................................................... 29
Water Valve ................................................................................................................................................... 30
Remove ....................................................................................................................................................... 30
Install ......................................................................................................................................................... 31
Filtration ............................................................................................................................................................31
Fresh Air Filter ..............................................................................................................................................31
Remove ....................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
Recirculation Air Filter ................................................................................................................................. 31
Remove ....................................................................................................................................................... 31
Install ......................................................................................................................................................... 31
Air Conditioning Technical Detail ....................................................................................................................33
Maintenance Procedures and Required Equipment ............................................................................................33
Maintenance Procedures ...................................................................................................................................34
Installing Manifold Gauges .............................................................................................................................. 34
Refrigerant Recovery .........................................................................................................................................35
Refrigerant Leak Check .................................................................................................................................... 37
Evacuation and Dehydration ............................................................................................................................ 37
General ...........................................................................................................................................................37
Preparation .................................................................................................................................................... 37
Procedure For Evacuation and Dehydrating System (Triple Evacuation) .................................................37
Procedure For Evacuation and Dehydrating System (One Time Evacuation) .............................................. 38
Adding Refrigerant to a System ....................................................................................................................... 38
Checking Refrigerant Charge ....................................................................................................................... 38
Adding Full Charge ....................................................................................................................................... 38
Adding Partial Charge .................................................................................................................................. 38
Filter Drier .........................................................................................................................................................39

This section is for the following models:

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0100 SRM 2107 Series Code / Model Designation Reference Table

Series Code / Model Designation Reference Table

This section is for the following models:

Series Code European Model Americas Model

B238 H16XM-9, H16XM-12, H18XM-7.5, H360-36HD, H360-48HD
H18XM-9
C236 H18-20XM-9, H18-20XMS-9 H400HD, H450HD, H400HDS, H450HDS
C917 H40XM-12, H44XM-12, H48XM-12, H800HDS, H900HDS, H970HDS,
H36XMS-12, H40XMS-12, H44XMS-12, H1050HDS
H48XMS-12
D222 RS45-27CH, RS45-31CH, RS46-36CH, RS45-27CH, RS45-31CH, RS46-36CH,
RS46-41L CH, RS46-41S CH, RS46-41LS RS46-41L CH, RS46-41S CH, RS46-41LS
CH, RS46-33IH, RS46-38L IH, RS46-38S CH
IH, RS46-38LS IH
E214 H8XM-EC6, H8XM-EC7, H9XM-EC7, H180HD-EC6, H180HD-EC7, H200HD-
H9XM-EC8, H9XM-ECD7, H9XM-ECD8, EC7, H200HD-EC8, H200HD-ECD7,
H10XM-ECD8, H11XM-ECD8, H11XM- H190HD-ECD8, H210HD-ECD8,
ECD9 H230HD-ECD8, H230HD-ECD9
H008 H25-32XM-12, H25-32XMS-9, H550-700HD, H550-700HDS
H28-32XM-16CH
H117 H40.00-52.00XM-16CH H1050HD-16CH, H1150HD-16CH
K019 H13-16XM-6 H210-250-48HD2, H300-360HD2
L007 H8-12XM-6 H190-280HD2, H250HD2

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Description and Operation 0100 SRM 2107

Description and Operation

HEATER SYSTEM conditioner have three additional vents at the foot
area that can be opened or closed. Cooling capacity
General is increased by opening the three vents. When the
Lift trucks with a closed cab are equipped with a three vents are open, air flow is less restricted,
heater assembly which is installed on the underside increased air volume passes through the evaporator,
of the cab. The main components of the heater and the majority of the air no longer becomes warm
assembly are the fan, heater core, vent door, and an in the air channels that lead to the front window.
evaporator for the optional air conditioning system. See Figure 2.
See Figure 1. The heater consists of a heater core and a water
Cabs manufactured after September 2017 have an valve. See Figure 1. The water valve controls the
improved HVAC system. Cabs with air conditioning flow of heated coolant to the heater core. By varying
contain the following features: the opening of the water valve, the desired amount
of heat is transferred by the heater core to the air
• An additional re-circulation air filter, located that enters the cab. The water valve opens
on the removable cover of the side console
proportionally to the selected position of the heat
• Paper-type fresh air filter control knob. On standard units the knob and valve
• Copper heater core are connected mechanically, on units with an Air
• Improved control panel Conditioning system there is an electronic
connection.
• Improved drain valves underneath the A/C
unit
The vent door determines the percentage of fresh air
and recirculated air that the fan pulls through the
heater assembly. In heater assemblies without an
air conditioner, the vent door is in a fixed position
and allows for an air mixture of 85% fresh air and
15% recirculated air.
Cabs that are equipped with an air conditioner have
an electrically controlled vent door that can be used
to vary the percentage of recirculated air between 0
and 100%. The operator can select the position of
the vent door by turning a knob on the dashboard.
Cooling performance increases by reducing the
percentage of incoming fresh air.
Recirculated air enters the heater assembly through
the openings in the side console at the fuse cover.
Fresh air enters the heater assembly through the
cab air filter, which is located at the left rear corner A. RECIRCULATED AIR
of the cab. For units with A/C, the recirculated air B. FRESH AIR ENTRY
filter is located in the side console. C. CAB AIR FLOW
When fresh air content and fan speed is increased, 1. VENT DOOR
positive air pressure is created in the cab, 2. VENT DOOR ACTUATOR
preventing dust from entering the cab. The air 3. EVAPORATOR CORE
pressure escapes through the cab door posts and 4. HEATER CORE
through openings in the pedal area and sliding 5. BLOWER
6. THERMOSTAT
window brush profiles. 7. WATER VALVE
When the fan is switched ON, air is pushed through 8. EXPANSION VALVE
channels in the cab floor to the air ducts at the front
Figure 1. Heater/Airco Assembly Components
window. Cabs that are equipped with an air

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0100 SRM 2107 Description and Operation

the clutch is determined by several sensors and

switches that are connected in series. The operator
must switch ON the button for the air conditioning
system and select one of the fan switch speeds.
Refer to the electrical schematic SRM pertaining to
each lift truck, for the schematic locations and
interconnections of the sensors and switches.
The compressor compresses the refrigerant and
continuously pumps the refrigerant through the air
conditioning system. As the refrigerant is being
compressed, the refrigerant temperature will rise.
The absorbed heat is dissipated in the condenser,
which is installed outside the cab. Fans at the
condenser accelerate heat dissipation to the outside
air as the refrigerant is condensed to liquid.
After the refrigerant passes through the condenser,
the liquefied refrigerant passes through the dryer
that also serves as a reservoir for the refrigerant. At
the expansion valve, the refrigerant will expand in
the evaporator, causing the temperature of the
refrigerant to drop substantially as it vaporizes and
absorbs the ambient heat in the cab through the
evaporator. The expansion valve regulates the flow
of the refrigerant, depending on the pressure
difference between the dryer and the compressor
A. OPTIONAL AIR VENT
B. AIR TO FRONT WINDOW inlet. A minimum pressure difference is necessary
C. CAB AIR FLOW to open the valve. After leaving the evaporator, the
D. FRESH AIR ENTRY refrigerant will reenter the compressor as a low
E. RECIRCULATION AIR ENTRY (REAR SIDE) pressure vapor.
1. CAB AIR FILTER
Dryer
Figure 2. Ventilation The refrigerant functions as a coolant, and contains
lubricant for the compressor. Because humidity
AIR CONDITIONING affects the properties of the refrigerant and the
lubricant, a dryer is installed to absorb the trapped
General humidity. The dryer also filters impurities in the
refrigerant.
CAUTION Normal refrigerant leakage is approximately 10%
Replacement, installation, and repairs to air per year. To help prevent additional leakage
conditioning units that require discharging and/or through the compressor seals, the air conditioning
refilling of the refrigeration fluid may only be system should be operated at least every two weeks
performed by a certified technician. for 15 minutes. The air conditioning system cannot
be operated at temperatures below 0°C (32°F)
The air conditioning system consists of a compressor because the anti-ice switch will prevent the
with an electromagnetic clutch, condenser, dryer, compressor clutch from being activated.
evaporator, and interconnected sensors and
The dryer, refrigerant, and lubricant must be
switches. See Figure 3.
replaced every three years. Contact a certified
The engine drives the compressor when the clutch technician every three years to perform these
at the compressor has been activated. Activation of repairs.

3
Description and Operation
1. CONDENSER
2. SERVICE CONNECTION, HIGH PRESSURE
3. COMPRESSOR
4. SERVICE CONNECTION, LOW PRESSURE
5. ANTI-ICE SENSOR
Figure 3. Refrigerant Cycle
Compressor Lubrication
The oil specification for the compressor is indicated
on the nameplate of the compressor.
Most of the compressors used on Big Truck air
conditioning systems use SP-15 oil.
Only exception is for the compressor as installed on
the Cummins QSM-11 Tier-3 engines on series
D222, H117 and C917.
The compressor on QSM-11 engines requires ZXL
100PG oil.
For replacement compressors, make sure to check
for correct oil fill.
Control Systems, Sensors, and Switches
The air conditioning system (A/C) is activated by
pushing the A/C switch on the dashboard and
selecting one of the fan speeds. A control light in the
A/C switch will illuminate, and the fans on the
4
0100 SRM 2107
6. EVAPORATOR
7. EXPANSION VALVE
8. RESERVOIR
9. DRYER
10. PRESSURE SWITCH
condenser will turn. If the anti-ice switch or one of
the pressure switches is open, the clutch will
disengage and the air conditioning system will not
activate.
Water in the air condensates on the evaporator.
Normally, the condensated water drips on the
bottom plate of the heater assembly and escapes
through two hoses that open into the engine
compartment. If the condensated water becomes ice,
the air flow through the evaporator will be blocked,
which will block the entire cab ventilation system.
The anti-ice switch protects the evaporator against
ice buildup by opening at -1°C (30.2°F), causing the
clutch to disengage and allowing air to warm the
evaporator. The anti-ice switch, which is inserted
between the fins of the evaporator, will close when
the temperature reaches 2.3°C (36.14°F). The anti-
ice sensor is indicated by "T" on the electrical
schematic.
0100 SRM 2107
The two pressure switches, P1 and P2, are located
at the drier, and protect the system against
excessive pressures that are too low or too high. See
Figure 4.
If the system pressure drops below
0.1 MPa (14.5 psi), the refrigerant level is too low
for proper functioning of the system and proper
lubrication of the compressor.
High system pressure is a recurrent situation. The
expansion valve has a limited flow capacity. The
refrigerant flow generated by the compressor
fluctuates with engine speed, and regularly exceeds
the flow capacity of the expansion valve. When the
flow capacity of the expansion valve is exceeded, the
compressor will have raised system pressure to the
maximum allowable level. The pressure switch (P1)
will send a signal to disengage the compressor
clutch, and the expansion valve will continue to
regulate refrigerant flow. Pressure will drop until
the pressure switch is enabled, causing the clutch to
reengage. System pressure may rise again until the
maximum allowable level has been reached.
1. CONDENSER COVER
2. CONDENSER COIL
3. SIGHT GLASS
4. DRYER
5. PRESSURE SWITCH
6. FAN
Figure 4. Condenser
Description and Operation
CAUTION
NEVER bypass the electric clutch of the air
conditioning compressor. If the clutch does not
receive a signal, the evaporator is iced, or the
pressure switch is not be enabled to protect the
system against excessive pressure. If the clutch
does not receive a signal, contact a certified and
qualified air conditioning specialist. Bypassing the
compressor will ALWAYS lead to system damage.
The pressure switch, as installed on the drier,
physically combines the high and medium pressure
switches and their electrical interconnection. The
pressure switch is indicated by "P1 or P2" on the
electrical schematic.
The medium pressure switch (P2) changes the
connection to the fans on the condenser, causing
them to turn at a higher speed when pressure in the
system has exceeded 1.6 MPa (232 psi). At lower
pressures, the fans are connected in series, causing
them to turn at a lower speed. The medium
pressure switch is indicated by "P2" on the electrical
schematic. The high pressure switch, (P1)
disengages the compressor above
2.70 MPa (392 psi). A low pressure cutout switch is
not used on HYG equipment.
CLIMATE CONTROL
Description
Functionality of the individual components of the
normal air conditioning systems and the Climate
Control system is the same. The difference is that
for the Climate Control a controller sends the
signals to the components instead of the manually
operated knobs on the dashboard for the normal
system. This Controller is part of the control unit on
the dashboard that also has a display and a select
button. The display provides information on mode,
temperature, blower speed and fault conditions. An
explanation of the normally available information
and settings is in the Operating Manual.
The explanation for how to read information and
apply settings for service purposes is described
under Service Menu.
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Description and Operation 0100 SRM 2107

Service Menu The date format is Month/Day/Year. To set the date,

1. Push the Power Button to turn the HVAC unit
ON. See Figure 5.
2. Pressing the Set Button scrolls the screen
between:
• Climate Control Mode Settings
• Air Circulation Settings
• Display Settings
1. POWER BUTTON
2. SET BUTTON
Figure 5. Climate Control
3. Press the set button to scroll to the Air
Circulation Settings.
4. Push and hold the Power Button, and turn the
Set Button three clicks clockwise to enter one of
the service menu selections:
• Set Up (Not an option for Hyster Lift trucks)
• View
• Error List
• Statistics
• Exit
To scroll to a next service screen, turn the Set
Button one click clockwise. Push the Set Button
to enter the selected service screen. Turning
the Set Button after the Exit screen further
clockwise will bring you back to the Set Up
screen. To leave the Service Menu scroll to Exit
and push the Set Button.
Set Up
The Set Up screen allows setting the date and the
blower speed for an additional interior heater. An
additional interior heater is not a standard option.
go to Set Up screen and push the Set Button until it
flashes digital for "Month". Turn the Set Button
until the correct month number appears and push
the button to confirm. The digits for "Day" will now
flash. Repeat the procedure to set "Day" and "Year".
When finished, turn the knob to scroll to the Exit
screen and push the button to leave the service
menu.
View 1 and View 2
There are two View pages that show readings and
actual setting of the HVAC unit. After leaving the
previous service screen "Set Up", screen View 1 will
appear. Push the button to scroll between screen
View 1 and screen View 2 (see Figure 6).
Screen "View 1" displays below information:
• Scale - Selected temperature scale: Cel for
Celsius or Fah for Fahrenheit.
• Setpoint - Selected (desired) interior
temperature.
• Inside - Cab interior temperature as
measured by the Inside Sensor.
• Outside - Cab exterior temperature as
measured by the Outside Sensor.
• Deice - Temperature of the refrigerant leaving
the evaporator coil.
• Coil - Temperature of the air at the blower.
• Heat - Flapper door position: Fresh or Recirc.
Screen "View 2" displays below information:
• AC - Indicates whether Air conditioning Mode
is switched ON or OFF.
• Heater - Indicates whether Heating Mode is
switched ON or OFF.
• Blower - Indicates the selected percentage of
maximum blower speed.
• D Heat Fan - Indicates the selected blower
speed percentage for an additional interior
heater.
• Valve - Indicates the percentage of maximum
heater valve opening that the controller sends
out as a signal.
• Contrast - Indicates the contrast percentage
of the display.
• Brightness - Indicates the brightness
percentage of the display.

6
0100 SRM 2107
In case a temperature sensor is disconnected, the
display will show "open". Comparison of the
different values may provide an indication for a
possible defect.
Figure 6. Climate Control View Display
Error Types
1. Open: Open circuit error for temperature
sensors or heater valve position sensor.
2. Short: Short circuit error for temperature
sensors or heater valve position sensor.
3. Stuck: Heater Valve failure to rotate.
4. Fault: A/C system has been disabled due to
pressure switch opening four times
consecutively. This error locks out the A/C
system until the operator manually resets.
5. PS Low: Pressure in A/C system is low when
compressor clutch turned on.
Error List
The Main Display shows a warning sign in the left
hand bottom corner of the Main Display if a fault
occurs. See Figure 7.
1. WARNING SIGN
Figure 7. Climate Control Warning
Description and Operation
The Error List page shows for each of the
temperature sensors and for the water valve the
number of occurrences that the connection was
shortened or open since the last reset date. For the
Water Valve there is an additional indication for the
number of times that the Water Valve was stuck.
See Figure 8.
Figure 8. Climate Control Error Display
To further establish the cause of failure, see
Temperature Sensors or Water Valve.
To reset the number of occurrences and the reset
date, turn the Set Button one click in a counter
clockwise direction and push the Set Button for a
dialog box. When the dialog box is shown, press the
Set Button once to reset all values.
Statistics
The Statistics page shows operating hours and cycle
times since the last reset date. To reset the
Statistics Page, go to the Error Page, turn the Set
Button one click counter clockwise. A dialog box will
appear. When the dialog box is shown, press the Set
Button once to reset all values. See Figure 9.
Figure 9. Climate Control Statistics Display
7
Description and Operation 0100 SRM 2107

Exit Troubleshooting
To leave the Service menu scroll to Exit and push When a fault for open or short circuit has been
the Set Button. indicated, use a volt meter to measure the voltage
over the different connections. Measures can be
Temperature Sensors taken at either the connector of the water valve or
at the controller connector. See Table 2. There are
In addition to the de-ice temperature sensor in the
also two 15 amp fuses located in the wiring system
evaporator, there are three further temperature
check these if a fault for open or short circuit has
sensors that influence the reaction of the controller:
been indicated. For location of theses fuses see
See Figure 10.
electric schematic for your truck.
• Outside Temperature Sensor, which is located
outside the cab under the condenser. Table 1. Sensor Resistance Values
• Coil sensor, which is located behind the
°C °F kΩ
evaporator and heater coil, in the suctioned
air flow of the blower fan. 0 32 32.649
• Inside Sensor, which is located in the side 5 41 25.394
console, measures the cab interior
temperature. Interior air flow past the sensor 10 50 19.903
is through a tube that connects between 15 59 15.713
suction side of the blower fan and inside
sensor. 20 68 12.493
The system uses these sensor inputs to set the 25 77 10.000
system performance required to meet the desired 30 86 8.056
cab temperature.
35 95 6.530
Troubleshooting 40 104 5.325
Disconnect the sensor for which an error has been
Table 2. Water Valve Pin Outs
indicated. Use an Ohm meter to measure its
resistance. See Table 1 that provides an overview of Water Controller Value
the resistance value for different temperatures. The Valve
electrical properties of the four sensors are the
Pin 8 Pin 31 ground
same. When the sensor itself shows no defects,
check continuity of the wiring harness. See Pin 10 Pin 30 3.3 Volt
Figure 10. The sensors are connected to the Pin 9 Pin 5 0.6 Volt when
controller connector at the following pin numbers: valve is closed.
• Inside Sensor: Pin 14 and 32. 2.2 Volt when
Outside Sensor: Pin 4 and 33 valve is open.
•
• De-Ice Sensor: Pin 13 and 24 Pin 6 Pin 18 12 Volt when
the valve is clos-
• Coil Sensor: Pin 12 and 34 ing. 0 Volt when
opening or not
Water Valve moving.
Fault indication "Valve Stuck" indicates a physical Pin 5 Pin 19 12 Volt when
obstruction that prevents the valve from moving. the valve is
The physical obstruction may have its cause at the opening. 0 Volt
outside or inside of the water valve. The components when closing or
of the water valve are not serviced separately. not moving.
Replace the water valve if there is no obvious
problem that can be rectified.

8
0100 SRM 2107 Description and Operation

Figure 10. Climate Control Wiring Diagram

For connector and wire numbers, see the truck

wiring diagram.

9
Description and Operation 0100 SRM 2107

Figure 11. Standard A/C Wiring Diagram

10
0100 SRM 2107
For connector and wire numbers, see the truck
wiring diagram.
Troubleshooting
INSUFFICIENT OR NO COOLING
Preliminary Checks
Make certain that the evaporator filters are not
clogged with dirt. Check to make certain that all
vehicle body openings are air tight. Check the
adjustment and condition of the compressor drive
belt(s), and adjust or replace as necessary.
Checking System Air Output
If the evaporator air flow appears less than normal,
check the evaporator filter and coil for dirt and
obstructions. Clean where necessary. Check the
blower assembly for proper operation.
Check The Sight Glass for Bubbles
If the preceding steps do not remedy the problem,
check the sight glass for bubbles. Run the vehicle
engine at high idle (approximately 1200 RPM) while
maintaining a minimum discharge pressure of 150
psi. The thermostatic switch should be positioned
for maximum cooling.
Table 3. General System Troubleshooting Procedures
INDICATION/TROUBLE
SYSTEM WILL NOT COOL
Compressor will not run
Electrical malfunction
SYSTEM RUNS BUT HAS INSUFFICIENT COOLING
Water valve staying open or partially open during
cooling
Compressor
Troubleshooting
Bubbles in the sight glass may indicate an
undercharge of refrigerant and/or a restriction in
the liquid line. If the charge is low, check the system
for leaks; repair if necessary and charge the system
with the proper amount of refrigerant.
NOTE: Under certain ambient conditions a few
bubbles may appear in the sight glass.
No bubbles in the sight glass will indicate either a
full charge or a complete loss of refrigerant. To
determine if there is refrigerant in the system, run
the vehicle engine at high idle (approximately
1200RPM) with the thermostatic switch positioned
for maximum cooling. Allow system to stabilize,
then shut system down while observing the sight
glass. If bubbles begin to appear, the system has a
refrigerant charge. If no bubbles appear, system is
without refrigerant.
A restriction in the liquid line can be found by
feeling the liquid line. Any portion that is cold to the
touch or that frosts up is restricting the refrigerant
flow.
POSSIBLE CAUSES
• Drive Belt loose or defective
• Clutch coil defective
• Clutch malfunction
• Low refrigerant charge
• Defective P1 pressure switch
• Compressor malfunction
• Blown fuse
• Relay defective
• Pressure switch or anti-ice switch defective
• Defective water valve
• Blown resistors in harness
• Drive-Belt loose or defective
• Compressor defective
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Troubleshooting 0100 SRM 2107

Table 3. General System Troubleshooting Procedures (Continued)

INDICATION/TROUBLE POSSIBLE CAUSES
Refrigeration system • Abnormal pressures
• No or restricted evaporator airflow
• Expansion valve malfunction
• Restricted refrigerant flow
• Low refrigerant charge
Air passage leakage • Warm air leakage into the evaporator inlet
from under the cab due to misplaced foam
seals between the cab and evaporator box.
ABNORMAL PRESSURES (See Table 5).
High discharge pressure • Refrigerant overcharge
• Noncondensables (air in system)
• Condenser motor(s) failure or defective P2
pressure switch
• Dirty condenser coil
Low discharge pressure • Expansion valve malfunction
• Compressor defective
• Low refrigerant charge
High suction pressure • Compressor defective
• Expansion valve malfunction
Low suction pressure • Filter drier partially plugged
• Reciever drier partially plugged
• Low refrigerant charge
• Expansion valve malfunction
• Restricted air flow
Suction and discharge pressures equal or near equal • Compressor valves defective
• Expansion valve sticking open
ABNORMAL NOISES, VIBRATIONS OR CONDITIONS
Compressor-Engine area • Compressor or compressor mounting loose
• Liquid slugging
• Insufficient oil
• Excessive oil
• Clutch is loose, rubbing or defective
• Dirt or debris on vehicle fan blades
• Drive belt cracked, worn or loose
Evaporator area • Evaporator blower assembly broken or loose
• Blower wheel loose or out of alignment
• Blade interference

12
0100 SRM 2107 Troubleshooting

Table 3. General System Troubleshooting Procedures (Continued)

INDICATION/TROUBLE POSSIBLE CAUSES
Condenser area • Broken or missing fan blade
• Condenser assembly loose
• Fan assembly loose
NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW
Air flow through coil blocked • Coil frosted over due to defective anti-ice
switch
• Dirty coil
• Dirty filter assembly
No or partial evaporator air flow • Motor running in reverse
• Motor(s) defective
• Evaporator fan loose or defective
• Fan damaged
• Dirty cab filter or recirculation filter
• Icing of coil
• Fan speed relay(s) defective
• Fan rotation incorrect
EXPANSION VALVE MALFUNCTION
Low suction pressure • Low refrigerant charge
• Ice formation or dirt at expansion valve orifice
CONTROL SYSTEM MALFUNCTION
Will not operate/control • Fuse or relay defective
• Fan speed switch defective
• Cab thermostat defective
NO OR INSUFFICIENT HEATING
Insufficient heating • Dirty or plugged heater core
• Coolant heat valve(s) malfunctioning or plug-
ged
• Low coolant level
• Electrical controls or harness issue
• Engine water pump defective
No heating • Electrical controls or harness issue
• Coolant heat valves(s) malfunctioning or plug-
ged
Continuous heating • Hand valve(s) defective
• Electrical controls or harness issue
• Coolant heat valves(s) malfunctioning or plug-
ged
• Debris under heat valve diaphragm

13
Remove and Replace 0100 SRM 2107

Table 4. Climate Control Display Diagnostics Menu Errors

Error Types
1. Open Open circuit error for temperature sensors or heater
valve position sensor.
2. Short Short circuit error for temperature sensors or heater
valve position sensor.
3. Stuck Heater Valve failure to rotate.
4. Fault A/C system has been disabled due to pressure switch
opening four times consecutively. This error locks out
the A/C system until the operator manually resets.
5. PS Low Pressure in A/C system is low when compressor
clutch turned on.

Remove and Replace

STANDARD HEATER ASSEMBLY 1. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
Access panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure Fuse Panel and Cover Location.
WARNING
Make sure no one is under cab when raising or 2. Remove the heat control knob at the
lowering cab. instrument panel top console. See
Figure Switch Locations.

WARNING 3. Remove the nut that retains the rotary control

Before placing any part of your body under cab,
always make sure the cab is fully tilted, or when
partially open, is locked using the tilt latch.
To access the heater assembly, raise the cab to the
fully open position. Support the heater assembly,
then remove the three screws holding the heater
assembly in place. Lower the heater assembly down,
remove screws and the cover plate. Individual
components are now accessible.
Remove
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
to the instrument panel top console. See
Figure 12.
4. Remove the rotary control assembly for the
water valve from the underside of the
instrument panel top console and place it with
the cable on the heater assembly.
5. Disconnect the wire harness from the fan speed
knob at the underside of the instrument panel
top console.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.

14
0100 SRM 2107 Remove and Replace

provide sufficient clearance between heater

assembly and cab frame. See Figure 13 for the
location of the capscrews.

10. Make sure the wire harness and the cable

control are free and can be removed together
with the heater assembly.

11. Support the heater assembly and remove the

capscrews that retain the heater assembly to
the hinge brackets.

12. Remove the heater assembly from the

underside of the cab.

Install
1. Position the heater assembly to the underside
of the cab.

2. Route the cable harness and cable control

correctly to the inside of the instrument panel
box.

3. Support the heater assembly and install the

capscrews to retain the heater assembly to the
hinge brackets. Do not tighten capscrews at
1. CABLE CLIP this time.
2. EXTENDED CABLE (FULL HOT POSITION)
3. NUT
4. KNOB LOCATION 4. Swing the heater assembly up toward the cab
5. ROTARY CONTROL and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
Figure 12. Rotary Control the location of the capscrews.

6. Remove the pressure cap to release the

pressure and place it back on the radiator
expansion tank.

7. Tilt/raise the cab to the fully open position.

Refer to the section Raising and Lowering Cab.

8. Tag and disconnect the two heater hoses from

the heater inlet and outlet ports, and plug the
heater hoses and ports. See Figure 13.

NOTE: The heater assembly fits tightly underneath

the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
9. Loosen the two nuts and capscrews at the hinge 1. HEATER HINGE BRACKET
bracket. Remove the three capscrews that 2. HEATER ASSEMBLY CAPSCREW LOCATION
3. HEATER OUTLET
retain the heater assembly to the cab. Pull the 4. HEATER INLET
heater assembly downwards and push
simultaneously towards the hinge bracket to Figure 13. Heater Assembly

15
Remove and Replace
5. Tighten the two capscrews at the hinge
bracket.
6. Remove the plugs and connect the heater hoses
to the inlet and outlet ports.
7. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
8. Connect the outer cable to the rotary control as
described in the section Push/Pull Cable,
Water Valve Cable, Install.
9. Connect the inner cable to the rotary control as
described in the section Push/Pull Cable,
Heater/Air Conditioner Assembly, Install.
10. Connect the wire harness for the fan speed
knob to the connector at the underside of the
instrument panel top console.
11. Install the rotary control assembly for the
water valve to the underside of the instrument
panel top console.
12. Install the nut to retain the rotary control to
the instrument panel top console. See
Figure 12.
13. Install the heat control knob at the instrument
panel top console. See Figure Switch Locations.
14. Position the fuse panel cover to the right side of
the instrument panel and install the four
screws. See
Figure Fuse Panel and Cover Location.
15. If required, fill the coolant to the correct level.
Depending on your lift truck see Periodic
Maintenance SRM .
16. Start the engine and warm the engine to
normal operating temperature.
17. Make sure the heater functions correctly.
STANDARD HEATER PARTS
Heater Core
Remove
16
0100 SRM 2107
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
When replacing the heater hoses, make sure the
replacement hoses meet correct specifications.
Failure to meet specifications may cause personal
injury.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
1. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
2. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
3. Loosen the hose clamp and disconnect the
heater inlet hose from the heater core pipe
located at the underside of the heater assembly
and plug the heater hose.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
4. Loosen the two nuts and capscrews at the hinge
bracket. Remove the three capscrews that
retain the heater assembly to the cab. Pull the
heater assembly downwards and push
simultaneously towards the hinge bracket to
provide sufficient clearance between heater
assembly and cab frame. See Figure 13 for the
location of the capscrews.
5. Remove the 10 screws that retain the top cover
to the heater assembly.
0100 SRM 2107 Remove and Replace

6. Remove the top cover from the heater

assembly.

7. Loosen the hose clamp and disconnect the top

heater hose from the heater core, located
between the heater core and the water valve.
See Figure 14.

8. Remove the two capscrews that retain the

heater core bracket to the inside of the heater
assembly. See Figure 15.

9. Remove the heater core bracket from the heater

assembly.

10. Slide the heater core out of the heater

assembly.

Install
1. Slide the heater core into the heater assembly. 1. HEATER CORE
2. BLOWER
2. Position the heater core bracket to the inside of 3. WATER VALVE
the heater assembly and install the two 4. HEATER CORE BRACKET
5. HEATER CORE BRACKET CAPSCREWS
retaining capscrews.
Figure 15. Heater Assembly Components
3. Connect the top heater hose to the heater core
and tighten the hose clamp. 4. Position the top cover on the heater assembly.

5. Install the 10 screws to retain the top cover to

the heater assembly.

6. Swing the heater assembly up toward the cab

and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.

7. Connect the heater inlet hose to the heater core

pipe located at the underside of the heater
assembly and tighten the hose clamp.

8. Lower the cab to the fully lowered and latched

position. Refer to the section
Raising and Lowering Cab.

9. Add coolant as needed. Depending on your lift

truck see Periodic Maintenance SRM .

1. BOTTOM HEATER HOSE 10. Start the engine and check for leaks. Add
2. WATER VALVE coolant as needed.
3. TOP HEATER HOSE
4. HEATER CORE 11. Make sure the heater functions correctly.
5. HOSE CLAMP

Figure 14. Heater Water Valve

17
Remove and Replace 0100 SRM 2107

Blower
Remove
1. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.

NOTE: The heater assembly fits tightly underneath

the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
2. Remove the three capscrews that retain the
heater assembly to the cab and swing the
heater assembly down. See Figure 13 for the
location of the capscrews.

3. Remove the 10 screws that retain the top cover

to the heater assembly.

4. Remove the top cover from the heater

assembly.

5. Tag and disconnect the electrical connector

connected to the blower assembly. See
Figure 16.
1. ELECTRICAL CONNECTOR
6. Remove the four screws that retain the blower
to the heater assembly housing. See Figure 17. Figure 16. Blower Electrical Connector
7. Partially remove the blower assembly from the
heater assembly housing and tag and
disconnect the four electrical wires from the
blower assembly. See Figure 18.

8. Remove the blower assembly from the heater

assembly housing.

Install
1. Connect the electrical wires to the blower
assembly. See Figure 18.

2. Position the blower assembly into the heater

assembly housing.

3. Install the four screws to retain the blower to

the heater assembly housing. See Figure 17. 1. BLOWER RETAINING CAPSCREWS

4. Connect the electrical connector to the blower Figure 17. Blower Retaining Screws
assembly. See Figure 16.

18
0100 SRM 2107
1. ELECTRICAL WIRE CONNECTION
Figure 18. Blower Electrical Wire Connection
5. Position the top cover on the heater assembly.
6. Install the 10 screws to retain the top cover to
the heater assembly.
7. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.
8. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
9. Make sure the blower functions correctly.
Water Valve
Remove
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
When replacing the heater hoses, make sure the
replacement hoses meet correct specifications.
Failure to meet specifications may cause personal
injury.
Remove and Replace
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
1. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
2. Turn the heat control knob on the instrument
panel counterclockwise to the fully open
position or (full hot position). See
Figure Switch Locations .
3. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
4. Remove the three capscrews that retain the
heater assembly to the cab and swing the
heater assembly down. See Figure 13 for the
location of the capscrews.
5. Remove the 10 screws that retain the top cover
to the heater assembly.
6. Remove the top cover from the heater
assembly.
7. Remove the cable clip that retains the outer
cable to the water valve.
8. Remove the snap ring that retains the inner
cable to the water valve and disconnect the
inner cable from the water valve.
9. Loosen the two hose clamps that retain the
water valve between the heater hoses. See
Figure 14.
10. Disconnect the two heater hoses from the water
valve.
11. Remove the water valve from the heater
assembly.
19
Remove and Replace
Install
1. Make sure the heat control knob in the cab is in
the full hot position
2. Position the water valve between the two
heater hoses inside the heater assembly. See
Figure 14.
3. Connect the two heater hoses to the water
valve and tighten the hose clamps.
4. Connect the inner cable to the water valve and
install the snap ring to retain the inner cable to
the water valve.
5. Push the lever of the water valve towards the
heater core until it reaches its final position.
Hold the lever and push the outer cable
towards the water valve.
6. Install and tighten the cable clip to retain the
outer cable to the water valve.
7. Position the top cover on the heater assembly.
8. Install the 10 screws to retain the top cover to
the heater assembly.
9. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13 for
the location of the capscrews.
10. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
11. Add coolant as needed. Depending on your lift
truck see Periodic Maintenance SRM .
12. Start the engine and check for leaks. Add
coolant as needed.
13. Make sure the heat control knob functions
correctly.
PUSH/PULL CABLE
Water Valve Cable
Remove
20
0100 SRM 2107
1. Turn the heat control knob on the instrument
panel counterclockwise to the fully open
position or the (full hot position). See
Figure Switch Locations .
2. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure Fuse Panel and Cover Location.
3. Remove the heat control knob at the
instrument panel top console. See
Figure Switch Locations.
4. Remove the nut that retains the rotary control
assembly to the instrument panel top console.
See Figure 12.
5. Remove the cable clip that retains the outer
cable to the rotary control assembly.
6. Remove the snap ring that retains the inner
cable to the rotary control and remove the
inner cable from the rotary control.
7. Raise the cab to the fully open position. Refer to
the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
8. Remove the three capscrews that retain the
heater assembly to the cab and swing the
heater assembly down. See Figure 13.
9. Remove the 10 screws that retain the top cover
to the heater assembly.
10. Remove the top cover from the heater
assembly.
11. Remove the cable clip that retains the outer
cable to the water valve.
12. Remove the snap ring that retains the inner
cable to the water valve and disconnect the
inner cable from the water valve.
13. Remove the water valve cable from the
instrument panel box and heater assembly.
0100 SRM 2107
Install
1. Position the water valve cable inside the
instrument panel box and heater assembly.
2. Connect the inner cable to the water valve and
install the snap ring to retain the inner cable to
the water valve.
3. Push the lever of the water valve towards the
heater core until it reaches its final position.
Position the outer cable until it extends a few
mm out of the cable clip.
4. Install and tighten the cable clip to retain the
outer cable to the water valve.
5. Position the top cover on the heater assembly.
6. Install the 10 screws to retain the top cover to
the heater assembly.
7. Swing the heater assembly up toward the cab
and install the three capscrews to retain the
heater assembly to the cab. See Figure 13.
8. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
9. Turn the rotary control into the (full hot
position). See Figure 12.
10. Connect the inner cable to the rotary control
and install the snap ring to retain the inner
cable to the rotary control. See Figure 12.
11. Hold the inner cable extended and pull the
outer cable away from the rotary control.
12. Install the cable clip to retain the outer cable to
the rotary control assembly.
13. Make sure the heat control knob functions
correctly.
14. Install the rotary control assembly to the
underside of the instrument panel top console.
15. Install the nut to retain the rotary control
assembly to the instrument panel top console.
See Figure 12.
16. Install the heat control knob at the instrument
panel top console. See Figure Switch Locations.
Remove and Replace
17. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See
Figure Fuse Panel and Cover Location.
Heater/Air Conditioner Assembly
Remove
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
1. Turn the key switch to the ON position.
2. Place the recirculation knob on the instrument
panel in position 1 or position 2.
3. Turn the key switch to the OFF position.
4. Remove the four screws that retain the fuse
panel cover to the right side of the instrument
panel and remove the cover to gain access to
the underside of the instrument panel. See
Figure Fuse Panel and Cover Location.
5. Disconnect the wire harness for the fan speed
knob, heater knob, and recirculation knob from
the connectors at the underside of the
instrument panel top console.
6. Tag and disconnect the electrical wires for the
air conditioner switch at the underside of the
instrument panel top console.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
7. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
8. Tilt/raise the cab to the fully open position.
Refer to the section
Figure Fuse Panel and Cover Location.
21
Remove and Replace 0100 SRM 2107

9. Tag and disconnect the two heater hoses from
the heater inlet and outlet ports and plug the
heater hoses and ports. See Figure 19.
CAUTION
Repairs to the air conditioning system that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a certified air
conditioning specialist.
10. Contact a certified air conditioning specialist to
have the refrigerant extracted from the air
conditioning system.
11. Disconnect and plug the hose fittings leading to
the evaporator.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
12. Loosen the two nuts and capscrews at the hinge
bracket. Remove the three capscrews that
retain the heater assembly to the cab. Pull the
heater assembly downwards and push
simultaneously towards the hinge bracket to
provide sufficient clearance between heater
assembly and cab frame. See Figure 19 for the
location of the capscrews.
2. Support the heater/air conditioner assembly
and install the capscrews to retain the
heater/air conditioner assembly to the hinge
brackets. Do not tighten the capscrews at this
time.
3. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position.
4. Route the wire harness correctly to the side
instrument panel box.
5. Swing the heater/air conditioner assembly up
toward the cab and install the three screws to
retain the heater/air conditioner assembly to
the cab. See Figure 19 for the location of the
capscrews.
6. Tighten the two nuts and capscrews at the
hinge bracket.
7. Remove the plugs and connect the heater hose
to the inlet and outlet ports.
8. Connect the hose fittings leading to the
evaporator.

13. Make sure the wire harness is free and can be

removed together with the heater/air
conditioner assembly.

14. Disconnect the electrical connector on top of the

top cover from the actuator that controls the
vent door position.

15. Support the heater/air conditioner assembly

and remove the capscrews that retain the
heater/air conditioner assembly to the hinge
brackets.

16. Remove the heater/air conditioner assembly

from the underside of the cab. 1. HEATER INLET
2. HEATER OUTLET
3. HEATER ASSEMBLY CAPSCREW LOCATION
Install 4. CONDENSATION DRAINS
5. AIR CONDITIONING OUTLET
1. Position the heater/air conditioner assembly to 6. AIR CONDITIONING INLET
the underside of the cab. 7. HEATER HINGE BRACKET

Figure 19. Heater/Air Conditioner Assembly

22
0100 SRM 2107
CAUTION
Repairs to the air conditioning system that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a certified air
conditioning specialist.
9. Contact a qualified and certified technician to
have the air conditioning system filled with
refrigerant. See
Air Conditioning Technical Detail, Table 5 for
the type and the amount of refrigerant required
to charge an evacuated A/C system.
10. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
11. Connect the electrical wires for the air
conditioning switch at the underside of the
instrument panel top console.
12. Connect the wire harness for the fan speed
knob, heater knob, and recirculation knob to
the connectors at the underside of the
instrument panel top console.
13. Add coolant as needed. Depending on your lift
truck see Periodic Maintenance SRM .
14. Position the fuse panel cover to the right side of
the instrument panel and install the four
retaining screws. See
Figure Fuse Panel and Cover Location.
15. Make sure the heater/air conditioner functions
correctly. Turn the recirculation knob a few
times to the fully open and fully closed
positions to be sure that the recirculation
functions correctly.
HEATER/AIR CONDITIONER PARTS
Vent Door
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
Remove and Replace
4. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
5. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19 for the location of the
capscrews.
6. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
7. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
8. Remove the top cover from the heater/air
conditioner assembly.
9. Remove the washer located on top of the nylon
bushing.
10. Remove the capscrew, two nuts, two washers,
and lock washer that retain the vent door to
the actuator that is located on the top cover.
11. Remove the vent door.
1. ELECTRICAL CONNECTOR
2. VENT DOOR ACTUATOR
3. TOP COVER
Figure 20. Electrical Connector Location of Vent
Door Actuator
23
Remove and Replace
Install
1. Position the vent door and install the capscrew,
two nuts, two washers, and lock washer to
retain the vent door to the actuator on the top
cover.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
2. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
3. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
4. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
5. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19 for the location of the
capscrews.
6. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
NOTE: The key switch much be turned to the ON
position before performing the following step.
7. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions correctly. See
Figure Switch Locations.
Heater Core
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
24
0100 SRM 2107
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
4. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
5. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
6. Loosen the hose clamp and disconnect the inlet
heater hose from the heater core pipe located at
the underside of the heater/air conditioner
assembly. Plug the inlet heater hose. See
Figure 19.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
7. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19 for the location of the
capscrews.
8. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
9. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
10. Remove the top cover from the heater/air
conditioner assembly.
11. Remove the washer that is positioned on top of
the nylon bushing.
12. Tag and disconnect the two electrical
connectors from the thermostat. See Figure 21.
0100 SRM 2107 Remove and Replace

4. Position the top cover on the heater/air

conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.

5. Install the 12 screws to retain the top cover to

the heater/air conditioner assembly.

6. Connect the electrical connector on top of the

top cover to the actuator that controls the vent
door position. See Figure 20.

7. Swing the heater/air conditioner assembly up

toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19 for the correct location of
the capscrews.

8. Connect the inlet heater hose to the heater core

1. THERMOSTAT
2. HOSE CLAMP pipe located at the underside of the heater/air
3. TOP HEATER HOSE conditioner assembly and tighten the hose
4. BOTTOM HEATER HOSE clamp.
5. WATER VALVE
6. WATER VALVE BRACKET 9. Lower the cab to the fully lowered and latched
7. BRACKET CAPSCREW (INNER) position. Refer to the section
8. BRACKET CAPSCREW (OUTER)
9. HEATER CORE Raising and Lowering Cab.

Figure 21. Thermostat, Water Valve, and Heater
Hoses
13. Loosen the hose clamp that retains the top
heater hose to the heater core inside the
heater/air conditioner assembly and disconnect
the heater hose from the heater core.
14. Slide the heater core out of the heater/air
conditioner assembly.
Install
1. Slide the heater core into the heater/air
conditioner assembly.
10. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
NOTE: The key switch much be turned to the ON
position before performing the following step.
11. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions correctly. See
Figure Switch Locations.
Evaporator Core

2. Connect the top heater hose between the water Remove

valve and heater core to the heater core and
tighten the hose clamp. See .
3. Connect the two electrical connectors to the
thermostat.
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.

NOTE: Make sure the nylon bushing and washer 3. Turn the key switch to the OFF position.
are correctly positioned inside the heater/air
conditioner assembly.

25
Remove and Replace 0100 SRM 2107

10. Disconnect the electrical connector on top of the

WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
top cover from the actuator that controls the
vent door position. See Figure 20.
11. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.

12. Remove the top cover from the heater/air

WARNING conditioner assembly.
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the 13. Remove the washer that is positioned on top of
pressure cap is removed, the pressure is released the nylon bushing.
from the system. If the system is hot, the steam
and boiling coolant can cause burns. 14. Remove the blower. Refer to the section Blower,
Remove.
4. Remove the pressure cap to release the
pressure and place it back on the radiator 15. Remove the water valve. Refer to the section
expansion tank. Water Valve, Remove.

5. Tilt/raise the cab to the fully open position. 16. Remove the two clips that retain the evaporator
Refer to the section Raising and Lowering Cab. core inside the heater/air conditioner assembly.
See Figure 23.

CAUTION 17. Slide the evaporator core out of the heater/air

Repairs to the evaporator core that require conditioner assembly.
discharging and/or refilling of the refrigeration
fluid must be performed only by a trained and 18. Remove the expansion block from the
certified air conditioning specialist. evaporator core fittings.

6. Contact a certified technician to have the

refrigerant extracted from the air-conditioning
system. See Air Conditioning Technical Detail,
Table 5 for the type and amount of refrigerant
required to charge an evacuated A/C system.

7. Tag and disconnect the two evaporator hoses

that are connected to the expansion block at
the underside of the heater/air conditioner
assembly. See Figure 19.

8. Remove the two capscrews that retain the

expansion block bracket to the bottom plate of
the heater/air conditioner assembly. See
Figure 22.

NOTE: The heater assembly fits tightly underneath

the cab and will require a limited amount of force to
swing the heater assembly down and away from the 1. EXPANSION BRACKET CAPSCREWS
cab.
Figure 22. Expansion Bracket Capscrews
9. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19 for the correct location of
the capscrews.

26
0100 SRM 2107
1. EVAPORATOR CORE CLIP
Figure 23. Evaporator Core Clips
Install
NOTE: Adjustment of the expansion valve is not
recommended.
1. Install the expansion block to the evaporator
core pipes.
2. Slide the evaporator core into the heater/air
conditioner assembly. Make sure the expansion
block is positioned correctly at the underside of
the heater/air conditioner assembly.
3. Install the two clips to retain the evaporator
core inside the heater/air conditioner assembly.
See Figure 23.
4. Install the two capscrews to retain the
expansion block bracket to the bottom plate of
the heater/air conditioner assembly. See
Figure 22.
5. Install the water valve. Refer to the section
Water Valve, Install.
6. Install the blower. Refer to the section Blower,
Install.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
7. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
Remove and Replace
8. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
9. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
10. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19 for the correct location of
the capscrews.
CAUTION
Repairs to the evaporator core that require
discharging and/or refilling of the refrigeration
fluid must be performed only by a trained and
certified air conditioning specialist.
11. Connect the two evaporator hoses to the
expansion block at the underside of the
heater/air conditioner assembly.
12. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
13. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
14. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions properly. See
Figure Switch Locations.
Blower
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
4. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
27
Remove and Replace
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
5. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19 for the correct location of
the capscrews.
6. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
7. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
8. Remove the top cover from the heater/air
conditioner assembly.
9. Remove the washer that is positioned on top of
the nylon bushing.
10. Tag and disconnect the electrical connector
connected to the blower assembly. See
Figure 16.
11. Remove the four screws and nuts that retain
the blower inside the heater/air conditioner
assembly. See Figure 17.
12. Partially remove the blower assembly from the
heater/air conditioner assembly housing and
tag and disconnect the four electrical wires
from the blower assembly. See Figure 18.
13. Remove the blower assembly from the
heater/air conditioner assembly housing.
Install
1. Connect the four electrical wires to the blower
assembly. See Figure 18.
2. Position the blower assembly into the
heater/air conditioner assembly.
3. Install the four screws and nuts to retain the
blower inside the heater/air conditioner
assembly. See Figure 17.
4. Connect the electrical connector to the blower
assembly. See Figure 16.
28
0100 SRM 2107
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
5. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.
6. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
7. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
8. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19.
9. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
10. Make sure the blower functions correctly.
Thermostat
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
0100 SRM 2107 Remove and Replace

4. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
5. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
6. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19.
7. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
8. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
2. Install the nut and washer located outside the
heater/air conditioner assembly to retain the
thermostat inside the heater/air conditioner
assembly.
3. Install the temperature switch sensor wire to
the evaporator core. See Figure 24.
4. Connect the top heater hose between the water
valve and heater core to the water valve and
tighten the hose clamp.
5. Connect the two electrical connectors to the
thermostat.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
6. Position the top cover on the heater/air
conditioner assembly and make sure the pin at
the underside of the vent door is positioned in
the washer and nylon bushing.

9. Remove the top cover from the heater/air 7. Install the 12 screws to retain the top cover to
conditioner assembly. the heater/air conditioner assembly.

10. Remove the washer that is positioned on top of

the plastic bushing.

11. Tag and disconnect the two electrical

connectors from the thermostat.

12. Loosen the hose clamp that retains the top

heater hose to the water valve inside the
heater/air conditioner assembly and disconnect
the heater hose.

13. Remove the temperature switch from the

evaporator core. See Figure 24.

14. Remove the nut and washer located outside the

heater/air conditioner assembly that retains
the thermostat inside the heater/air conditioner
assembly.

15. Remove the thermostat and temperature

switch from the heater/air conditioner
assembly.

Install
1. Position the thermostat and temperature
1. TEMPERATURE SWITCH SENSOR WIRE
switch inside the heater/air conditioner
assembly and correctly route the temperature Figure 24. Temperature Switch
switch sensor wire.

29
Remove and Replace
8. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
9. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
to retain the heater/air conditioner assembly to
the cab. See Figure 19.
10. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
11. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
12. Turn the recirculation knob a few times from
the fully open position to the fully closed
position to be sure that the recirculation
system functions correctly. See
Figure Switch Locations.
Water Valve
Remove
1. Turn the key switch to the ON position.
2. Turn the recirculation knob located on the
instrument panel to position 1 or position 2.
See Figure Switch Locations.
3. Turn the key switch to the OFF position.
WARNING
Before removing the heater hoses, make sure the
heater hoses are cool. Hot coolant may cause
severe burns.
WARNING
DO NOT remove the pressure cap from the
expansion tank when the engine is hot. When the
pressure cap is removed, the pressure is released
from the system. If the system is hot, the steam
and boiling coolant can cause burns.
4. Remove the pressure cap to release the
pressure and place it back on the radiator
expansion tank.
30
0100 SRM 2107
5. Tilt/raise the cab to the fully open position.
Refer to the section Raising and Lowering Cab.
NOTE: The heater assembly fits tightly underneath
the cab and will require a limited amount of force to
swing the heater assembly down and away from the
cab.
6. Remove the three capscrews that retain the
heater/air conditioner assembly to the cab and
swing the heater/air conditioner assembly
down. See Figure 19.
7. Disconnect the electrical connector on top of the
top cover from the actuator that controls the
vent door position. See Figure 20.
8. Remove the 12 screws that retain the top cover
to the heater/air conditioner assembly.
9. Remove the top cover from the heater/air
conditioner assembly.
10. Remove the washer that is positioned on top of
the plastic bushing.
11. Tag and disconnect the two electrical
connectors from the thermostat.
12. Loosen the two hose clamps that retain the top
heater hose between the water valve and
heater core.
13. Remove the top heater hose and the two hose
clamps between the water valve and heater
core.
14. Loosen the hose clamp that retains the bottom
heater hose to the water valve.
15. Remove the two capscrews located at the
outside of the heater/air conditioner assembly
that retain the water valve bracket to the
heater/air conditioner assembly.
16. Disconnect the electrical connector from the
water valve actuator.
17. Loosen the hose clamp and disconnect the
bottom heater hose from the water valve.
18. Remove the water valve bracket from the
heater/air conditioner assembly.
0100 SRM 2107 Remove and Replace

19. Remove the two screws that retain the water
valve to the water valve bracket.
Install
1. Position the water valve to the water valve
bracket and install the two retaining screws.
2. Position the water valve bracket inside the
heater/air conditioner assembly.
3. Connect the bottom heater hose to the water
valve and tighten the hose clamp.
4. Connect the electrical connector to the water
valve actuator.
5. Install the two capscrews located at the outside
of the heater/air conditioner assembly to retain
the water valve bracket inside the heater/air
conditioner assembly. See .
6. Install the top heater hose and the two hose
clamps between the water valve and heater
core. Tighten the hose clamps.
7. Connect the two electrical connectors to the
thermostat.
NOTE: Make sure the nylon bushing and washer
are correctly positioned inside the heater/air
conditioner assembly.
8. Position the top cover on the heater/air
conditioner assembly and make sure that the
pin at the underside of the vent door is
positioned in the washer and nylon bushing.
9. Install the 12 screws to retain the top cover to
the heater/air conditioner assembly.
10. Connect the electrical connector on top of the
top cover to the actuator that controls the vent
door position. See Figure 20.
11. Swing the heater/air conditioner assembly up
toward the cab and install the three capscrews
that retain the heater/air conditioner assembly
to the cab. See Figure 19.
12. Lower the cab to the fully lowered and latched
position. Refer to the section
Raising and Lowering Cab.
13. Start the engine and check for leaks. Add
coolant as needed. Depending on your lift truck
see Periodic Maintenance SRM for the
correct coolant specifications.
14. Turn the heat control knob a few times from
the fully open position to the fully closed
position to be sure that the heating system
functions properly. See
Figure Switch Locations.
FILTRATION
Fresh Air Filter
Remove
1. Locate the fresh air filter. See Figure 2.
2. Press the latches and pull the filter housing
from the side of the cab.
3. Loosen the two bolts and remove the filter
from the housing.
Install
1. Install the new fresh air filter. See Tighten
the bolts.
2. Press the latches and insert the filter housing
into the cab.
Recirculation Air Filter
Remove
1. Locate the recirculaion air filter. See
Figure 25.
2. Loosen the two latch studs. See Figure 26.
3. Remove the cover.
4. Remove the filter.
Install
1. Install the new recirculaion air filter.
2. Install the cover and tighten the two latch
studs.

31
Remove and Replace 0100 SRM 2107

1. COVER
2. SEAL
3. FILTER
4. LATCH STUD
5. LATCH RECEPTACLE
1. RECIRCULATION AIR FILTER 6. LATCH RETAINER

Figure 25. Recirculation Air Filter Location Figure 26. Recirculation Air Filter

32
0100 SRM 2107 Remove and Replace

AIR CONDITIONING TECHNICAL DETAIL

NOTE: Table 5 provides technical details. It is
intended for use by a certified air conditioning
specialist.

Table 5. Air Conditioning Specifications

Compressor Values
Lubricant Type PAG See Compressor Nameplate
Lubricant Quantity 200 grams
Suction Port 7/8-14 UNF
Discharge Port 3/4-16 UNF
Refrigerant
Refrigerant R134a
Fill Capacity 1300 ± 25 grams
Pressure Switch
High pressure (P1) OFF 2.70 ±0.2 MPa (392 ±29 psi)
High pressure (P1) ON 2.10 ±0.2 MPa (305 ±29 psi)
Med pressure (P2) OFF 1.30 ±0.15 MPa (188 ±22 psi)
Med pressure (P2) ON 1.60 ±0.13 MPa (232 ±19 psi)
Anti-Icing Switch
Opens -1°C (30.2°F)
Closes 2°C (35.6°F)
This chart is intended for use by a certified air conditioning specialist.

33
Maintenance Procedures and Required Equipment 0100 SRM 2107

Maintenance Procedures and Required Equipment

NOTE: The following procedure is only to be - Accurately weighs the transfer of
performed by a qualified AC technician. refrigerant into the air-conditioning
system.
MAINTENANCE PROCEDURES 8. Refrigerant Cylinder
The following air conditioning service equipment is - Storage tank for R134a.
required in order to properly perform the 9. Oil Injector
maintenance procedures. Used to add additional amounts of oil to
-
1. Manifold Gauge Set MCC P/N 07-00294-00, a closed system.
or equivalent
- Provides access to and monitors INSTALLING MANIFOLD GAUGES
pressures within the system. Manifold The manifold gauge set is used to determine system
gauge sets are available in different
operating pressures, add refrigerant charge, and to
configurations and styles: 3-way or 4-
way, liquid filled gauges, with or without equalize or evacuate the system. See Figure 27.
a sight glass, 3 hoses or 4 hoses, 1/4 inch
or 3/8 inch manifold connections, etc.
Familiarize yourself with the proper
operation of your manifold gauge set
before attempting any service.
2. R134a Low Side (Suction) Coupler
MCCP/N 07-00307-04, or equivalent
- Connects the air conditioning system
Suction Access Port to the Manifold
Gauge Set.
3. R134a High Side (Discharge) Coupler
MCC P/N 07-00307-05, or equivalent
- Connects the air conditioning system
Discharge Access Port to the Manifold
Gauge Set.
4. Vacuum Pump - 2 Stage 142 l/min (5 cfm)
Minimum MCC P/N 07-00176-11, or
equivalent
- Removes moisture and air from the air
conditioning system in order to obtain
required micron level.
5. MicronGauge, Digital MCCP/
N07-00414-00, or equivalent
- Monitors the evacuation process in units
of µm, Hg or Pa. Micron Gauges can be
either digital (electronic) or analog. 1. MANIFOLD GAUGE SET
6. Recovery/Recycle Machine (R134a) MCC 2. HOSE FITTING
P/N MVS-115-F-L-CT (115VDC), MVS-240-F- 3. REFRIGERATION AND/OR EVACUATION HOSE
L-CT (240 VDC), or equivalent (SAE J2196/R134A)
4. HOSE FITTING WITHOUT O-RING (M14 X 1.5)
- Recovers and recycles R134a refrigerant 5. HIGH SIDE FIELD SERVICE COUPLER
that is present within the air 6. LOW SIDE FIELD SERVICE COUPLER
conditioning system. 7. OPENED HAND VALVE
7. Refrigerant Scale MCC P/N 07-00315-00, or 8. SUCTION PRESSURE GAUGE
equivalent 9. DISCHARGE PRESSURE GAUGE
10. CLOSED HAND VALVE

Figure 27. Manifold Gauge Set

34
0100 SRM 2107
NOTE: Today modern equipment is available that
is able to run a full purge - evacuation - charge cycle
automatically.
When the suction pressure hand valve is closed
(turned all the way in), the suction (low) pressure
can be checked.When the discharge pressure hand
valve is closed, the discharge (high) pressure can be
checked. When both valves are open (turned
counter-clockwise all the way out), high pressure
vapor will flow into the low side. When the suction
pressure valve is open and the discharge pressure
valve shut, the system can be charged.
A R134a manifold gauge/hose set with self-sealing
hoses is required for service of the models covered
within this manual. The manifold gauge/hose set is
available from Mobile Climate Control (Mobile
Climate Control P/N 07-00294-00, or similar, which
includes items 1 through 6, on Figure 27). To
perform service using the manifold gauge/hose set,
do the following:
a. Preparing Manifold Gauge/Hose Set For
Use
If the manifold gauge/hose set is new or was
exposed to the atmosphere it will need to be
evacuated to remove contaminants and air as
follows:
1. Open (turn counterclockwise) both field
service couplers and open both hand
valves halfway. See Figure 27.
2. Connect the yellow hose to a recovery
machine, vacuum pump or refrigerant
R134a cylinder. Depending on tools
available and service to be performed.
3. Evacuate to 34 kPa (4.9 psi) of vacuum
and then charge with R134a to a slightly
positive pressure of 10 kPa (1.4 psi).
4. Close both manifold gauge set valves and
disconnect from cylinder. The gauge set
is now ready for use.
b. Connecting Manifold Gauge/Hose Set
To connect the manifold gauge set, see
Figure 28, and perform the following steps:
1. Connect the high side field service
coupler to the discharge line service
valve port. See Figure 27.
Maintenance Procedures and Required Equipment
2. Turn the high side field service coupler
(red) clockwise, which will open the high
side of the system to the gauge set.
3. Connect the low side field service coupler
to the suction service valve port.
4. Turn the low side field service coupler
(blue) clockwise, which will open the low
side of the system to the gauge set.
c. Removing the Manifold Gauge Set
WARNING
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
1. Open (turn counterclockwise) the high
side (discharge) field service coupler (red
knob).
2. Open both hand valves on the manifold
gauge set halfway and allow the pressure
in the manifold gauge set to be drawn
down to suction pressure. This returns
any liquid that may be in the high side
hose to the system.
3. Open the low side (suction) field service
coupler (red knob) and close both
manifold gauge set valves. Remove the
couplers from the service ports.
4. Install both service port caps (finger-
tight only).
REFRIGERANT RECOVERY
To remove the entire refrigerant charge, do the
following:
a. Connect a manifold gauge set to the system as
shown in Figure 28.
b. Connect a reclaimer to the center manifold
gauge set connection.
c. Recover refrigerant in accordance with
reclaimer manufacturers instructions.
35
Maintenance Procedures and Required Equipment 0100 SRM 2107

1. VACUUM PUMP 7. R134A LOW (SUCTION) SIDE COUPLER

2. MICRON GAUGE 8. COMPRESSOR
3. MANIFOLD GAUGE SET 9. CONDENSER COIL
4. REFRIGERANT CYLINDER 10. FILTER DRIER
5. RECOVERY/RECYCLE MACHINE 11. SIGHT GLASS RECIEVER/DRIER
6. R134A HIGH (DISCHARGE) SIDE COUPLER 12. EVAPORATOR COIL

Figure 28. Refrigerant Service Connections

36
0100 SRM 2107
REFRIGERANT LEAK CHECK
A refrigerant leak check should always be
performed after the system has been opened to
replace or repair a component. To check for leaks in
the refrigeration system, perform the following
procedure:
WARNING
Never use air for leak testing. It has been
determined that pressurized, air-rich mixtures of
refrigerants and air can undergo combustion when
exposed to an ignition source.
a. If the system is without refrigerant, charge
the system with refrigerant vapor to build up
pressure to approximately 206 kPa (30 psi)
(R134a).
b. Add sufficient nitrogen to raise system
pressure to 1.034/1.379 MPa (150/200 psi).
c. Check for leaks. The recommended procedure
for finding leaks in a system is with a R134a
electronic leak detector. Testing joints with
soapsuds is satisfactory and may be necessary
under conditions where when an electronic
leak detector will not function properly, such
as with large leaks.
d. Remove test gas and replace filter drier.
e. Evacuate and dehydrate the unit. See
Evacuation and Dehydration.
EVACUATION AND DEHYDRATION
General
The presence of moisture in a refrigeration
system can have many undesirable effects.
The most common are copper plating, acid
sludge formation, “freezing-up” of metering
devices by free water, and formation of acids,
resulting in metal corrosion. A triple
evacuation should be performed after a major
system repair (compressor, evaporator, or
condenser replacement). See
Procedure For Evacuation and Dehydrating
System (Triple Evacuation). A one time
evacuation should take place after a minor
system repair, such as a filter drier
replacement.
Maintenance Procedures and Required Equipment
Preparation
NOTE: Using a compound gauge for determination
of vacuum level is not recommended because of its
inherent inaccuracy.
a. Evacuate and dehydrate only after pressure
leak test. See Refrigerant Leak Check.
b. Essential tools to properly evacuate and
dehydrate any system include a vacuum
pump (170 l/min (6 cfm)) volume
displacement - (MCC P/N 07-00176-11) and
an electronic vacuum (micron) gauge (MCC
P/N 07-00414-00) or equivalent.
c. Keep the ambient temperature above 60° F
(15.6° C) to speed evaporation of moisture. If
the ambient temperature is lower than 60° F
(15.6° C), ice may form before moisture
removal is complete. Heat lamps or alternate
sources of heat may be used to raise the
system temperature.
Procedure For Evacuation and
Dehydrating System (Triple Evacuation)
a. Remove all refrigerant using a refrigerant
recovery system.
b. The recommended method is connecting lines
(3/8“ refrigerant hoses designed for vacuum
service). See Figure 28.
c. Make sure vacuum pump valve is open.
d. Start the vacuum pump. Slowly open valves
halfway and then open vacuum gauge valve.
e. Evacuate the system to 500 Pa (3750 µm Hg),
then charge with Nitrogen to 200 kPa.
f. Purge the nitrogen from the system.
g. Repeat step d. through step f. one time.
h. Evacuate to 200 Pa (1500 µm Hg) and wait 30
min to see if vacuum holds.
i. Charge system. See
Adding Refrigerant to a System.
37
Maintenance Procedures and Required Equipment 0100 SRM 2107

PROCEDURE FOR EVACUATION AND b. Evacuate and dehydrate system. See

DEHYDRATING SYSTEM (ONE TIME
EVACUATION)
a. Remove all refrigerant using a refrigerant
recovery (reclaimer) system. See
Refrigerant Recovery.
b. The recommended method is connecting lines
(3/8“ refrigerant hoses designed for vacuum
service). See Figure 28.
c. Make sure vacuum pump valve is open.
d. Start the vacuum pump. Slowly open valves
halfway and then open vacuum gauge valve.
e. Evacuate to 200 Pa (1500 µm Hg) and wait 30
min to see if vacuum holds.
f. Charge system. See
Adding Refrigerant to a System.
ADDING REFRIGERANT TO A SYSTEM
Checking Refrigerant Charge
The following conditions must be met to accurately
check the refrigerant charge.
• Engine operating at high idle.
• Air conditioning system operating in high cool
10 to 15 minutes.
• Compressor discharge (head) pressure a
minimum of 1030 kPa (150 psi) with R134a. It
may be necessary to block condenser air flow
to raise discharge pressure.
• On HYG systems, see Table 6, to determine if
correct charge has been obtained.
Adding Full Charge
a. Install manifold gauge set at the suction and
discharge service valves. See Figure 28.
Evacuation and Dehydration.
c. Place R134a refrigerant cylinder on scales.
d. Open discharge service coupler (to close off
gauge port). Close liquid valve on cylinder.
1300 Grams (45.8 oz.) required on all HYG
equipment as an approximate starting point.
e. Start unit in cooling mode. Run
approximately 10 minutes and check the
refrigerant charge. See
Checking Refrigerant Charge.
Adding Partial Charge
a. Examine the unit refrigerant system for any
evidence of leaks. Repair as necessary. See
Refrigerant Leak Check.
b. Maintain the conditions outlined in
Adding Full Charge.
c. Connect charging line between suction service
port and cylinder of refrigerant R134a. Open
VAPOR valve.
d. Open discharge service coupler (to close off
gauge port). Close liquid valve on cylinder.
e. Slowly add charge in small steps of 113 grams
(4 ounces). Start unit in cooling mode. Run
approximately 10 minutes and check the
refrigerant charge. See Table 6.
Use the following table to determine if the correct
charge has been obtained.
NOTE: Use this table to determine the discharge
(high side) pressure only. Subtract 17°C (30°F) from
the outside ambient temperature to determine the
approximate low side pressure. See Table 7.

Table 6. Mobile Climate Control System Performance Chart

Procedure Your Entry Example
1. Connect Manifold Gauge Set To Air Conditioning System NONE NONE
2. Measure outside (ambient) air temperature. Enter here: ________°F 100°F
________°C 38°C
3. Add 40°F to the outside (ambient) air temperature. 40°F + 40°F +
Add 22.2°C to the outside (ambient) air temperature. ____°F 140°F
22.2°C + 22.2°C +
____°C 60.2°C
4. Locate closest refrigerant temperature in Table 7. Enter here: ________°F 140°F
________°C 60.0°C

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0100 SRM 2107 Maintenance Procedures and Required Equipment

Table 6. Mobile Climate Control System Performance Chart (Continued)

Procedure Your Entry Example
5. Going across the Table, find the corresponding pressure. (D)=________ PSI 229 PSI
(D)=________ MPa 1.58 MPa
6. If the Discharge Pressure (High Side) on gauges (With compressor *** ***
engaged, engine speed 1200 RPM, and system operating) is:
• Greater than (D) - Reduce refrigerant by 113 grams (4 oz)
increments.
• Less than (D) - Add refrigerant in steps of 113 grams (4 oz). Wait
10 minutes for system to stabilize before taking new readings.

FILTER DRIER refrigerant flow (liquid refrigerant flows from

the condenser to the evaporator). Finger
HYG condensers are supplied with a filter drier. If a tighten the liquid line fittings.
pressure drop across the filter drier is indicated or
i. Tighten filter drier. O-ring fittings using two
the moisture-indicator shows an abnormal (wet) open end wrenches.
condition, the filter drier must be changed. See
j. Evacuate to 200 Pa (.03 psi) and wait 30 min
Table 6.
to see if vacuum holds.
a. Check for a restricted filter by touching the k. Charge system. See Adding Full Charge.
filter drier on inlet and outlet 3 connections.
If there is a noticeable temperature difference
the filter is probably restricted and should be
replaced.
b. Recover refrigerant. See
Refrigerant Recovery.
c. Place a new filter drier near the unit for
immediate installation.
d. Using two open-end wrenches, slowly crack
open and remove the liquid line O-ring
fittings on each side of the filter drier.

WARNING
The filter drier may contain liquid refrigerant.
Slowly open the fitting nuts and avoid contact with
exposed skin or eyes.

e. Loosen the hose clamp(s) securing the filter

drier to the condenser assembly.
f. Remove the filter drier. Transfer high 1. O-RING
pressure switch if required. 2. CLAMP
g. Remove seal caps from the new filter drier. 3. O-RING
Apply a light coat ofmineral oil to the fittings 4. FILTER DRIER-SIGHT GLASS ASSEMBLY
and O-rings.
Figure 29. Filter Drier
h. Assemble the new filter drier to the liquid
lines ensuring that the arrow on the body of
the filter drier points in the direction of the

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Maintenance Procedures and Required Equipment 0100 SRM 2107

Table 7. R134a Temperature - Pressure Chart

Temperature Pressure Vacuum
°F °C PSI kPa Inch Hg cm Hg
-40 -40.0 -7.3 -50.1 14.8 37.6
-35 -37.2 -6.1 -42.3 12.5 31.8
-30 -34.4 -4.8 -33.2 9.8 24.9
-25 -31.7 -3.4 -23.4 6.9 17.5
-20 -28.9 -1.8 -12.5 3.7 9.4
-18 -27.8 -1.1 -7.8 2.3 5.8
-16 -26.7 -0.4 -2.7 0.8 2.0
-14 -25.6 0.4 2.8
-12 -24.4 1.1 7.6
-10 -23.3 1.9 13.1
-8 -22.2 2.8 19.3
-6 -21.1 3.6 24.8
-4 -20.0 4.6 31.7
-2 -18.9 5.5 37.9
0 -17.8 6.5 44.8
2 -16.7 7.5 51.7
4 -15.6 8.5 58.6
6 -14.4 9.6 66.2
8 -13.3 10.8 74.5
10 -12.2 11.9 82.0
12 -11.1 13.1 90.3
14 -10.0 14.4 99.3
16 -8.9 15.7 108.2
18 -7.8 17.0 117.2
20 -6.7 18.4 126.9
22 -5.6 19.9 137.2
24 -4.4 21.3 146.9
26 -3.3 22.9 157.9
28 -2.2 24.5 168.9
30 -1.1 26.1 180.0
32 0.0 27.8 191.7
34 1.1 29.5 203.4
36 2.2 31.3 215.8
38 3.3 33.1 228.2

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0100 SRM 2107 Maintenance Procedures and Required Equipment

Table 7. R134a Temperature - Pressure Chart (Continued)

Temperature Pressure Vacuum
°F °C PSI kPa Inch Hg cm Hg
40 4.4 35.0 241.3
45 7.2 40.1 276.5
50 10.0 45.4 313.0
55 12.8 51.2 353.0
60 15.6 57.4 395.8
65 18.3 64.0 441.3
70 21.1 71.1 490.2
75 23.9 78.7 542.6
80 26.7 86.7 597.8
85 29.4 95.2 656.4
90 32.2 104.3 719.1
95 35.0 114.0 786.0
100 37.8 124.2 856.3
105 40.6 135.0 930.8
110 43.3 146.4 1009.4
115 46.1 158.4 1092.1
120 48.9 171.2 1180.4
125 51.7 184.6 1272.8
130 54.4 198.7 1370.0
135 57.2 213.6 1472.7
140 60.0 229.2 1580.3
145 62.8 245.7 1694.0
150 65.6 262.9 1812.0

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 NOTES

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 TECHNICAL PUBLICATIONS

0100 SRM 2107 12/17 (11/17)