4650 and 4850 Section 90

l OPERATOR STATION REPAIR
Section 9O
CONTENTS
GROUP 05 - AIR CONDITIONING SYSTEM GROUP 06 - AIR CONDITONING SYSTEM

SERVICE
Specral Tools 90-05-0 Special Tools
1
90-06-01
Olher L4aterials 90-05-01 Other lvlaterials 90-06-01
Service Parts Kits For Compressor ...... 90-05-01 Specrticatrons 90-06-02
Compressor Specifications .... 90-0 5-02 Servicing 90-06-03
Hose and Tubing Flare Connection Determining Flelrigerant Oil Charge ...... 90-06-04
Torques. 90-05-02 Addrng Fefrrgerant Oil .... 90-06-05
Hose and Tubing O-ring Connection Flushing the System . 90-06-09
Torques. 90-05-03 Purging the Sysrem . 90-06-09
Cap Screw Torque Chart ..... 90-05-03 Evacuating the System 90-06-10
Servrcrng Flefngerant Couplings 90-05-04 Charging the System 90-06-11
Discharge the System 90-05-0 5
Compressor GROUP 1O - HEATING SYSTEM
Remove. 90-05-05
Drssemble and Inspect 90-05-08 Feplace Heater Control Valve 90-10-01
Replace Clutch Pulley Bearing ........ 90-05-12 Feplace Heater Hoses ...... 90-10-02
Replace Shaft Seal Seat . . .. 90-05-13
Assemble 90-05-14 GBOUP 15 . SEAT
Servicing l\,4anrfolds 90-09-16
Install Compressor ....... 90-05-16 Specifications 90- J 5-01
Tests Other Tools .. ...... ... 90-15-01
Volumetflc Efticiency 90-05-06 Remove Hydracushioned Seat 90-15-01
ShaftSeal Leak . . . . . . . . . . . . 90-05-07 Remove Vertical Suspension
Condenser Assembly 90-15-02
Remove. 90-05-18 Disassemble. Inspect. and Fepair
I eak Test 90-05-19 Vertical Suspenston Assembly ........ 90-15-02
Install ... 90-05-20 Assemble Vertical Suspension
Fleceiver Dryer Assembty 90-15-05
Replace. 90-0 5-20 Remove Horizontal Suspension
Evaporator/Heater Core Assembly 90- 15-06
Fiemove. 90-05-21 Disassemble, lnspect, and Repair
Test and Install .. 90-05-22 Horizontal Suspension Assembly ...... 90-15-07
Servicing Expansion Valve .. 90-05-24 Assemble Horizontal Suspension
Air Conditoning Timer Relay Assembly 90-1 5-10
Fleplace. 90-05-26 Install Seat and Vertical
Servicing Temperature Control Su spensio n 90-15-10
Switch . . 90-0 5-2 7 Remove, Repair and Install
Compressor RelieJ Valve Deluxe Seat 90-15-1 1
Service. 90-05-28 Disassemble and Inspect Deluxe
Air Filters Seat Support Assembly 90-1 5-12
Remove. 90-05-28 Assemble Deluxe Seat
Clean and Install .. 90-05-28 Support Assembly 90- 15-14
Litho in u.s.A. 90-01 TM-1354 (Sep-87)

CONTENTS-Continued
GROUP 15 - SEAT-Continued GROUP 20 . MISCELLANEOUS COMPONENTS
Disassemble and Repair Special Tools 90-20-01

Deluxe Seat Suspension 90-1 5-14 Other lvlaterials 90-20-01
Assemble Deluxe Seat Repair SOUND-GARDrv Body 90-20-02
Suspensron 90-15-'16 Replace Curved Glass . . . 90-20-03
Grammar Seat Suspension Replace Flat Glass . . . 90-20-04
Flemove/lnstall 90-15-17 Remove SOUND-GAFD Body
Repair .. 90-15-17 Door and Stop .... 90-20-05
Remove Upper Housing Plate 90-15-18 Replace Door Hinges .. ....... 90-20-06
Remove Arm Assembly 90- 15-1 9 Service Auxiliary Door ... ..... 90-20-06
Disassemble Weight Adjuster 90-15-22 Service Door Handle . ........ 90-20-07
Replace Seat Base Wear Strips ....... 90-15-24 Bemove Inner and Outer Roof .......... 90-20-08
Replace Weight Strip . . . 90-15-25 ....
Install Inner Roof 90-20-09
Assemble Weight Adjuster 90-1 5-26
Lrtho in u.s.A. TM-1354 (Sep-87)

Group 05
AIR CONDITIONING SYSTEM
SPECIAL TOOLS
NOTE: Order tools from your Service-Gard Catalog, unless otherwise indicated.
Number Name use
D-18009KD Electronic Leak Detector Detect Relrigerant Leaks

D-18019KD l,4anifold Pressure Gauge Set Test Air Conditioning System
JDG-1 16 clutch Hub Puller Pull Compressor Clutch
JDG- 1 17 Clutch Holding Tool Hold Compressor Clutch
JDG.219 Key Driver Install Key
JDG.22O Driver Pull Compressor Clutch
JDG-221 Driver Removal & Installation of Pulley Bearing
JDG-225 Support Install Compressor Pulley Bearing
Hex Head Adapter Removal & Installation of Compressor Head
Pu ller Pull Valve Plates From Head
JDG-228 Driver Removal & Installalion of Seat From Head
JDG-229 Driver Install Seal Seat in Head
OTHER MATERIALS
Name U9e
Refrigerant- 1 2 Charge system.
525 Viscosity Compressor Oil Syslem Lubrication.
SERVICE PARTS KITS FOR COMPRESSOR
The lollowing kits are available for service parts:
Compressor Shalt Seal Kit

Compressor Clutch Hub Kit
Cornprocoor Cl(.rtoh pqll€y Ki(
Compressor Hardware Kit
Litho in U.S.A. 90-05-01 TI/-1258 (Dec-83)

Air Conditioning System
COMPRESSOR SPECIFICATIONS
Item Measuiement Specifacation
Hublo-Pulley Clearance 0.55-1.05 mm

(0.022-0.041 in)
Compressor O'l Charge 330 mL (1 1 fL oz.)
Discharge Pressure (at 2000 rpm) .. . .. 690-2070 kPa (7-20 bar)
(100-300 psi)
Suction Pressure (at 2000 rpm) 7 -24O kPa (0.07-2.4 bar)
(1.0-35 psi)
Clutch Coil Current draw at 12 volts,
20"c (68'r) 2.8-3.5 amps
Resrstarce at 20'C (68 F) 2.8-4.5 ohms
Oil Charge Quantity . 330 mL (1 1 f l. oz.)
Drive Bell Tension (new) 578-622 N (130-140 lb force)
(after run-in) 378-423 N (85-95 lb lorce)
Compressor Relief Valve Opening Pressure 3030 kPa (30 bar) (4a0 psi)
Compressor Suction Line Torque 31 Nm (23 lbjt)
Compressor Discharge Line Torque 22 N m (16 lbjt)
Compressor Adiusting Bolt
Torque 45 Nm (33 lb-ft)
Hub Retaining Nut ...... Torque 16 N m (12 lb-ft)
Compressor Through-Bolts Torque 26Nm(19lb-ft)
HOSE AND TUBING FLARE CONNECTION TORQUES
Aluminum or
Steel Tubingt* Copper Tubing'
Torque Torque
Nm (rb.f0 (rb-fi)
1/A 7 /16 20 (15) 7-9 ( 5-7)

3/8 5/B 41 (30) 15-18 (1 1-1 3)
3/4 47 (35) 15-18 (1 1-1 3)
5/8 7/8 108 (80) 24-29 (1e-21)
3/4 1-1 / 16 135 (100) 31-38 (23-28)
*lf a connection is made with steel to aluminum or copper,

use the lower torque specification.
.'Use steel tubing torques only when both ends of connection are steel.
Litho in U.S.A. 90-05-02 TM-1258 (Dec-83)

HOSE AND TUBING O-RING CONNECTION TOROUES
Metal Tube Throad and Tofque

Outside Olameter Flttlng Sl.s N.m (1b.ft)
1/4 7/16 14-20 (10-1 5)

3/8 5/8 14-20 (10-15)
1/2 3/4 33-39 (24-29't
5/8 7/8 35-42 (26-31)
3/4 1-1/ 16 41-47 (30-35)
ENGLISH TOROUE SPECIFICATIONS
NOTE: Wrench torque tolerance is t 2oo/o.
Bolt
Oiameter Plrln H€adr
lb.tt N.m tb-fr N.m tb.ft N.m
1/4 in. 6 8 9 12 12 16
5/ 16 in. 10 '18
24 25 34
3/8 in. 20 27 30 4'l AF 61
7/16 in. 30 41 50 68 70 95
1/2 in. 61 75 101 110 149
9/ 16 in. 70 95 1 '10 150 155 2'to
5/8 in. o6 128 155 210 215 290
3/4 in- 165 225 270 ;to3 385 520
7 /g in. 170 230 435 590 620 840
1 in. 255 345 660 895 930 1 260
Torque ligures indicated above and in the Specification Sections of this manual are valid for non-greased or non-oiled
threads and heads unless otherwise specified. Therefore, do not grease or oil bolts or cap s"reius unless
otherwise
specified in this manual.
- Torque value lor bolts
and cap screws are ldentitied by their head markings.
u10;0t0000 FX2 2905a5
Litho in u.s.A. 90-05-03 TM-1354 (Sep-87)

SERVICING REFRIGERANT COUPLINGS
lf refrigerant couplings leak or do not function properly, use
the lollowing procedure for disassembly and repair.
g*
€-64
1. Remove lock nut (F) and remove male coupling half.
2. Unscrew body (D) with poppet valve assembly (C) trom #

qi<
€-o
adapter (A).
3. Remove O-ring (B).
4. Unscrew union nut and body assembly (G) Irom adapter

(K) and remove O-ring (J).
5. Replace either or both coupling halves (male or female)

as necessary.
6. Replace O-rings (B and J) andseal (E). Valveassemblies

€.-@
(C and l) are nol serviced separately from bodies.
7. Lubricate new O-rings with refrigerant oil and install on

adapters.
8. Insert poppet valve assembly (C) into body (D) and

tighten onto relrigerant line until body contacts line. Then
tighlen additional 3 mm (7s in.).
L Lubricale poppet valve O-ring (H) with re{rigerant oil and

install valve assembly into body (G).
1 0. Tighten until body contacts refrigerant line adapter, then

tighten an additional 3 mm (7s in.).
c.-:.--O
A-Tubing Adapter G-Union Nui and Body
B-O-Ring Assembly
C-Poppet Valve Assembly H-O-Ring
D-Body l-Valve and Sleeve Assembly
E-Gasket Seal
F-Lock Nut
J-O-Binq
K-Tubing Adaptei
m--"
Lirho in u.s.A. 90-05-04 Tlvl-1354 (Sep-87)

DISCHARGING THE SYSTEM
1 . lf the compressor is operable, operate tor 1O minutes with

engine at 2000 rpm. Be sure to have temperature control
set tor maximum cooling and blower switch set at purge. This
allows the refrigerant oil to be circulated through the system
and more nearly indicates the quantitv of oil in the
compressor.
t;,"'""**
discharge the system:
use the lollowing procedure to
a) Connect manilold gauge set to compressor as shown.

With both valves closed, connect low side hose to
suction fitling on compressor (C). Remove pressure
sensrng switch and connect high side hose to dis-
charge fitting (E) in steel tine.
b) Place center charging hose (D) in a quart jar or other
suitable container so that quantity of discharged oil can
be measured.
CAUTION: High pressure may sti exist at dis-
charge fitting. Release pressure slowly or there
may be a considerable discharge of oil and
refrigerant.
Slowly open high side valve (A) and allow oil and
relngerant to discharge into jar.
When pressure reads below 290 kpa (2.75 bar) (40
psr), open low side valve (B) and allow system to
completely discharge.
Remove gauge set and cap fitlings to prevent dirt and
moisture from entering the system. A-Hi9h Side Valve D-Charging Hose
B-Low Side Valve E-Discharge Fitting
C-Suction Fitting
REMOVE COMPRESSOR
1. Disconnect suction (A) and discharge (B) lines from
compressor. Cap all lines and fittings to keep dirt and
moisture lrom entering system.
2. Loosen tension bracket cap screw(D) and two mountino
cap screws. Rotate compressor toward engine and remove
he{t {rom comprcscor pulloy
3. Disconnect clutch coil wire and Hi-pressure switch lead

(C). Remove tension bracket cap screw and two mounting
bracket cap screws. Remove compressor.
Litho in U.S.A. 90-05-05 TM-1354 (Sep-87)

i
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A;. eut qvcl.|/'.
tultut tt tg ere.v,,t
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MAKE VOLUMETRIC EFFICIENCY TEST

1. Drain compressor oil from suction port (B) or from drain
plug (A) at botlom of compressor, if equipped.
2. ll compressor has not been disassembled and internal

parts are wet, add 120-150 mL (4-5 oz.) refrigeranl oil. lf
compressor has been disassembled and internal parts are
wet, add 150-180 mL (5-6 oz.) refrigerant oil. Add oil through
suction port.
3. Stand compressor on each end, then slowly roll for 30

seconds.
AC7;RV/5955 R$/1267 4 LlqCiU90005 FXr ?4043i
4. N/ount compressor in a vise and remove dusl cover.
5. Remove large caps from both suction and discharge

ports, and install No. 2632 (C) and 2635 (B) service fittings.
6. Connect low pressure (left-hand) hose (A) from gauge set

to No. 2632 adapter. Leave suction port open. Open low
pressure valve on manifold.
NOTE: Low pressure gauge is connected to discharge

adaptet so that pressure rcading can be more easily
read.
7. Use a speed handle (D) and 12 mm socket to quickly

rotate the compressor shaft five times.
h$
A-Low Pressure Hose
B-No. 2635 Fitting $'
C-No. 2632 Fitting
t!-Speed Handle
acTrR\!l6r! u!r0:09000a Glr 2b0931
Litho in u.s.A. 90-05-06 Tlvl-1354 (Sep-87)

8. Close low pressure gauge valve and use the speed

handle to rotate compressor shaft exacfly 2O times in exactly
20 seconds. Read and record pressure on gauge.
9. It pressure read is 370 kpa (9.70 bar) (55 psi) or greater,

compressor is serviceable. Check for shaft seal leakage.
10. lf pressure is less than 370 kPa (3.70 bar) (55 psi),
disassemble the compressor and check the lollowino:
a) Front and rear head gaskets.
D) Front and rear suction reed valves.

Front and rear valve plates.
d) Scored cylinder walls.
**,
MAKE SHAFT SEAL LEAK TEST
NOTE: It is normal for the compressor shalt seat to seep
oil at the wick on lower front of compressor. lf
leakage exceeds one pound of refrigerant per year
and no other leak is found, replace the shaft seal.
1. Remove large cap from discharge port and install No.

2632 (B) and 2635 (C) service fittings. Remove small cap
from suction manitold, and install low pressure hose from
gauge set. EP
2. Install high pressure hose from gauge set to No. 2635
litting.
*$$ '
J
3. Connect a 397 g (14 oz.) can of R-12 refrigerant (A) to
center hose of gauge set. Open both valves on gauge set
and pressurize the compressor.
4. Use an electronic leak detector lo check for leaks from

the shaft seal and front and rear neaos.
5. lf there is any leakage, replace shaft seal and end plate
uasIets.
6. Bleed pressure lrom compressor and repair or reinstall
on tractor.
u90 090005 .rxL 231036
Litho in U.S.A. 90-05-07 TL4-135a (Sep-87)

Ai Conditioning System
DISASSEMBLE AND INSPECT COMPRESSOR ]

1. [,4ount holding fixture in a bench vise and support l
comDressor on holdino fixture.

I
NOTE: Mountlng fixture can be made with two pieces of flat

stock and two lengths of thrcaded rod.
Weld one ptece ol src.A pcrpendicular to the other,

drill two holes and tnstall threaded rod as shown.
Compressor can atso be mounted n pivoling D-

0100644 Bench Holding Fixture or similiar holding
devtce.
.l\.0
Remove six dust cover cap screws (A) and remove cover.
3. Hold clutch hub with JDG-217 holding tool (A), and

remove clutch hub retaining nut from shaft.
NOTE.' lf clutch drive plate sfips on hub, drill a y'a in. hole "\i:$:i.., ,,
through flanges ol drive plate and hub. lnsert a

punch to hold clutch hub for removal of hub retaining
nut.
..*gt*.-

L___
5. lnstall lorcing screw (B). Hold hub wilh JDG-217

tighten forcing screw unlil hub can be removed.
6. Remove shims (A) from shaft and note quantily.

shims for reinstallation.
7. Remove and discard snap ring (B) and shaft key

Save
(C). ?
/ )
8. lnstall JDG-22O Driver (A) and use a suitable three jaw

puller as shown to remove clutch pulley.
9. Remove snap ring (A) and disconnect clutch {ield

-\
coil wire
Irom comoressor bodv. Remove clutch f ield coil.
Litho in U.S.A. 90-05-09 TIV-13s4 (Sep-87)

10. Flemove six head through-bolts using JDG-226 hex

__i l
head adapter (A). . r$.
IMPORTANT: Do not remove through-bolts unless suc_

tion and discharge manifolds are in place
and tight.
11. Carefully pry head from body using a screw driver. pry
only slightly around the circumference of the head. Repeat
this procedure until head is removed.
]
lr
12. Remove and discard shaft seal (A).
13. Use two screw drivers to remove discharge valve plate

(B).
,,
{
14. lI valve plate remains with front head, caref ullv separate
inlet reed valve (A) from valve plate (C). Do not looie locatrnq
dowel pin (B).
*'.:
,iii,, Rirar0 3 J9c,|90rn5 LllXl
15. lnstall JDG-227 puller (A) and caref ulty pull valve plate
(B) from head (C).
&"
Litho in U.S.A. 90-05-10

Air Condttioning System
16. Insoect valve olate side of inlet reed valves for a

complete circular wear pattern (A).
17. lf wear pattern has any voids in it, replace reed valve
t,l0 otf005 vrl 140235
18. nspect discharge valve plate for general condition.

Valves (A) should have slight pressure against valve plate.
19. Hold valve plate up to light and verify that valve is

against its seat. lf condition is doubtjul, replace valve plate.
il l0 rt00!s .,x1 1r1185
-
20. Turn compressor over and remove rear head by prying
on the small tabs cast into the head. Pry lightly around
circumference of head.
21 . Separate reed valve (A) from valve plate (B). Inspect the
three valves (C) for complete circular wear pattern as
oreviouslv instructed.
22. Use JDG-227 Valve Plate Puller to remove valve plate

from head.
Aa:,R!.rlLa9 Lq0 0l001lr Aalxl rci:3t

Litho in U.S.A. 90-05-11 TN/-1354 (Sep-87)
23. Inspect cylinders for scorrng or excessjve wear. lf

cylinders are scored or damaged. replace compressor.
NOTE: Some cylinder scuffing (light scratches) is normal.
A:r Rl;r6ai t,9|n.rt!lr ii!i:
CLUTCH PULLEY, BEARING AND HUB

INSPECTION
1. Inspect surfaces o{ clutch pulley (A) and clutch hub (B).

lf pulley is more than 0.3 mm (0.012 in.) from flat, replace
pu lley and clutch hub.
2. Rotate bearing in pulley. lf bearing is rough or has

evldence of loss of lube, replace bearing.
3. Clean up as necessary.
REPLACING CLUTCH PULLEY BEARING
1. Remove retaining ring (A) from pulley bore.
2. Support pulley on JDG-223 receiving cup (A). Use

JDG'221 driver (B) and JDG-220 driver (C) to press bearing
trom pu lley.
Litho in U.S.A. 90-05-12 Tl\/l-1354 (Sep-87)

3. Before installing new bearing, be sure to place dust shield
into pulley. Install as shown with lip edge lacing up.
4. Support pulley on JDG-225 support (A). Be sure dusl

shield seats in support tool and set bearing in place.
5.Use JDG-22'l driver (B) and JDG-220 driver (C) to press

bearing in until it bottoms on dust shield.
6. Instali bearing retaining ring.
]
REPLACE SHAFT SEAL SEAT
1. Support front head on press and use JDG-228 driver to
press seat from head.
K
2. Lubricate the new O-ring (A) on the seal seat (B) with a
small amount ol clean refrigerant oil.
3. Place seat in bore with grooved surface oJ seat facing

uD as shown.

4. Press seal seat in using JDG-229 driver until it bottoms
rn bore.
ASSEMBLE COMPRESSOR
1. Remove gaskets from both front and rear heads. Be sure
all gasket material is removed. Wash all parts in clean
solvent be{ore assembly.
2. Place suclion reed valve against compressor side of rear
head. lnstall locating dowel pin to assure that reed valve and
valve plate are properly indexed. Set in place in compressor.
3. Carefully install new head gasket. Be sure it is properly

in place.
4. Carelully install rear head. Be sure locating dowel pin is

in position in head. Lightly tap head into ptace.
5. Turn compressor over and install suction reed and valve
plate. Install new head gasket.
6. Be sure to install new shaft seal (A) as shown. Be sure
slotted rear side of seal engages with llats on compressor
shaft.
This is a two piece seal. Be sure they are
properly installed or breahage will occur
during assembly ol front head.
7. Place tront head on compressor. Be sure to align head

with dowel pin. Use the six boits to draw the head down
EVENLY, then torque to 26 N.m (19 ft-lbs)
B. Place new shalt key in key way. Position JDG-219 key

driver (A) over key. Be sure slotted area of driver (B) fits in
place over key.
9. Use a small hammer to tap key in until it bottoms in key

way groove.

10. Position clutch coil over head. Be sure to position it

properly over roll pin (g). Insta snap ring (A). Insta with
rounded edge facing upward.
11. Connect clutch coil wire to ground screw on

compressor.
12. Set clutch pulley in place over coil. Slight tap may be
needed to properly position pulley on shaf't.
13. lnstall new snap ring (A) with rounded edge oI snap ring
facing upward. Install removed shims (B) on front head. p.':!id'
14. Place clutch hub over compressor shaft. Be sure hub

*"t *"U is aligned with key.
j
l5.Tighten pulling nut until clutch hub is pulled tight against
shrms on compressor shaft shoulder. ${ l$
,a
16. Use a feeler gauge to check pulley.to-hub clearance.

Check clearance in three equally spaced locations around
the hub.
17. Rotate the pulley one-halJ turn (180') and again check
the clearance in three equally spaced locations.
18. Correct clearance is 0.53-0.91 mm (0.02i -0.036 in). Add

or remove shrms as necessary to obtain proper clearance.
9. After correct pulley-to-hub clearance is obtained, torque

'1
clutch hub nut to 16 N m (12 ft-lbs).
Litho in U.S.A. 90-05-15 TM.1258 (Sep-82)

SERVICING MANIFOLDS
IMPORTANT: Do not remove manitold unless f ront and
rear head bolts are installed and
tightened.
1 . Remove retaining bolts using JDG226 Speciat Socket (A).
AG7;RVr'4981 U90j090005 ATIXl t7O9a5
2. Inspect parting surfaces and O-rings. Replace as

necessarv.
INSTALL COMPRESSOR
1. Belore inslalling any compressor, be sure it conlains the
correct quantity of oil. Determine compressor oil charge as
instructed in Determining Refrigerant Oil Charge, Group 06.
2. Mount compressor on tractor, install tension bracket and

tighten cap screw (D).
3. Connect suction (A) and discharge (B)

compressor.
4. Connect clutch coil wire (C) and tighten mounting cap

screws securely.
A67;RW5944 U90j09o005 EX3 rrt1g3
Litho in U.S.A. 90-05-16 TM-13s4 (Sep-85)

IMPORTANT: Be sure to reinstall manitold port caps to
prevent any dirt or moisture from enter-
ing compressor.
5. Be sure to flush the complete system if compressor failed

internally due to damaged parts or seizure. Refer to Flushing
the System.
6. Install drive belt and adjust. (See Adjust Compressor Belt,

in this group.)
7. Evacuate and recharge syslem. (See Evacualing the

System, Group 06.)
IMPORTANT: ll new compressor clutch was installed,

turn compressor on and otf (engine run-
ning) in one second intervals for five
seconds (cycle five times in five sec-
onds). This will burnish clutch and hub
drive surfaces.
AC7; U9ojo90005 CGIXI 160935
ADJUST COMPRESSOR BELTS

1. Be sure belts are in good condition.
2. Install JDG-138-1 Adapter (A) ol JDG-138 Belt Tension
Tool over cap screw (B) between adjusting strap (C) and
washer (D). Install torque wrench (E) on adapter.
3. With compressor rotated inward toward block, slowly

rotate compressor outward while reading torque wrench.
Reading should be smooth and less than N.m (20 lb-ft).
NOTE: lf rcading is erratic and more that 27 N.n (20 lb-fl)

pivot points should be lubricated or cleaned.
4. Use the following specifications lo determine correcl

toraue for Steo 5:
ComDrrsror Bell To.que
Initial torque reading

plus 48 N.m (35 lb-tt)
New Initial torque reading

plus 68 N.m (50 lb-ft)
A---JDG.138-t Adaptor D-WaBher

B-AdluEtlng cap Scr6w E-Torque wrench
C-Adlurtlng Strap F-Mountlng Bolt

5. Slowly increase the torque to specification determined on
Slep 4 and tighten adjusting screw. Torque specification
tolerance is + 4 N.m (3 lb-ft).
IMPOBTANT: Do not over torque, then relax to correct

specilication. Friction will cause belts to
be over torqued.
Tighten mounting bolt.
J9C;C900O5 alrlXl 2i0335
SERVICE OTHER SYSTEM COMPONENTS

lf replacing other system components, it is recommended
lhat compressor also be removed. Follow procedures for
checking and adding oil as previously instructed.
NOTE: lf complete system was purged with components in

place, the amount of oil tost is considered negtigibte.
ll any component was removed and individually drained and

flushed, add the lollowing amounts of oil:
Evaporator .....45mL('1.5 11.o2.)
Condenser ... . 30 mL (1 .0 ll. oz.)

Receiver-Dryer ........ 29 mL (0.75 fl. oz.)
ll any component is removed because of damage and

leakage is evident, remove compressor and determine
amount o{ oil needed to bring system to full charge. Refer
1o prevaous instructions.
REMOVE HYDRAULIC OIL

COOLER/CONDENSER
1. Remove hood and grille screens.
2. Remove cap screws (A) from right-side only.
NOTE: Right is always as viewed from tractor seat.
A(i7;kW5945 U90,090c05

*-',t
3. Discharge air conditioning system as instructed in Dis- |
charging The Systern, this group. il$$
4. Slide cooler/condenser partially out left side. {
..!t*: *
.,,,_
5. Disconnect coo erlcondenser rnlet and outlet lines.

* "
ffi$t
NOTE: See Section 70 (Remove Hydraulic Oil Cooler).
6 Disconnect oil cooler hoses (A).
7. Slide cooler/condenser completely out to srde and

remove.
LEAK TEST CONDENSER

1. Remove caps from openings and flush condenser. See
Flushing the System, Group 06.
2. lnstall 2632 and 2633 Fittings at inlet fittng. Cap ouflet

with 2634 Fitting and 7447 Cap.
3. Place a refrigerant container in a pail of water heated to

a of 52"C (125'F). This will create a pressure of
MAXlN,4Ul\,4
1 160 kPa (1 1 .6 bar) (168 psi).
4. Connect refrigerant supply to schrader valve and open

retngerant container to pressurize condenser.
5. Use an electronic leak detector to check for leaks.

Fleplace condenser as necessary.
Litho rn U.S.A. 90-05-19 Tl\,4-1258 (Aug-84)

INSTALL HYDRAULIC OIL
COOLER/CONDENSER
1. nstal cooler/condenser by reversing removal sleps.

Fefer to hose and fitting torque specifacations at the
begrnning ot thts group.
Lrs0 0r0c0f (xl 160t34
NOTE. lf condenser was completely llushed or a new one

tnstalled and no major leaks are found in the system,
add 30 mL (/ oz.) refrigerant oil. lf leaks are evident
tn the system, follow procedure for checking and
addtng oil as tnstructed under Determining Refriger-
ant Oil Charge, Group 06.
2. Purge, evacuale and charge the
REPLACE RECEIVEB-DRYER
NOTE. The receiver-dryer is not repairable. lf malfunction
ts sLtspected, tnstall new receiver-dryeL
lf the air condthonrng system is discharged for

servcrng and the recetver-dryer ts two years old or
alder, it should be replaced. lf receiver dryer is less
tnitn two years old it should only be replaced if
svstem was contamtnated.
1. Discharge the system as Instructed under Fiemove

Compressor, th s g roup.
2. Disconnect nlet (A) and outiet (C) lines from receiver-

oryer.
3. Remove clamp cap screw (B) and remove receiverdryer.
Lrtho n U.S.A. 90-05-20 Tlvl-1258 (Aug'84)

4. Cap lines to prevent contaminants from entering system.

5. nstal by reversing removal steps.
NOTE: lUhert a new receiver-dryer is installed and there
were na major leaks found in the system, add 22 mL
(0.75 az.) of refrigerant oil. lf leaks are evident in the
systetn. follow procedure for checking and adding
refrigerant oil as lnstructed undet Adding Refrigerant
Oit. Group 06.
6. Purge, evacuate and charge system, Group 06.
REMOVE EVAPORATOR/HEATER CORE
1. Discharge the system as instructed under Discharging

The System. thrs group.
2. Flerrova rwo a.ge cap screws (A, one each side) from
top of SOUND-GARD body roof.
3. Remove three screws (B) from lront and raise roof.
4. Remove sealing tape from outside edges of pressurizer

housing and remove all cover-to-inner roof screws.
$t''
5. Partia ly dra n cooling system and disconnect heater inlet
(A) and outlet hoses from core.
Litho in U.S.A. 90-05-21 Tl\,4 I 258 (May 83)

6. Remove insulatlon tape from sensing bulb and expansion

valve.
7. Disconn.^t sensing bulb (D) and evaporator inlet and

oullet lines (c).
8. Disconnect equalizer line (E) and carefully pull sensing

tube (F) from evaporator core.
IMPORTANT: The tube connecting the bulb to the

expansion valve contains a low pressure
gas. To avoid improper valve action, do
not kink or pinch the tube, or dent the
butb. A-Evaporator/Heater D-Sensing Bulb
Core E-Equalizer Line
B-Expansion Valve F-Sensing Tube
9. Remove evaporator core mounting screws (G), and cap C-Fittings G-Mounting Screws
open ing s.
TEST AND INSTALL EVAPORATOR/HEATER

COBE
1. l\,4inor leaks may be repaired but evaporator should be

replaced if there rs a restriction or major leak in the core.
2. Test core by applying at least 345 kpa (3.4 bar) (50 psi)
alr pressure.
L_
Lrtho in U.S.A. 90-o5-22 TM-1258 (May-83)

3. Before installing evaporator core, check condensate
drain tray (part of roof directly under evaporator core) to
make sure that drain outlets are not plugged.
4. Drain hoses (B) are connected to each ou et and routed

down through the front members ot the SOUND-GARD
body.
5. Each hose is clamped to a tube (C) that is interlocked

with a bushing (D) and sealed to the drain tray (inner roof)
with a rubber packing (E).
6. Access the tube as necessary by removing switch bezel

A-lnner Foof D-Bushing
and rear headliner from inside the SOUND-GARD body. The B-Hose and Clamp E-Packing
bottom end of drain tube must contain a circle just inside (;- | uDe
the SGB tube for a water trap and prevent back {low of dust
during air-conditioning operation.
7. lf water leaks around packing, replace bushing and

packing together.
8. Complele evaporator installation by reversing the re-

moval steps.
L Read the following notes before completing installation.
Litho in U.S.A. 90-05-23 TlVl-1258 (Sep-82)

NOTES: The expansion valve sensing bulb, evaporator
outlet plpe and temperature sensing tube must be
clean and free ol corrosion. Good contact is essen-
tial !.r proper operation.
lf evaporator was completely flushed or replaced

with a new one and no majot leaks are evident in
the system, add 45 mL (1.5 fl.oz.) of refrigetant oil
before tnstallation. lf leaks are found in the system,
refer to procedures given for checking and adding
rctrigerant oil as instructed under Determining Re-
frigerunt Oil Charye, Group 06.
10. Purge, evacuate and charge the system, Group 06.
SERVICE EXPANSION VALVE

'1. Dischargethe system as instructed under Discharging
the System, this group.
2. Faise SOUND-GAFD body rool and remove pressurizer

housing cover.
3. Remove insulating tape from sensing bulb and expansion

valve.
4. Disconnect sensing bulb (B) from evaporator pipe.
5. Disconnect equalizer line (C) and outlet fittings (A).
IMPORTANT: It valve was operating properly, do not

kink or pinch sensing bulb tube when
removing valve.
6. Carefully remove expansion valve and cap all lines and

fitlings. *
Litho in u.s.A 90-05-24 TM-1258 (May-83)

BENCH TESTING THERMAL EXPANSION

VALVE
i
An expansion valve should not be discarded until its

operation has been checked. partial blockage in inlet screen
or excessive moisture in the system which causes icinq in
the evaoorator. can indicate the same results as a faultv
valve. Connect expansion valve as shown and use the
Iollowing procedures to test the expansion valve:
1. Insta 4FTX-S 1/8-in. ([/) NpT x 7/16_20 (M) JtC

connector in 18-207 Blow Gun (D).
2. Install No. 2634 Adaprer (F) and No. 2632 Tee Jitting (c)
to the thermal expansion valve (E).
3. Install No. 2636 TEE with 0.51 mm (0.020 in.) orilice cap
(C) to low pressure side o{ gauge manifold.
4. Connect 18-207 blow gun or regulator (Ty-4945 or

D-160048K) to center charging hose. Connect low pressure
hose to tee fitting (G) and to expansion valve ouflet.
5. Connect right-hand high pressure hose to expansion

valve inlet (F). Connect pressure sensing lube (l) to No. 2632
Tee fitting (c).
6. Connect blow gun or regulator to shop air supply.
NOTE: Use blow gun from D-013615T Stopper./Leak De-

tector Kit. lf blow gun is not available, assemble a
/4-in. (M) NpT x 7,t 16-20 (M) 45. ttare adaptet and
1
mate air line quick coupler adapter to fit shop air

suPPly.
7. Perform upper pressure limit test as follows:
Depress blow gun valve and adjust high pressure (right-

hand) manifold valve to maintain 480-SZO kpa (4.8-5.2 bar)
(70-75 psi).
a) Holding thermal bulb (H) in hand to heat it to be sure

thermal expansion valve is wide open,
o) Correct pressure (read on low-side gauge) should be

280-385 kPa (2.8-3.8 bar) (40-55 psi).
lf pressure is not within above specitication, relieve air

pressure and remove thermal expansion valve outlet
tee fitting (c). A-High Side Valve F-Expansion Valve
B-Low Side Vatve lnlet
C-2636 Tee rr-zoJz I ee
D-18-207 Blo,r Guo H-Thermat Bulb
E-Expansion Valve l-Sensing Tube
A.4 RL!'r'!ita L i;01r2900t0 AFtl 240437

d) use a 3/16-in. allen wrench to turn superheat screw
(in 1/2 turn increments) in to decrease or out to
increase valve opening pressure.
e) Repeat upper pressure limit test and readiust as

necessarv to obtain correct oressure.
L Perform lower pressure limit check as 'follows:
CAUTION: Do not let R-l2 or starting f luid come

in direct contact with skin, Wear goggles to
protect eyes.
a) Spray Fl- 12 or starting f luid on thermal bulb to cool it

and close the exoansion valve.
b) Observe the low side (lelt-hand) manifold gauge for a

pressure drop as the bulb is cooled. The pressure
should drop to less than 180 kPa (1.8 bar) (25 psi)
indicating that the expansion valve has closed.
c) Repeat both upper and lower pressure limit tests. ll

expansion valve opens and closes, it is operating
sataslactorily.
9. Reinstall in reverse ol removal and purge, evacuate and

charge system, Group 06.
REPLACE AIR CONDITIONING TIMER RELAY

Belore replacing timer relay, test operation as instrucled in
the Electrical Operalion Checks at the beginning of Air
Conditioning Diganosis, TM-1 259.
1. Raise SOUND-GARD body roof. Disconnect harness (B).
2. Remove cap screws (A) and remove relay trom support

post.
Litho in u.s.A. 90-05-26 Ttvl- 1354 (Sep-87)

SERVICE TEMPERATURE CONTROL SWITCH
1. Remove bezel retaining screws (A).
2. Lower bezel from inner roof. Disconnect electrical leads

to A/C Hi/Lo pressure warning lamps and clock.
3. Remove control knob (B) and retaininq nut trom control

switch.
4. Disconnect wiring and remove swrtch.
&ryJ,&!!ll,!!t!U
',rrr rrr*lr-.. --"bJ X. *-*. &,
5. Remove two large cap screws (A, one each side) from
top ot SGB roof.
6. Remove 3 screws (B) from front and raise roof.
7. Remove sealing tape and retaining screws from pre_

ssurizer housing cover and remove.
Lrtho in U.S.A. 90-05-27 Tl\,4-1258 (lvay-8s)

8. Carefully withdraw sensing tube (B) from evaporator core.
Note position of tube so it can be reinstalled in same place.
9. Disconneci wiring lrom switch and remove from inside

cab.
The temperature control switch is not repairable, it should

be tested and replaced as necessary.
10. Turn knob fully clockwise and connect ohmmeter to

switch terminals.
1 1. Insert sensing tube and thermometer into container of

ice water and rock salt. Ohmmeter should read no continuity
(contacts open) at - 1'C (30'F).
'12. Remove sensing lube from ice water and hold in hand.
n lr?i3
Ohmmeter should show continuitv. Reolace switch as
necessary.
13. Reinstall by reversing removal steps.

IMPOBTANT: Do not pinch or kink the sensing tube. lf
necessary to reshape tube to fit into core,
avoid making too sharp a bend.
14. system does not operate properly refer to Air Condi-
l.f
tioning System Tests and Diagnosis, Section 290, TM-1259.
r.j: Rjr:5a Lri.eo00r !ir rr-3r
REPLACE COMPRESSOR RELIEF VALVE
1. Discharge system as instructed in this group.
CAUTION: High pressure may still exist at the

discharge titting. lf this pressure is released too
rapidly, there may be considerable discharge of
refrigerant and oil.
2. Slowly remove relief valve (A) from compressor. Be

aware that high pressure may exist.
3. The relief valve is not repairable. Replace valve as

necessary.
4. Charge system as instructed in Group 06.
Litho in U.S.A. 90-05-28 TM-1258 (May-83)

REMOVE AIR FILTERS
1. Flemove (4) screws retaining recirculating filter bezel as

shown.
2. Remove toam element and clean or replace.
3. Unscrewthe two retaining knobs, release safety latch and

remove tresh air filter element (A).
CLEAN AND INSTALL AIR FILTERS

Clean elements using one of the tollowing methods:
1. TAPPING - Gently tap filter on flat surface, dirty side

down.
2. COIVPRESSED AlFl - Direct compressd air 690 kpa (7.0

bar) (100 psi) maximum through element.
3. WATEF WASHING - Soak element in water and John

Deere R36757 Cleaner for t 5 minutes, rinse thoroughly and
allow to air dry (do not use compressed air).
NOTE: Recirculating filtet MUST be kept ctean to maintain

cooling efficiency.
Litho in U.S.A. 90-05-29 Tt\,,t-1258 (May-83)

Litho in u.s.A. 90-05-30 TI\,4-1258 (May-83)
Group 06
AIR CONDIT rqNlr.le JY9TEM sEEVlcE l
SYSTEM SPECIAL TOOLS
NOTE; Order tools from your SERVTCE-GARD Catalog untess otherwise indicated.
Number Name Use
D-18009KD Electronic Leak Detector Detect Refrigerant Leaks
D-18019KD Manifold Gauge Set Test Air Conditioning System
D-18023KD Flefrigerant Can Valve Tap Refrigerant Cans
D-05267ST Vacuum Pump Evacuate Air Conditioning System
D-15038NU Air Conditioning Service Fitting Kit Connecting Test Equipment
JDG-247 Convenience Fittjng Set Connecting Test Equipment
, 7r:l: - rt03
')
OTHER MATERIALS
Name Use
Retrigerant-12 Charge System

R-1 1 Flushing Solvent Flushing System
Refrigerant Oil A/C System Lubrication
(525 viscosity)

SPECIFICATIONS
Item Measurement Specitication
Evacuating System Fequired Vacuum at Sea Level .. ... ... 73 kPa (0.7 bar) (29 in. Hg)
Refrigerant ,,..... R-12 Capacity 1.8 kg (a lb.)
Compressor . .. ... Oil Charge 330 mL (1 1 ll. oz.)
Discharge Pressure (at 2000 rpm) .. .... 690-2070 kPa (7-20 bar)
(100-300 psi)
Suction Pressure (at 2000 rpm) 7-24O kPa (0.07-2.4 bat)

(1.0-35 psi)
Drive Belt Tensron (new) 578-622 N (130-140 tb.)

(after run-in) 378-423 N (85-94 lb.)
Clutch Coil Current draw at l2 volts,

20'c (68"F) 2.8-3.5 amps
Resrstance at 20'C (68'F) 2.8-4.5 ohms
Co ndenser Pressure Drop . .. 16-55 kPa (0.14-0.55 bar)

(2.3-8 psi)
Evaporator Pressure Drop 34-38 kPa (0.34-0.83 bao

(5-12 psi)
Temperature Control Switch .. . Opening Temperature - 1.6 to - 0.60'C

(29-32" F)
ClosingTemperature .... 2.2-3.3"C (36-38"F)
Compressor Felief Valve ...... Opening Pressure 3030 kPa (30 bat (440 psi)
Hi-Pressure Sensing Switch .... Opening Pressure 2480-2930 kPa (24.8-29.3 baO
(360-405 psi)
Lo-Pressure Sensing Switch ... Opening pressure 14-41 kPa (.14-.41 bar)
(2-6 psi)
Pressurizer Blowers Low .... 5 amps

High ... 6 amps
Purge .. 10 amps
Litho in U.S.A 90-06-02 TM-1258 (Nilay-83)

SERVICING THE AIR CONDITIONING
SYSTEM
This group cJntains information on flushing, purging, evacu-

ating and charging the system. Also included is the proce-
dure for checking and adding refrigerant oil. lt is important
to understand what each procedure does Ior the system and
exactly when each job should be performed. Carefully read
all intormation before performing any of these jobs.
FLUSHING
WHAT lT lS the system is forcing F-l1

- Flushing
(Jlushing solvent) through individual components in a
WHEN lT SHOULD BE DONE
-System components
should be flushed whenever contaminanls are sus-
liquid slate to remove moisture and contaminants. pected to have entered the system. Examples are;
Flushing with R-1 1 is recommended over R-1 2 for the
following reasons: 1) internal comoressor tailure.
a) F-11 stays in liquid form up to 24'c (76'F). 2) syslem has been exposed to dirty environment
(such as field condilions).
b) Above 0'C (32'F), R-1 1 will not freeze moisture
that may be trapped in a component. (R-12 will 3) system has been open to atmosphere for extended
freeze moisture, making it difficult to remove.) period of time.
R-11 will not freeze your skin when in direct After flushing, components and lines MUST be purged
contact. 1R-12 will freeze skin on conlact.) to remove R-1 1 .
PURGING
WHAT lT lS Purging is performed to remove air and WHEN lT SHOULD BE DONE Purging should be
-
moasture f rom the system. F-12 or dry nitrogen is blown perlormed any time the system -has been discharged
through the syslem to collect and remove moisture or opened up for service. Purge with 30-140 kPa (5-20
(R-12 collects moisture in its gaseous state) and to psi) pressure at point of gas entry. Purging should
expell air. always precede evacuating.
Litho in u.s.A. 90-06-03 TM-1258 (May-83)

Air Conditiomng System Service
EVACUATING
WHAT lT lS (85'F), the moisture will not boil and vacuuming lhe
- Evacuating removes air and moisture
trom the system. This is done using a vacuum pump. system will not elfectively remove moisture.
Subjecting the system to a vacuum lowers the boiling
point of any moisture that may be trapped in the WHEN lT SHOULD BE DONE The system shoutd
system. This allows the moisture to boil oJf to a vapor -
be evacuated any time the system has been dis-
where it can be drawn f rom the system. lt should be charged or opened up for service. Evacuating should
noted that this should be done at an ambient tempera- always follow purging.
ture above 29'C (85'F). lf temperature is less than 29"C
DETERMINING REFHIGERANT OIL CHARGE
1. lf R-12 leakage was detected and repaired, remove

compressor, this group.
CAUTION: All new compressors are charged

with a mixture of nitrogen, retrigerant-12, and
525 viscosity oil. To avoid possible in jury, wear
safety goggles and discharge compressor
slowly.
IMPORTANT: Use care when checking and adding oit.

Too much oil in the system will reduce
maximum cooling capacity. Too little oil
\\a----rit;-
will result in poor lubrication of the com- /.r_____J\
pressor leading to early compressor
failure.
"/9) |
2. Flemove caps lrom compessor suction and discharge
manilold openings. Drain oil lrom compressor and record
amount of oil. R 3179 3
NOTE: lf new compressor. drain oil and save.
3. lf 90-240 mL (3-8 fl. oz.) was drained irom OFIGINAL

compressor, add 180 mL (6.0 oz.) of new oil back into
compressor. Do not replace receiver-dryer il less that 2
years oto.
4. l{ [/ORE than 240 mL (8.0 fl. oz.) was drained from

OFIGINAL compressor. Add 180 mL (6.0 fl. oz.) of new oil
back into compressor. Replace receiver-dryer to remove
excess oil from system.

5. lf LESS than 90 mL (3 f l. oz.) was drained f rom ORIcINAL
compressor, flush system as instructed later in this group,
replace receiver-dryer, and add 330 mL (11.0 Jl. oz.) of new
oil back into compressor.
IMPOFTANT: For this condition fless than 90 mL 3 fl.

oz. drained) always install new receiver-
dryer.
6. l{ installing overhauled compressor (with no oil charge),

add an extra 30 mL (1 fl. oz.) to the amounts specified in
steps 3, 4, and 5.
7. lf complete system was disassembled and all lines and

components including the compressor were drained and
flushed, add 330 mL ('11 fl. oz.) to the compressor when
reassembling system.
8. After adding proper amount oJ oil, rotate compressor

sha{t lour or five times. This permils proper lubrication of
compressor seal. Be sure to remove any excess oil lrom
outside surlaces of compressor.
9. lf replacing componentsor if component was llushed and

purged, it is recommended that compressor be removed lo
determine oil charge.
lf compressor removal is not leasable, use the lollowing COMPONENT OIL CHARGE
chart at right as a general guideline for adding refrigerant
Condenser 30 mL (1.0 oz.)
orl to components. Evaporator 45 mL (1.5 oz.)
Receiver-dryer 23 mL (0.75 oz.)
NOTE: Total system oil charge is 330 mL (11.0 oz.). Relrigerant line (per line) 7 mL (0.25 oz.)
Compressor 180 mL (6.0 oz.)
1,90 090005 |Lt1 2910A6
ADDING REFRIGERANT OIL TO THE

SYSTEM
1 . lf system has been completely llushed, add 330 mL (1 1
oz.) oil through compressor suction port (B) with a squeeze

bottle (A).
IMPORTANT: Use 525 viscosity oil only.
It may be necessary to add some oil through
comprcssor line and fitting.
I COmpressor.
Litho in U.S.A. 90-06-05 TIV-135a (Sep-87)

3. lI compressor was not removed or a component other
than compressor was repaired or replaced, cil can be added
through suction port from manifold gauge set as illustrated.
NOTE: Compressot is not exactly as shown. Connect hose

to suction fitting on compressor.
4. Add the measured amount of oil into suction test hose

with a squeeze bottle.
I
---\\-
A-Low Side Valve

B-High Side Valve
C-Squeeze Bottle R 31791
5. Connect a can of R-12 to suction hose as shown.
NOTE: R-12 can must be upright.
6. Open can valve for 5 seconds to blow oil into compressor.
Litho in u.s.A. 90-06-06 TNI-1354 (Sep-87)

Air Conditioning System Service l
7. A{ter system has been charged wilh the proper amount

of oil and re{rigerant, run tractor at 1000 rpm and cycle
compressor clutch five times at 1 second intervals.
NOTE; This can be done by setting temperature control

switch at "Max" and then quickly turning blowel
motor switch on and off. Limit compressor oDeration
to approximately 1 second to allow the oil level in
the compressor to lower to a safe, continuous
operating level.
Litho in u.s.A. 90-06-07 Tl\,,1- 1258 (May-83)

D-Quik-Coupler G-Bear Lower SGB l-Hose
E-Receiver H-Fear Upper SGB J-Evaporator
F-Tube
Schemalic Diagram of Atr Condttoning System wth Lines and Fittngs
":' )
Litho in u.s.A. 90-06-08 Tl\,4-1258 (M ay-83)
FLUSHING THE SYSTEM
1. lsolate compressor, receiver-dryer and expansion valve
from system Do this by disconnecting inlet and ouflet
fitlings.
2. Flush all remaining components individually with R-1 1.

Use special fittings lrom D-15038NU Air Conditioning Ser-
vice Frtting Kit. Refer to the previous illustration for location
and identif ication ol fittings.
3. To flush compressor, remove it and drain oil.

NOTE: Record amount of oil drained for use when determin-
ing system oil charge.
4. Add R-1 1 through suction port. Shake and rotate com-

pressor, then drain.
5. Add refrigerant oil to compressor. Ref er to Determining

Refrigerant Oil Charge, this group.
6. Purge all components individually, then connect and

purge complete system.
7. Evacuate and recharge system,

headings in this group.
PURGING THE SYSTEM
NOTE: Components that have been flushed must be purged

individua y. Replacement components should also
be pueed individually. Purge components for l S-A0
seconds and connect into system.
1. Connect guage set and Fl-12 can as shown. With both

low (C) and high (B) side valves closed, purge air from
charging hose (A).
2. Loosen or disconnect low side hose (D) from gauge set.
3. Open valve (E) on R-12 can, then open high side valve
to purge from compressor discharge fitling toward receiver
dryer. Purge with 30-140 kPa (5-20 psi) pressure at point of
gas entry. A-Charging Hose t>-Low Side Hose
B-Hlgh Side Valve E-8.12 Cam Valve
4. Air and moisture will be purged out compressor low side C-Low Side Valve
fitting through low side hose of gauge set.
5, Furge for approximately 30 seoonds. Close valves and

evacuate syslems.
Litho in u.s.A. 90-06-09 TM-1258 (May-83)

Air Condilpning System Serwce
EVACUATING THE SYSTEM

NOTE: Discharge system as lnstructed in Discharging The
Syst.m, this section.
1. Attach manifold gauge set to compressor (C) as

illustrated.
NOTE: Compressor is not exactly as illustrated. Remove

Hi-pressure sensing switch lrom comprcssor dis-
charge llne and connect high side gauge hose.
Connect low side hose to suction fitting on
compressor.
2. Attach a vacuum pump (D) to center charging hose (E) of

manilold.
A-Low Side Valve D-Vacuum Pump
NOTE: Pump must be capable of pu ing at least 2A.6 in. Hg B-High Side Valve E-Charging Hose
C--{ompressor
vacuum (sea level). Deduct 1 in. Hg from 29.9 in. for
each 300 n (1000 ft.) elevation above sea level.
CAUTION: Do not operate compressor during

evacuation.
3. Start vacuum pump and open both manifold gauge valves

(A and B).
NOTE: Ambient temperature must be above 29'C (AS"F) to

remove moisture from the system with 2A 6 Hg
vacuum at sea leveL
4. lf pump does not reach deepest vacuum in 6 minutes,

close both valves on manifold guage set.
5. A decrease in vacuum of 1 in. Hg or more in 5 minutes

Indrcates an excessive leak or there is still liquid R-'12 in
system.
6. Slightly pressurize system with R-12 and use leak

detector to locate leak.
7. Evacuate system for at least 30 minutes.
Litho in U.S.A. 90-06-10 Tl\,4-1258 (May-83)

valve (C, with can upright) slighfly to purge moisture and
contamrnants from hose. Tighten center hose connection.
R 31797
A-Low Side Valve C-R- t2 Valve

B-High Side Valve D-Charge Hose Fltllng
4. FullyopenR-l2canvalveand nvert container as shown.

Low side valve (A) closed.
5. Open high side valve on gauge manlfold and allow

vacuum to draw B-12 into condenser and receiver-dryer.
NOTE: ll charging with 4549 (t S oz.) cans, close can valve

to change cans.
A-Low Side Valve

B-High Side Valve
C-R-12 Can Valve
L(ho in u.s.A. 90-06-1 1 TN/-1258 (ltzlay-83)

I
6. After high side pressure becomes slow to increase, open

low srde valve on gauge manifold.
7. After lo\r'q de pressure becomes slow to increase, close

high side valve.
CAUTION: DO NOT expose 14 oz. R-12 cans to

discharge pressure with compressor operating.
8. Close R-12 can valve and turn can upr|ght.
9. Start engine and run at 2000 rpm. Turn blower motor to

"Purge" and temperature control switch to "l\,4ax".
NOTE. lf "Lo' pressure llght comes on and compressor

clutch disenages. recycle blower switch in cab.
Compressor can also be temporarily "hot wired" to
starter solenotd terminal to keep clutch engaged
whtle chargrng.
10. Add F-1 2 until system is charged with 1.81 Kg ( tb.)

OR add 16 oz. after bubbles disappear in sight glass.
11. Check ambient temperature, cab temperature and sys-

tem pressures as Instructed in the diagnostic sequence, in
Section 290, TM 1259.
Litho n U.S.A 90-06-12 TM-1258 (May-83)

Group 10
HEATING SYSTEM
REPLACE HEATER CONTROL VALVE

1. Remove the two large cap screws (A, one on each side)
trom top of 'lot.
2. Remove the three screws (B) f rom underside f ront of roof.
3. Raise ioci and remove pressurizer housing cover.
4. Drarn a porton of the cooling system.
5. D sconnect control valve inlet (A) and ou et (B) hoses.
6. Flemove mounting cap screws (C).
7. Remove control knob from inside cab and disconnect

control valve from bezel. Remove valve.
B. Feplace val,/e as necessary. Feinstall in reverse of

removal making sure that heater core ouflet (upper hose)
rs connected to control valve inlet (upper fitting).
REMOVE HEATER/EVAPORATOR CORE

Follow prccedure for evaporator/ heater core removal as
tnstructed in Air Conditioning System, this section.
lithoinUSA 90-10-01 TN,4- 1 258 (May-83)

Heating System
REPLAOE HEAlER HOSES

' Llrain :)iJ0linal ivste[]
2 Dlscofnect s.rpply (/\) afrd return (B) hoses from engine

pip ng
3 Dis.onnect supply (A) andreturrr(B) hosesfromSOUND-

GARD body piprng.
4 D sa.o'i,rt (,r I osi. .. Arnrl rrr, rLrrr liOUl\D-GARD body (A)

aftd ir'( i' tr:r Lr ; S:r r-r a -i.:, iFll
5. F' . r leq , tr ir.r:. irni j{rT Sa, i,lND-GI\RD body.
6 Conf r.r I cf qrr i ,iLrirD v prpe (A) to SOUND-GAFD supply

prpe (B)
7 (,onnsct ..,rr r:r€r retuiI i]r1.. LL,/ to SCUND'GARD return

irne (Dl
Litl,o :,r U S.A 90-10-02 TIV 1 258 (Sep-82)

-_!- , -
- i., " .-,-"--

-
y'g',
r.,l j
5i-'.,' I
p_r',^ __,r- - - _
A-Heater Core C-Return Hose E-R6turn Flttlng

B-Heater Control Valve t!-Supply Hose (wlth strtpe) F-Supply Flttlng
The above rllustration shows components of a typical

nearng system.

Litho in u.s.A 90-10-04 TM-1258 (Sep-82)
Group 15
SEAT
SPECIFICATIONS -t
Item
Dimension
Deluxe Seat Side Play 0.13 to 0.76 mm (.005 to.030 in.)
SPECIAL TOOLS
NOTE. Order tools from your SERVICE-GARD Catalog unless othewse indicated.
N umber Name Use
Fabricated 4 ln. long piece of 2 x 4 o( 4 x 4 Hold up seat.

Fabr cated Shock Absorber Spring Compressor Service seat shock absorber.
rr lr , :\ tl ,.1
REMOVE HYDRACUSHIONEDTI.4 SEAT

1. Remove three screws (A) and remove front cover from
suspension assembly.
2. Remove four stud nuts (B) securing vertical suspension

assembly to horizontal suspension assembly.
3. Fernove seat with horizontal suspension assembly from

seat tracks.
Litho in U.S.A 90-15-01 Tlvl-1258 (Dec-83)

Seal
REMOVE VERTICAL SUSPENSION

ASSEMBLY
'1. Flaise suspension assembly and block up with a piece of
wood about 4 in. long.
NOTE: Be carelul seat position valve rod or levers are not

bent during the following operation.
2. Disconnect seat position valve rod swivel (D) Irom lever

(A).
3. Remove pin (C) and disconnect ride height rod (B) from
suspension assembly.
4. Remove six cap screws (E, three front and rea0 and
remove vertical suspension assembly.
A-Seat Poaltlon Lever O-Position Valve Swivel

B-Rlde Helght Rod E-Mounting Cap Screws
C-Reialning Pln
DISASSEMBLE, INSPECT AND REPAIR VER.

TICAL SUSPENSION ASSEMBLY
1. Turn assembly upside down and support on seat track
studs.
2. Raise suspension assembly to separate upper and lower

supports and block up with a piece of wood about 4 in. long.
3. Remove two bolts (A) and nuts (B). Remove two retaining
plates (C).
Litho in U.S.A. 90- t 5-02 Tl,4-1258 (Sep-82)

Seat
4. Remove block of wood and lift assembly away f rom top

support.
5. Lift assembly forward to remove guides (A) f rom tracks

(B).
6. Check to see that seat tracks move freely. Tracks can

be removed by removing four (two front and rear) cap screws
(A).
7. Working from bottom side oI upper support, remove small

locking nut. Hold large relaining nut and remove small cap
screw.
8. Carelully remove ride height lever, friction disks and

special washer.
Litho in U.S.A. 90-15-03 TN,l-12s8 (Sep-82)

9. Inspect friction disks (A) for glazing or excessive wear.
Replace disks as necessary.
10. Reassemble in reverse of disassembly. Be sure that

groove (B) in special washer engages wilh pin (C) on lever.
11. Remove nuts and bolts (A) from both sides of support.
Also remove retaining plates (B).
12. Slide assembly rearward until guides (A) are disengaged

from tracks (B).
13. Remove assembly lrom lower support.
14. Remove cap screw with washers (A) and bushing (B).
Inspect metal bushing for excessive wear and replace as
necessary.
15. Also inspect plastic bushing (C) inside bore of lrame.

Replace as necessary.
TN.4-1258 (Sep-82)
'16. Reinstall cap screw and bushings.
17. Inspect plastic bushings (A) in remaining bores of

support frames.
18. Also inspect corresponding metal bushings (removed

during disassembly).
NOTE: Plastic bushings in bores can be removed with soft

drift and hammer. New bushings can be pressed in
by hand.
19. Inspect plastic frame guides. Be sure they are not nicked
or cul and thal they slide freely in tracks.
ASSEMBLE VERTICAL SUSPENSION

ASSEMBLY
1. Install plastic guide (A) on pin of lower frame. Be sure to
install spring washer between guide and frame.
NOTE: Upper and lower frames are different. Lower frame

is identified by the rubber bumpers and upper frame
by the extra casting for the ride height valve.
2. Align guide with track (B) and slide assemblv forward until
guides are seated in tracks.
Litho in U.S.A. 90-15-05 Tlvl-1258 (Sep-82)

3. Install metal bushings inlo bores of frame and secure with
retainer (B) and nuts and bolts (A).
4. Use same procedure to install upper support with ride

height lever.
REMOVE HORIZONTAL SUSPENSION

ASSEMBLY
. Remove the four nuts (A) securing horizontal suspension

'I
assembly to bottom of seat.

Seat
3. Remove cotter ptn (A) and nut (B).

I Remove horrzontal suspension assembly lrom seat.
plast c disk for scratches, warpage or excessive

wear and repl?ce as necessary.
DISASSEMBLE, INSPECT AND REPATR HORI.

ZONTAL SUSPENSION ASSEMBLY
'1. Flemove sr.lap ring from plastic bushings on bolh sides
or assernory.
Litho in U.S.A 90-15-07 T lvl' J 258 (Sep-82)

2. Bemove plastic bushings (A) trom ends of support rails.
3. Slide suppo( rails rearward lo allow removal of plastic

caps from other end of rods.
4. Remove absorber attaching hardware (B) and push

absorber (C) ahead to disengage from lower support.
5. Lift upper support assembly with rods from lower support.
6. Attenuator lock lever and support bracket can be re-

moved as needed by removing two attaching nuts and bolts
(A) and pivot bolt (B).
7. Swivel control lever can be removed as needed by

removing the pivot bolts and nuts (A) and disconnecting
spring (B).
Litho in U.S.A. 90-15-08 TM- 1258 (Sep.B2)

)
Bemove snap ring from support rail bushing.
;,$
.:.
9. Wilhdraw support rail and remove bushing from support
10. Inspect bushing and replace as necessary.
Lirho in U.s.A. 90-15-09 Tl\,4-1258 (Sep-82)

ASSEMBLE HORIZONTAL SUSPENSION
ASSEMBLY
Reassemble horizontal suspension in reverse order ol

disassembly noting the following:
'1. When reassembljng upper and lower support frames,

slide support rails through upper support frame before
installing plastic bushings (A), absorber hardware (B) and
absorber (C).
NOTE: Upper frame refers to the frame that attaches to the

seat. Lower frame refers to the frame attaching to
verlical suspension assembly.
2. Atter lower support trame is in place, insert plastic caps

on opposite ends ol rails and position into upper frame.
3. Install plastic bushings (A) and attach shock absorber (C).
INSTALL SEAT AND VERTICAL SUSPEN-

SION ASSEMBLY
1. Place vertical suspension in tractor and block up with
piece oJ wood.
2. Install six cap screws (E, three front and three rear) and
tighten securely.
3. Connect ride height rod (B) to upper frame ol suspension

assembly and insert retaining pin (C).
NOTE: 8e sure seat valve rod levers were not bent and
adequate contact is made to hold valve rod on lever.
4. Connect seat position valve swivel (D) to lever (A) and

adjust friction nut to 80 N (18 lbs) lorce measured at grip
of lever.
A-Seat Position Lever
5. Place seat with horizontal suspension onto vertical B-Ride Heighi Rod
suspension assembly and install onto seat tracks. Install four C-Retaining Pin
stud nuts and tighten securely.
6. Reinstall plastic cover.
Lirho in U.S.A. 90-15-10 TM-1258 (Sep-82)

I
Seat
__., 1
REMOVE, REPAIR AND INSTALL DETUXE

SEAT
1. Femove four cap screws (A) securing seat cushions lo

seat support.
2. Flemove two cap screws securing seat back support to

the rear seat support and remove cusntons.
t 4. Repair seat
by replacing cushions as required.
5. lnstall seat by mounting on support assembly as shown

in removal.
6. Adjust tension of counterbaance by inserting a large

screwdriver (A) in counterbalance shaft (B), pushing inio
release shaft latch and turning counterclockwise until iorino
wili pull support with seat f rom jts extreme forward positioi
he.k to;ts er{treme rearward pCStiOn.
Litho in U.S.A. 90-15-1 1 T[,4- 1 258 (Sep-82)

DISASSEMBLE AND INSPECT DELUXE SEAT
SUPPORT ASSEMBLY
1. Insert a large screwdriver into slot in counterbalance

shalt (A) and push in, disengaging counterbalance shaft
latch from notches and turn in a clockwise direction allowing
counterbalance spring to unwind.
2. Unhook cable (B) from suspension frame.
3. Move seat adiustment lever (C) away trom notches and

slide seat support off suspension assembly.
4. Remove rollers (A) (with shims) Irom suspension trame

shaft.
5. For ease in installation, keep rollers and their shims

logether to reduce adjustment lime required during
assemory.

7. L4ove shaft in opposite direction of slotted end and
remove counterbalance shaft latch and spring (A), reel
spring (B) and reel (C).
L Remove snap ring (E), washer (D) and counterbalance

shaft (F).
A--Counterbalance Shaft Latch

and Sprtng
B-Reel Spring
C-Reel
9. Remove latch handle, bolt (A) and position seleclor lever

(B)
10.R_emove retaining rings (C) and pu seat tatch rod (D)

out ol seat support.
A-Position Selector Lever Bot

B-Posiion Selector Lever
C-Retaining Ring
D--Latch Bod
1 1 . Inspect parts for wear or damage. lf counterbalance

reel
cable need replaced, be sure spring pin is installed flush with
reel on the cable windinq side.
I
I
(F)^
A-Counterbatance Shalt Latch I Y(G)
B-Counterbalance Latch Sp.ln9 II
C-Reel Spring
fL-Pael
'l
E-Snap Ring
F-Washer
G-Snap Ring
@'\
H-Counterbalance Shatt
{s
Litho in U.S.A. 90-15-13 TL4- 1258 (Sep-82)

ASSEMBLE DELUXE SEAT SUPPORT
ASSEMBLY
1. Assemble seat support by reversing disassemble proce-

dure noting the following instructions.
2. Check rail to roller side play clearance to provide free

rolling of support through out its full range of travel, add or
subtract shims in rollers to provide side play specification
of 0.1 3 to 0.76 mm (0.005 to 0.030).
3. Turn counterbalance shalt counterclockwise to tighten

spring unlil spring will pull seat support trom it extreme
{orward position.
4. Install seat support on suspension assemble and install

seat.
DISASSEMBLE AND REPAIR DELUXE SEAT

SUSPENSION
1. Bemove seat and seat support assembly.
2. Remove two screws (A) which secure arm assembly (B)

lo susoension lrame (C).
Litho in U.S.A. 90-1 5-14 TN4-1258 (Sep-82)

Lower the arm assembly (A) whrle raising suspension
frame (B) and separate the upper end of sh3ck absorber (C)
from its mounting (D).
4. l\4ove shock absorber upward to disengage the shatt (E)

lrom links (F).
5. Remove shock absorber.
6. Flemove attaching screws tor further disassembly
7. Bushing (G) can be reptaced with the suspension

aSSembled.
A-Arm Assembly
8-Suspension Frame
C-Shock Absorber
D-Shock Absorber Mounting
E-Shock Absorber Shatt
F-Shock Absorber Links
G-Bushings
8. Remove suspensrcn arm assembiy bushings using No.

27 487 Drvet with No. 27497 Disk
f-
9. lf necessary remove rubber bushings (A) on shock
absorber (B) by removing retaining r ngs and prying off.
10. Replace rubber bushings by pushing onto shaft and

replace retaining rings.
NOTE; lf rubber bushings ar retaining rings are difficult to

J.<:t.l, !8..!) p/cc<; lc ccn?p/c'd rulLber bUS/titgS.

11. Use Shock Absorber Spring Compressor (See Fabri-
cated Tools, Section 99) to compress shock absorber spring
enough to allow rotation of lower mounting ring (C).
12. Carefully loosen compression tooL nuts (B) and remove

spring lrom shock absorber {A).
13. Examine spring (A) for cracks or breaks, replace as

requrred.
14. Replace shock absorber (B) if it does not ofter accept-

able resistance to both compression and extension when
held vertically with shock absoi'ber body down.
ASSEMBLE DELUXE SEAT SUSPENSION
1. Assemble deluxe seat suspension by reversing disas-

sembly procedures, install seat support assembly and install
seat.
Litho rn U.S.A, 90-15-16 TM-1258 (Dec-83)

Seat
REMOVE AND INSTALL GRAMMAR SEAT

SUSPENSION
1. Remove four cap screws (A) and lock washers securing

slide rails to seat suspension and remove seat with slide
rarls.
2. Inspect slide rails for wear or binding.
3. Fiemove SMV sign to remove nuts f rom cap screws (A).
4. Remove nuts (B) and cap screws (C).
5. Femove suspension assembly.
REPAIR GRAMMAR SEAT SUSPENSION

1. Flemove four cap screws (A) to separate suspension
assembly f rom mounting bracket.
::,ri r!,rl t3a / trlirr|!a.:,r:rrt ritni6

Litho in U.S.A. 90-15-1 7 TM-1354 (Sep-87)
2. Separate boot from suspension frame. Remove plastic
buttons caretully.
Bemove boot bv expanding boot over adiuster knob.
REMOVE UPPER HOUSING PLATE

1 . Unhook pin tang from arm assembly (A).
2. Remove pin (B).
90-15-18 TM-1354 (Sep-87)

Seat
3. Litt top plate and slide towards {ront of suspension frame.
4. Slide top plate rollers out of open slot, then lift plate
assembly f rom arm assembly.
5. Inspect rollers (A) (white in color) for wear or cracking.

I Replace if necessary.
REMOVE ARM ASSEMBLY
1. Unhook weight strip spring (A).
Litho in U.S.A. 90-15-19

Seat
2. Unhook pin tang from arnr assembly (A).
3. Remove pin (B).
NOTE: Lower pin is shorter than top pin. Keep pins separate
to avoid confusion durino reassemblv.
4. Remove arm assembly by twisting in base slots, then

pressrng Inward on arTns.
r,;,rl3.!2.r ilj ..9.r:rrit l
5. Inspect lower rollers (A) (gray in colo0, and replace if

worn or cracKeo.
IMPORTANT: Upper and lower rollers are identical in

size and shape, but should not be
interchanged.
il" ;u a; 90-15-20 TM-1354 (Sep-87)

Seat
6. Inspect plastic bearings (A) tor wear, cracking, or break_

ing. Beplace if necessary.
f-
7. Remove springs (A) to remove plate (B).
8. To remove plates (C). remove pin going through arm

assembly and plates.
9. Inspecl all parts for wear or breaking. Inspect spring tor

fatigue. Replace parts as necessary.

DISASSEMBLE WEIGHT ADJUSTER
ASSEMBLY
1. Unscrew weight adjuster knob until all tension has been

removed from springs (A).
2. Remove spring pin (B).
3. Remove yoke assembly (C) Jrom adjuster shaft.
4. Inspect yoke assembly for wear or flat spots. Replace

yoke assembly as necessary.
5. Unscrew adjuster knob (A) until completely loose.
6. Remove retaining ring (B).
7. Remove adjuster knob assembly from seat base.
8. Inspect shaft for worn or stripped threads (A).
9. Inspect spring pin (B), washer (C), and retaining rlng (D)
for breakage. Fieplace adjuster knob assembly if required.
A-Threads . A,i
B-Spring Pin
C-Washer
D-Betaining Ring
Litho in u.s.A. 90-15-22 TM,1354 (Sep-87)

10. Remove spacer (A), washers, and beanngs.
IMPORTANT: Springs will still have some tension on

them and will move when parts are
removed.
i,i2 r\!ar24 !l
1 f . inspect bearing (A) for misslng or worn balls.
12. Inspect washers (B) for wear and washer (C) for
cracking or breaking.
@
\ tQ ,C]
vI 1
ffi
1 3. Remove spring and shock assembly (A) by prying up on
shock absorbers at base studs.
Litho in U.S.A. 90-15-23 TIV-1354 (Sep-87)

Seat
A//;N46024 itl Ur0:090015 ABXt rtllStj
15. Unscrew spring (A) from spring nut (B).
16. Inspect spring for cracks or breakage. Replace if

necessary.
17. Remove nut (C).
18. Unscrew shock absorber (A) from retainer.
19. Inspect shock absorber for leaks and replace if

necessary.
Ar2.N36024 \J1 Ll90.C90C1r ADXt rttCSa
REPLACE SEAT BASE WEAR STRIPS

lnspect yoke rail (A) and rubber pad (B) for wear. Replace
as necessary.
472 N3a,1.24 R1 U90j0S00ra B!X1 r1t03r

Ld''; in U.S.A. 90-15-24 TM-1354 (Sep-87)
REPLACE WEIGHT STRIP
1. Flemove guide (A) by squeezing together tabs (B) and
removing guide, roller, and weight strip from seat base.
2. Inspecl roller (A) tor wear or broken studs on each end

of roller. Replace iI necessary.
3. Inspect weight strip (B) lor sptits or tears. Fleplace

necessary.
iJ o\ "'.',
4. Reinstall by placing weighl strip around roller and placing tB)
guide (C) over roller. Y
rl4:i!:-.-
5. Feed weight strip through hole in base and snap guide e33geg83e
into base. F-FeN(\l(\a\tc?)
6. Make sure weight strip and roller work lreely after

installation.
A72jN36C24 r1 f90j090015

Seat
I ASSEMBLE WETGHT ADJUSTER ASSEMBLy

I
1. Fleassemble wergf t adjuster assembly using reverse of

Steps 1 through 19 rn Disassemb e Weight Adjuster Assem-
blv in this qroup.
2. After spring and shocK assembly (A) has been assem-

bled, lnsert adjuster knob assembly (B) through seat base
and screw Into spring brackr.t.
3. Install spacer (()) smal flat washer (D), bearing (E),

second small f ai washer, large flat washer (F), and rubber
washer (G).
A-Spring and Shock

Assembly
B-Adjuster Knob
C-Spacer
D-Small Flai Washer
(2 used)
E-Bearing
F-Large Washer
G-Rubber Washer
r9C C.r!r 3Lrr1 rr r la6
4. lnstall spring and shocK.Jssembly by plac ng shock over

seat base siud and prying sonng over stud.
5. Press dovrn on 1op of shock absorber, with another

screwdriver, untrl spr ng hooks n notch of seat base stud.
6. Assemb e remainder of seatt u sing reverse of removal and

disassembly proce.Jirre.
Litho in U.S.A. 90-15-26 IN.4-1354 (Sep-87)

4650 and 4850 Section 90

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l OPERATOR STATION REPAIR

GROUP 05 - AIR CONDITIONING SYSTEM GROUP 06 - AIR CONDITONING SYSTEM

Litho in u.s.A. 90-01 TM-1354 (Sep-87)

Disassemble and Repair Special Tools 90-20-01

Lrtho in u.s.A. TM-1354 (Sep-87)

Number Name use

D-18009KD Electronic Leak Detector Detect Relrigerant Leaks

Refrigerant- 1 2 Charge system.

525 Viscosity Compressor Oil Syslem Lubrication.

SERVICE PARTS KITS FOR COMPRESSOR

The lollowing kits are available for service parts:

Compressor Shalt Seal Kit

Compressor Hardware Kit

Litho in U.S.A. 90-05-01 TI/-1258 (Dec-83)

Hublo-Pulley Clearance 0.55-1.05 mm

HOSE AND TUBING FLARE CONNECTION TORQUES

1/A 7 /16 20 (15) 7-9 ( 5-7)

*lf a connection is made with steel to aluminum or copper,

Litho in U.S.A. 90-05-02 TM-1258 (Dec-83)

Metal Tube Throad and Tofque

1/4 7/16 14-20 (10-1 5)

ENGLISH TOROUE SPECIFICATIONS

NOTE: Wrench torque tolerance is t 2oo/o.

u10;0t0000 FX2 2905a5

Litho in u.s.A. 90-05-03 TM-1354 (Sep-87)

2. Unscrew body (D) with poppet valve assembly (C) trom #

3. Remove O-ring (B).

4. Unscrew union nut and body assembly (G) Irom adapter

5. Replace either or both coupling halves (male or female)

6. Replace O-rings (B and J) andseal (E). Valveassemblies

7. Lubricate new O-rings with refrigerant oil and install on

8. Insert poppet valve assembly (C) into body (D) and

L Lubricale poppet valve O-ring (H) with re{rigerant oil and

1 0. Tighten until body contacts refrigerant line adapter, then

Lirho in u.s.A. 90-05-04 Tlvl-1354 (Sep-87)

DISCHARGING THE SYSTEM

1 . lf the compressor is operable, operate tor 1O minutes with

a) Connect manilold gauge set to compressor as shown.

3. Disconnect clutch coil wire and Hi-pressure switch lead

Litho in U.S.A. 90-05-05 TM-1354 (Sep-87)

MAKE VOLUMETRIC EFFICIENCY TEST

2. ll compressor has not been disassembled and internal

3. Stand compressor on each end, then slowly roll for 30

AC7;RV/5955 R$/1267 4 LlqCiU90005 FXr ?4043i

4. N/ount compressor in a vise and remove dusl cover.

5. Remove large caps from both suction and discharge

6. Connect low pressure (left-hand) hose (A) from gauge set

NOTE: Low pressure gauge is connected to discharge

7. Use a speed handle (D) and 12 mm socket to quickly

acTrR\!l6r! u!r0:09000a Glr 2b0931

Litho in u.s.A. 90-05-06 Tlvl-1354 (Sep-87)

8. Close low pressure gauge valve and use the speed

9. It pressure read is 370 kpa (9.70 bar) (55 psi) or greater,

a) Front and rear head gaskets.

D) Front and rear suction reed valves.

1. Remove large cap from discharge port and install No.

4. Use an electronic leak detector lo check for leaks from

u90 090005 .rxL 231036

Litho in U.S.A. 90-05-07 TL4-135a (Sep-87)

DISASSEMBLE AND INSPECT COMPRESSOR ]

comDressor on holdino fixture.

NOTE: Mountlng fixture can be made with two pieces of flat

Weld one ptece ol src.A pcrpendicular to the other,