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RigMaster Power Service and Repair ManualDocument # S1001009

Copyright RigMaster Power by Mobile Thermo Systems Inc. 09-28-09

S10.0 Air Conditioning System Overview

Figure 10-1 Figure 10-2

Location Description

A HVAC Intake FilterB Blower Motor (278 CFM)C Air Conditioning Expansion ValveD Electronic Coolant Control Valve

NoteSome of the information contained within this guide has been sourced from the Sanden SDService Guide. The Sanden service guide is available for download from the RigMaster supportmaterials section. It is advised to use both the RigMaster Service Manual in conjunction withthe Sanden service guide.

The RigMaster APU air conditioning system is similar in design to most automotive systems.General automotive air conditioning diagnostic techniques will apply to the RigMaster APU’sdesign.

WARNING

This air conditioning system must be serviced by qualified personnel, who arefamiliar with air conditioning and refrigeration systems, refrigerants and the dangersof pressurized components.

Avoid breathing a/c refrigerants and lubricant vapour mist. Exposure may irritateeyes, nose and throat. To remove R134a from the system, use equipment certified tomeet the requirements of SAE j2210. If accidental system discharge occurs, ventilatethe area before resuming service.

The RigMaster APU requires a large volume of airflow in order to maintain proper operatingtemperatures. Running of the air conditioning system with the cover removed may result inoverheating of the system.

CAUTIONCross contamination with other refrigerants will cause damage to this air conditioningsystem.

A

BC

DD



NOTEIt is recommended that the receiver-dryer be replaced whenever air conditioning componentsare replaced or the system is breeched. If the system becomes contaminated or if it is open foran extended period of time, it is recommended that the system be flushed using an airconditioning flushing agent.

The RigMaster APU is shipped with the air conditioning system capped to reduce the possibilityof contamination, which may result from extended storage of the unit.

An aluminum condenser is used in the air conditioning system for its optimum heat exchangeproperties. Care should be taken when connecting and removing the air conditioning linesbecause of the brittle nature of aluminum.

NOTE

WD-40 should be used to prevent corrosion between aluminum and steel fittings.

Air Conditioning System Operation and Specifications

The RigMaster APU’s A/C system uses EPA approved R-134a refrigerant. R-134a is a very lowtemperature refrigerant used to effectively remove excess heat and moisture from the sleepercab of the truck.

The A/C compressor is belt driven by the APU’s diesel engine. The compressor operates onlywhen the magnetic clutch activates engaging the belt driven pulley. The R-134a refrigerant iscompressed into a high pressure gas which is discharged out through the high pressuredischarge hose and force to flow into the condenser and on to the balance of the A/C system.

The refrigerant exiting the discharge port has excess heat added due to the compression of thegas charge. The excess heat is removed to the outside air through the use of a condenser.Ambient air flowing through the condenser by way of the electric fan removes heat from the highpressure gas which condenses into a high pressure liquid. The high pressure liquid then flowsthrough a receiver/drier to remove any moisture from the refrigerant prior to flowing to theexpansion valve.

The expansion valve is a variable orifice that divides the high and low pressure sides of the A/Csystem. It is placed in the liquid side of the system between the condenser and evaporator. Byallowing small amounts of high pressure liquid refrigerant to pass through the valve, thepressure is lowered creating a low pressure liquid flowing to the evaporator. When the liquidrefrigerant enters the evaporator, hot air passes into the HVAC module and through theevaporator core which causes the refrigerant to boil. The boiling refrigerant absorbs the heatfrom the ambient air and draws water vapour onto the core to condense into liquid water. Theevaporator core temperature is regulated between 30° to 42°F for effective cooling. Therefrigerant then turns into a low pressure gas that flows back out the other side of the expansionvalve, down the suction line, back to the compressor. Depending on the temperature of theexiting low pressure gas, the expansion valve can vary the size of is orifice to allow more or lessrefrigerant to pass into the evaporator insuring that all the liquid refrigerant boils off into a lowpressure gas.



The following schematics detail the circuit that supplies the air conditioning compressor withpower. The electric condenser/radiator fan is integrated into this circuit. On all RigMaster RMPand RMC models the electric fan takes power from the AC clutch connector at the receiver drier(Figure 11-4). On all MTS T4-6 models the power for the electric condenser fan is taken fromthe 12V supply at the power module to the AC circuit before the thermostatic cycle switch(Figure 11-3). For more information on the electrical circuit that controls the electric fan pleasesee section S10.1. For more detailed schematics see section S8.5.

Air Conditioning Electrical Circuit Diagram (MTS Models)

Figure 10-3

Air Conditioning Electrical Circuit Diagram (RMP/RMC Models)

Figure 10-4



Location Component Operation

A Cabin ControllerHouses the climate control thermostat and sends

signals to the power module to control the ON/OFFcycle of the compressor

B Power Module

Receives inputs from the cabin controller andoutputs voltage through the J1 connection point

(green wire, pin number 2) to the evaporatorthermostatic switch to power the AC system

CEvaporator

ThermostaticSwitch

Monitors the temperature of the evaporator andregulates power to the binary pressure switch to

prevent the evaporator core from freezing

DBinary Pressure

Switch

Allows voltage to pass to the compressor and ACcontrolled fan relay when the pressure in the

system is within an acceptable range (between 28and 450 PSI)


E7.5 Amp

Compressor FuseFuses the AC compressor

F CompressorReceives its power from the binary switch through

7.5 amp in-line fuse

GAC Controlled Fan

Relay

Receives its signal from the binary pressure switchwhen energized and ensures the electric fan runs

when the compressor is active

H35 Amp Electric

Fan FuseFuses the electric fan

I Receiver/Dryer Removes moisture from the refrigerant

Engine Temperature Switch Circuit


JCoolant

TemperatureSwitch

Outputs signal voltage to the engine temperaturecontrolled fan relay when the engine reaches

195°F

K

EngineTemperature

Controlled FanRelay

Receives its signal from the coolant temperatureswitch ensuring that the electric fan operates when

engine temperature rises above the switchesthreshold. (See figure 11-2)

L35 Amp Electric

Fan FuseFuses the electric fan

M Electric Fan Cools the radiator and/or the condenser

NOTE

For additional information on engine cooling refer to S7.0

Cautionary Information



When servicing or repairing any air conditioning system it is highly advised to take someprecautionary measures for your own safety as well as the safety of others.

Pressure Release

Prior to the removal of any AC lines or oil drain cap, make sure to relieve the AC systempressure by recovering the refrigerant with approved AC recovery equipment.

When working on a compressor, separate from the AC system, make sure to relieve the internalpressure in the compressor by removing the shipping caps/pads from both ports.

Refrigerant Recovery

Never release refrigerant to the atmosphere. Always recover refrigerant using approvedrecovery equipment. Never mix refrigerants from different systems using different refrigerants.Use separate equipment for different types of refrigerants. While R134a used in RigMaster ACsystems has zero potential to damage ozone it does have global warming potential.

Handling Refrigerant

Always wear eye and hand protection when working with refrigerants. Liquid refrigerants cancause frostbite and/or blindness if release into exposed eyes or skin.

Ventilation

Keep refrigerants and oils away from open flames. Work in well ventilated areas as refrigerantscan produce poisonous gases when coming in contact with open flames.

Avoid Use of Compressed Air

Never use compressed air in an AC system as this can introduce contamination to therefrigerant.

Proper Handling of R134a and PAG oil

Always follow proper safety precautions Never discharge R134a into the atmosphere Never mix R134a with any other refrigerants Use only specified PAG oil PAG oil can absorb atmospheric moisture. Never leave a bottle of PAG oil open.

Reseal the container after use. Cap all open AC hoses and fitting connections immediately to prevent contamination and

remove only when ready to reconnect fittings When repairing AC systems, vacuum the system for 30 minutes to remove any and all

accumulated moisture from the PAG oil within the system.



Table of Saturation Temperatures and Pressures (R-134a)

Temp. (F) Pressure

(psig)

Temp. (F) Pressure

(psig)

Temp. (F) Pressure

(psig)-40 -7.2 in. Hg 25 22 105 135

-30 -4.8 in. Hg 30 26 110 147

-20 -1.7 in. Hg 40 35 115 159

-15 0 50 45 120 172

-10 2 60 57 130 200

-5 4 70 71 140 231

0 6 80 85 150 264

5 9 85 95 160 301

10 12 90 104 180 386

15 15 95 114 200 485

20 18 100 124 210 549

Using and Understanding Pressure Gages

The best way to diagnose a customer’s A/C concern is to first operate the system under theconditions the complaint was made. Operate the system for no less than 5 to 10 minutes withpressure gages connected. Check the pressure gages and note the maximum high sidepressure and minimum low side pressure. As well, place a thermometer into the vent andrecord the air temperature coming out with the fan on high speed. A correctly working A/Cshould see between 35 - 45º F coming out of the vents depending on the ambient temperatureand humidity.

By utilizing your gages, you can read and best understand what is happening with the A/Csystem. A simple quick check to see if the system is even working correctly is to feel the highand low pressure lines. The high pressure lines should be hot to the touch while the lowpressure lines will feel ice cold. This will give you a quick indication if the system is workingcorrectly.

Checking the service manual, note the operating pressures of both the high and low side of theA/C system. Then compare with your gage readings. Keep in mind that the ambienttemperature and humidity will have an effect on system pressures. You will see higherpressures on hotter days than on cooler days depending on heat load. With your recordedpressure and temperature readings you can then utilize the correct diagnostic sheet for troubleshooting.

With your recorded pressure and temperature readings you can then utilize the correctdiagnostic sheets (S11.1) and the Air Conditioning Performance Chart.

High Pressure vs. Temperature ReadingsHigh temperatures and pressures are approximate. Readings within 10-15% of figure 11-5, willdeliver acceptable performance. See Chart next page.



Air Conditioning Performance

AIR CONDITIONING SPECIFICATIONSRefrigerant Type R134aVolume of Refrigerant: 2.2 lbs; 35oz; 0.95 kgCompressor Oil Type SP-46 PAG Compressor OilAir Conditioning System Oil Capacity 7.0 fl oz; 207 cc; 207 ml

Air Conditioning System Hoses and Components Diagram

Suction Pressures – Low SideCommon low side pressure will be between 15-40 PSI depending on the ambienttemperature and humidity.

Figure 10-6

Figure 10-5



LEGEND PRESSURE Part Number

A Condenser HighRP9-002K or

RP9-011

B Compressor High/LowRP9-128K or

RP9-132

C Receiver Dryer HighRP9-027 orRP9-027B

D Evaporator High RP9-201

EEvaporator Core Temperature Probe[Thermostatic Switch]

High/Low RP9-113

F Bulkhead Section of Frame N/A RP10-001-1AG Evaporator to Bulkhead High RP9-404H Evaporator to Bulkhead Low RP9-405I Receiver Dryer to Bulkhead High RP9-403J Compressor to Bulkhead Low RP9-401K Condenser to Receiver Dryer High RP9-402L Compressor to Condenser High RP9-400M Expansion Valve High/Low RP9-112



S10.1 Air Conditioning Diagnostics

Get as much information about the unit as possible. (i.e. service/maintenance records).

1. Operate the system to verify the customer’s complaint.2. Check and note for proper operation of the system. Does the A/C compressor turn on?

Touch both the suction and discharge lines. Are the discharge lines hot? Are the suctionlines cold? Does the compressor cycle? Does the electric fan turn on? What is thetemperature at the vents?

3. Check for missing or loose belts or a seized compressor.4. Check around compressor clutch and surrounding area for signs of oil leaks and dirt.5. Check the A/C lines for visible signs of leaks or cuts.6. Check for loose or broken electrical connections. Check for broken or chaffed wiring.7. Check compressor clutch. Ensure that it working properly. Follow diagnostic chart A

CAUTIONShould you be required to jump power to the A/C compressor to operate the system,doing so directly at the clutch can lead to damage to the compressor. Use the terminalsat the thermostatic switch on the HVAC box. Jumping power to the circuit from thislocation will allow the binary switch to disable the compressor should system pressuresexceed specifications. If bypassing the thermostatic switch, watch for frost build up onthe expansion valve. This is a sign of the evaporator core freezing up.

Leak Testing

There are many methods of leak testing the AC system and all are valid means of testing forleaks.

Soap Bubble Detection (Gross Leaks)1. If the system has a charge you can use this method. If the system has lost its charge,

pressurize the system to 100 lbs with dry Nitrogen.2. Listen for hissing, look for bubbling using a soapy solution.3. Use a soapy water solution to help identify leaks

Leak Detection Equipment

1. Make sure the leak detector is calibrated to detect R134a. R12 leak detectors cannot detectR134a leaks.

2. Use the detector as per the manufacturer’s instructions.3. Ensure that the detected leak is a flow of R134a and not a pocket of trapped refrigerant.

Cleaning the area with soap, not solvents, or blowing compressed air will confirm if there is aleak.

NOTE

The most common air conditioning problem is leakage. If there are no obvious sign of leaking,test the system with either nitrogen or leak tracing dye.



Leak Detection Dye

When first installing a RigMaster APU, leak detection dye can be added upon initial charge ofthe system. The dye stains the oil and in the event of a small leak the dye can be visible withthe use of an ultraviolet light. If installing the dye with the initial charge after installing aRigMaster APU, tag or label the system to inform others that the AC system has leak detectiondye already added.

Unusual Noise Not Due to Compressor

Many components in the drive system other than the compressor can make noises. Check thefollowing:

1. Loose belts (See Section 2 for belt tension) or weak auto tensioner.2. Broken adjustment arm, worn out pivot block or damaged compressor ears.3. Missing, loose or broken mounting bolts4. Proper fit of compressor to mounting bracket or bracket out of alignment.5. Loose or wobbling drive pulley.6. Bad idler pulley bearing.

Unusual Noise Due to Compressor

1. Suction pressure below 6 psig can cause unusual noise. Ensure system has propercharge and test system by applying heat to the evaporator to increase suctionpressures.

2. Clutch bearing.3. Insufficient oil levels in the AC system can cause unusual noise.4. Compressor suction or discharge valve breakage.

Diagnosis and Confirmation of Compressor Failure

The AC compressor is the most expensive components in the AC system. The following stepscan be used to verify the correct operation of the AC compressor and to help avoid replacementof a good compressor.

Compressor Rotation Test

Turning of the compressor clutch by hand can indicate issues with internal components.The compressor clutch should turn smoothly with binding or catching.

Binding or hanging of the AC clutch is an indication of internal component damage. Thecompressor should be removed and replaced with a new unit.

Clutch Inspection (voltage check)

Using a digital volt meter, check at the connector to the AC clutch for applied voltage. Thereshould be no less than 11.5V applied to activate the clutch. With the clutch engaged the pulleyshould spin freely with no wobbling or vibration/roughness.



Clutch Inspection (resistance check)

Field coils with internal shorts should be check using a digital ohm meter. Resistance valuesshould fall between the following spec:

Resistance value at room temperature2.8 to 4.4 Ω

Diagnostic Selection Sheets

Chart ANo A/C compressor operation.

Chart BLow side and high side pressure normal but outlet temperature too warm.

Chart CLow side pressure is higher than spec, high side pressure within or below spec.

Chart DBoth low and high side pressure higher than spec.

Chart EHigh side pressure greater than spec, low side pressure within or lower than spec.

Chart FHigh side pressures low, low side pressures at or near vacuum.

Diagnostic Chart A

Symptom

A/C compressor is inoperative.

Possible Causes.

Low gas pressures. Possible faulty thermostatic switch. Possible faulty binary switch. A/C clutch or compressor failure. Possible faulty power module

Diagnostics

1. Inspect the 7.5 A fuse in the fuse holder. If the fuse is ok, disconnect the harness at theA/C compressor and using a test light, check if power is going to the compressor clutch. If



no power is going to the clutch inspect the wiring in the harness for any breaks or chaffedwires. Inspect the connector for any loose or poor connections. If power is present to theclutch then the A/C clutch is faulty. Replace the compressor..

2. If no power is present at the compressor clutch connector, check for voltage at the binaryswitch on the receiver/dryer. If no voltage is present on the blue wire to the binary switch,check for a broken wire or loose connection. If there is voltage to the binary switch on theblue wire but no power out of the switch, connect a set of pressure gauges and check tomake sure there is more than 28 psi pressure to close the binary switch. Use the chartbelow to determine static system pressure based on temperature.

Temp. (F) Pressure

(psig)

Temp. (F) Pressure

(psig)

Temp. (F) Pressure

(psig)-40 -7.2 in. Hg 25 22 105 135

-30 -4.8 in. Hg 30 26 110 147

-20 -1.7 in. Hg 40 35 115 159

-15 0 50 45 120 172

-10 2 60 57 130 200

-5 4 70 71 140 231

0 6 80 85 150 264

5 9 85 95 160 301

10 12 90 104 180 386

15 15 95 114 200 485

20 18 100 124 210 549

If there is more than 28 psi to close the switch then the binary switch faulty. Replace thebinary switch. If there is less than 28 psi in the system then follow the procedure tocheck for leaks and reseal the system.

3. Check for voltage from the power module at connector J1, pin #2 to the thermostaticswitch. If no voltage is present on the switch circuit, the power module is faulty. If novoltage is present after the switch or, is short cycling on and off, then the thermostaticswitch is faulty. Replace the switch

Diagnostic Chart B

Symptom

Low side and high side pressure normal but outlet temperature too warm.

Possible Causes

Poor or restricted air delivery. Low system charge. Contaminated refrigerant.



Diagnosis

1. Check HVAC box and make sure air filter is not plugged. Check HVAC box hasadequate air flow with no blockage or restrictions. Check return air vent holes are notblock or restricted.

2. Inspect and feel both high and low side A/C lines. The suction line should be cold to thetouch. The discharge line should be hot. If:

Discharge line is hot. Suction line is cool or warm.

This is an indication the system has a low system charge. Recover system charge to findhow much is missing. Either charge with nitrogen or recharge with refrigerant and add leakdye to the oil to find leak and repair. Recharge A/C system and proceed to step 4.

3. If: Discharge line warm to hot. Suction line cool to warm.

This is an indication the A/C system may have been contaminated with either foreign gas ortoo much air. Using an A/C machine, test the refrigerant during recovery. If foreign gas isfound, recover refrigerant to a scavenging tank. If the system has too much air simplyrecover and recharge, then proceed to step 4.

4. Run A/C system and check outlet temperatures.

Outlet temperatures still too high.

The A/C system has too much oil. Recover the system of refrigerant, drain the A/Ccompressor of all oil and replace filter/drier. Attempt to drain condenser of all oil. Ifcondenser cannot be drained and cleared of oil, replace condenser. Vacuum A/C systemand add 5oz of PAG oil to system then charge with refrigerant.

Diagnostic Chart C

Symptom

Low side pressure is higher than spec, high side pressure within or below spec.

Possible Causes

System is under charged. Malfunctioning A/C compressor.

Diagnosis

1. Check and feel A/C discharge and suction lines. The suction line should be cold to thetouch. The discharge line should be hot. If:



Discharge line warm to hot. Suction line cool to warm.

Recover refrigerant from system using an A/C machine. If the system charge is low, checkthe system for leaks using either nitrogen or A/C leak dye. Repair any leaks found andrecharge system.

2. If system charge is ok then there is a malfunction in the A/C compressor.

Diagnostic Chart D

Symptom

Both low and high side pressure higher than spec.

Possible Causes

Restricted condenser air flow. In-operative cooling fan. Malfunctioning expansion valve. A/C system overcharged.

Diagnostics

1. Start the A/C system and check for: Electric cooling fan operation. The electric fan relay takes power from the A/C clutch at

the binary switch.

2. Visually inspect condenser for:

Damaged or missing fins. Blocked or restricted air flow.

3. Feel the high pressure liquid line both before and after the expansion valve.

If the liquid lines on either side of the valve have similar temperatures the expansionvalve is faulty.

Replace the expansion valve.

If the high pressure liquid line on either side of the expansion valve has differenttemperatures.

The A/C system is either overcharged or has air in the system. Recover system andrecharge with correct amount of refrigerant. Operate the system and verify repair.



Diagnostic Chart E

Symptom

High side pressure greater than spec, low side pressure within or lower than spec.

Possible Causes

Restrictions in the lines. Debris in the system.

Diagnosis

1. Follow along and feel the following high side components:

Compressor discharge hose. Condenser. Liquid line between the condenser and expansion valve.

Feel for an abrupt change in temperature throughout the lines. Any abrupt change intemperature would indicate a blockage. Remove the blockage or replace the component. Ifno abrupt change in temperature is felt then proceed to step 2.

2. Feel the liquid line at the expansion valve and inspect for:

Extreme cold temperatures before the expansion valve. Warm temperatures after the expansion valve. Heavy frost build up at the valve.

If this condition is found, replace the filter/drier and expansion valve and inspect for metalflakes. If present, remove compressor hoses and blow out with shop air. If large amounts ofmetal flakes are present, replace the condenser and back flush the A/C system. If notproceed to step 3.

3. Feel the suction line from evaporator to compressor as well as compressor discharge hoseand condenser.

If any of these components are mildly warm check for a restriction or blockage at thecompressor suction port.

If debris is found removed debris and inspect filter/drier and expansion valve for debris. If debris is present, replace the drier, expansion valve and condenser.

Back flush the A/C system and charge.

Diagnostic Chart F

Symptom

High side pressures below spec, low side pressures at or near vacuum.

Possible Causes



Faulty expansion valve Faulty compressor

Diagnosis

1. Recover the AC system and replace the expansion valve. Test operation of the ACsystem and note pressures. If no change in system pressures, most likely cause is astuck reed valve in the compressor on the discharge side. Replace the compressor.



S10.2 AC Flushing Procedure

Equipment Types

1. Refrigerant recovery machines with a solvent recirculation pump to clean R134asystems.

2. A closed loop recirculation machine which circulates a cleaning solvent to a containerwith a filter

3. A pressurized solvent gun with pulsating spray.

Safety

Always were eye protection and gloves when flushing an AC system of debris. Do not useunapproved cleaning agents or flammable liquids to flush the AC system. Do not use R11, 113or 115 and Methyl Chloroform as they are not acceptable as per the Clean Air Act.

Components to Flush

Flush all AC lines, hoses and heat exchangers. DO NOT flush the compressor, drier orexpansion valve as the residual cleaning solvent cannot be removed from these components.

Why Suction Side Flushing is so Important

When the off cycle pressure equalizes back through the damaged valves of the compressor,this can force debris back up into the system on the suction side which can be pulled back intoany new compressor installed.

Importance of Flushing Direction

“Back flush”, or flushing in the reverse direction to normal flow, is the most effective. Theplate fin evaporators used on many front and rear evaporators have many small passageswhich are difficult to clean without a strong pulsating reverse flow.

How Long Do I Flush

Closed loop procedure, flush until the flushing fluid leaving the AC components are clean.Manual pressurized gun method requires a minimum of three times, but more if exiting fluid isnot clean.

Removal of Residual Flushing Fluid before Evacuation and Charge

The primary vacuum pump should be protected from flushing fluid and fumes. Purging offlushing solvent is necessary before connecting the recovery recycle machine to evacuateand charge the AC system. The best method is to allow Nitrogen to flow through thecomponents. If Nitrogen is not available, clean and dried compressed air can be blownthrough the flushed components until the flush liquid is evaporated.



10.3 Compressor Replacement (V Belt)

Figure 10-7

A. Compressor adjusting bolt and oversized washerB. CompressorC. Compressor mounting blockD. Compressor pivot bolt

1. Loosen the compressor adjuster bolt and pivot bolt and remove the belt.2. Disconnect the wiring harness.3. Evacuate the refrigerant using approve recovery equipment.4. Remove the high and low pressure lines from the manifold.5. Remove the adjuster bolt and pivot bolt from the adjuster arm and pivot block and

remove the compressor.6. Remove the drain plug on the old compressor and drain as much oil as possible into a

suitable container. Drain the ports of the old compressor by turning the clutch using asocket wrench and measure the total amount of oil from the old compressor.

7. Drain the new compressor of all oil just as in step 6.8. Add back the amount of oil measured from the old compressor in step 6 and re-install

the drain plug on the new compressor. (11-15 ft/lb)9. Install and the new compressor.10. Inspect and reinstall the V belt. (see Section 2.5)11. Reinstall the high and low pressure hoses.12. Reconnect the wiring harness.13. Vacuum and recharge – pressure test if a leak is suspected.14. Start the APU and test the air conditioning system.

A

BC& D



S10.4 Compressor Replacement (Serpentine Drive System)

NoteThis compressor does not pivot and the belt is automatically tensioned.

1. Remove serpentine belt.2. Disconnect the wiring harness. (A-Figure 10-8)3. Evacuate the refrigerant using approve recovery equipment and note the amount of oil

drained from recovery.4. Remove the high and low pressure lines from the manifold.5. Remove the (4) mounting bolts, flat washers and lock-washers and remove the

compressor.6. All new compressors are shipped with oil which can be found on the manufacturers tag.

The desired amount of oil needed for the AC system is 7 fl/oz (207 cc)7. Compare the shipped amount of oil in the compressor with the desired amount of oil

needed for the AC system. If additional oil is required, open the drain plug and add theamount needed to bring the total oil volume to the desired amount. If there is too muchoil, then drain the compressor of oil to the desired amount.

8. Install and bolt down the new compressor to 37 ft.-lbs. (50 N-m). .9. Inspect and reinstall the serpentine belt. (see Section 2.5)10. Reinstall the high and low pressure hoses.11. Reconnect the wiring harness.12. Vacuum and recharge – pressure test if a leak is suspected.13. Start the APU and test the air conditioning system.

Compressor Mounting Hardware

Figure 10-8

A: Hex Head Mounting BoltB: Lock WasherC: Flat Washer

Component Torque Spec.Compressor 37 lb ft (50 N m)

Oil Drain Plug11 – 18 ft/lb (12 – 25

Nm)ABC



S10.5 Air Conditioning Hose Installation

CAUTIONDo not put excessive stress on air conditioning hoses as it may result in leaks and

possible failure of the fittings.

NOTE

Very fine particles of foreign matter are capable of preventing an o-ring from sealing aconnection properly. Install only clean o-rings. It is recommended that all o-rings belubricated to prevent accidental tearing during installation.

Evaporator Lines (Bulkhead to HVAC)

Remember to use a wrench to hold the fitting on the inside of the bulkhead when tightening thefitting on the outside of the bulkhead; this will prevent the fitting on the inside from rotating out ofalignment.

1. Install the two #6 o-rings on the #6 refrigerant hose (RP9-404) and connect it to the bulkheadfirst. Hand-tighten the fitting and torque to between 21 and 27 ft-lbs. Route the hose andconnect it to the expansion valve. (21-27 ft-lbs)

2. Install the two #10 o-rings on the #10 refrigerant hose [RP-9405] and connect it to thebulkhead first. Hand-tighten the fitting and torque to between 21 and 27 ft-lbs. Route thehose and connect it to the expansion valve. (21-27 ft-lb).

3. Excess hose must be secured and allow for movement of the cab. Install the hoses with thecab air suspension inflated. After installation, deflate the air suspension and inspect hoseclearances for potential problems. A/C hoses should not be under twisting or flexingstresses after installation as this may cause fittings to leak and/or break.

Figure 10-9 Figure 10-10

#10

#6

Expansion Valve

Bulkhead

Connections HVAC Connections



Dual Clamp Tie

The air conditioning lines RP9-400k and RP9-401k are sold with a dual clamp tie which shouldbe used to prevent the lines from rubbing together and creating a potential cause for failure.The clamp tie can also be ordered separately under the part number (RP9-406).

Compressor Connections

Figure 11-10

The dual clamp tie should be fitted as shown in figure 11-10. Notice that there are spacesbetween the hoses and the engine to prevent rubbing.

Engine Compartment Connections

Compressor to Condenser Hose [RP9-400]

1. It is recommended that all o-rings be lubricated to prevent accidental tearing duringinstallation.

2. Carefully thread and hand tighten the hose at both ends.3. Tighten the condenser fitting (15-20 ft-lb). Use two wrenches so excess stress is not placed

on the condenser resulting in damage.

Bulkhead to Compressor Hose (RP9-401)

1. Attach hose, carefully treading and hand tighten fitting ensuring it is facing upward.2. Leave approximately a ¼” gap between the condenser hose and fitting.3. Carefully tighten fitting being careful not to crush O-ring. (21-27 ft-lb)4. Tie wrap the hoses together approximately 8” above compressor.

Receiver/Drier to Bulk Head Hose (RP9-403)

1. Loosen receiver/dryer clamp. Ensure binary switch is facing toward the bottom right cornerof the unit.

2. Attach hose to receiver/dryer and hand-tighten. Ensure the compression fitting is properlyseated in the receiver/dryer before tightening. (11-13 ft-lb)

Notice the gaps between the

AC hoses and engine



Receiver/Dryer to Bulkhead Connection

Figure 11-11

NOTEThere should be a cable tie holding the radiator hose and the air conditioning line togetherabove the engine fan. Ensure that the hoses are not pinched in a way that restricts coolant orrefrigerant flow.

Figure 11-12

Condenser to Receiver/Dryer Hose (RP9-402)

1. Attach hose to both ends and hand-tighten. Ensure the compression fitting is seated in theReceiver Drier. (See Figure 11-11)

2. Raise Receiver Drier about 5/8” from frame ensuring no stress is put on the attached airconditioning lines (See Figure 11-13) and tighten clamp.

Receiver/Dryer

Binary Pressure Switch

Wire Tie on Coolant and AC Hose

Notice the wire tie holding the

AC hose to the coolant hose.

Bulk Head Hose Connection



Receiver/Dryer Alignment

Figure 11-13

3. With the fitting facing downward in the 6 o’clock position. Use two wrenches to tighten thecondenser side of the hose, ensuring not to put stress on the condenser.

4. Tighten the remaining receiver drier hoses ensuring proper placement of the fitting angles(11-13 ft-lb). The receiver drier should be in the 2 and 7 o’clock position with the hosesaligned as to minimize stress on the fittings. (See Figure 11-14)

NOTEWhen installing the AC hose that connects the condenser to dryer (RP9-402), ensure that thefitting on the dryer is turned such that the hose does not contact the front cover or the othercompressor hoses.

Receiver/Dryer Connections

Figure 11-14

5/8” Gap

Bulkhead connection to

the receiver/dryer is at the

2 o’clock position and the

condenser connection is

at the 7 o’clock position.

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