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Chapter 2 -- Air Conditioning Component Service

1. RI99M049 54 TJ 375 425 450 Chassis Components HOLIMS SYNSS3AYd H9IH 3N1VA NOISNVdaX3 Ol HadilHda H3AIHOHH YASNACNOO YASNACNOO 4 OL HOSS3HudlNOO YOSSAYdNOO OL YAAIBOAY OL H3SN3QNOO 9 ANIVA NOISNVdX3 IVINH3HI S YOSSAYdNOO H S1IN3NOdMWOO SISSVHO 0St Sct SZE RI99M048 55 3SOH Nuf113H H31V3H 3SOH AlddNS H31V3H H SIN3NOdMWOO 9SNILV3H 09 ANV Set SLE RI99M047 56 A C COMPRESSOR CLUTCH Clutch Removal NOTE This procedure shows a compressor with six screws holding the dust cover on the clutch Your unit has three Torx screws for attaching the dust cover and only differs in this manner STEP 91 A21250 See this section for compressor removal Clean the external surfaces of the compressor before doing any work on the compressor STEP 92 A21251 Remove the three Torx screws for the clutch dust cover STEP 93 A21252 Remove the clutch dust cover STEP 94 a A21253 Remove the retaining nut for the front plate Use the special spanner wrench from the service tool set to keep the plate and shaft from turning STEP 95 _ A21254 Install the special puller from the service tool set on the clutch front plate STEP 96 21255 Turn the center screw to pull the
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3. 29 When performing electronic leak detection with FNHO00855 follow these general guidelines 1 There must be enough refrigerant in the system to produce normal pressures at least 50 psi 2 Leak test in an area free of wind and drafts 3 Operate the tractor long enough to circulate the refrigerant and produce normal system pressures 4 Shut the tractor and system off when leak testing 5 Clean oily spots with dry shop cloths solvents can leave a residue which may confuse FNHO00855 6 Hold the leak detector probe under the point being checked since refrigerant is heavier than air 7 The probe on the leak detector should never come into contact with the component being checked 8 If FNHOO0855 indicates a leak move the probe away blow out the area with clean shop air and verify the leak with the detector 9 If the leak cannot be found with 855 use UV florescent leak testing to locate the problem 10 Repair all leaks and recharge the system The dye which dissolves into the SP 20 PAG oil in the system is particularly helpful in detecting intermittent leaks that occur only when the system is running because of change of temperature high System pressures vibration or contact between components WARNING Wear safety goggles and non permeable gloves when working with the fluorescent dye and leak testing M817 This fluorescent dye will normally remain useful over the life of the
4. 01 rez LZZ 0122 Do 8E 21 4 99 onem Bisd 8 opz 6159 Lpz 91 202 6154 010 6154 0 oz 4 06 Que DEL 6 61 01 9991 ed 2991 010071 SSZ 01202 641 01 851 DZE 499 eb Bisd gez o zoz 6154 961 01991 6154 og 0192 61 01 v1 4208 61 0 6 1791 01 681 1481 OI SPILL ZOZ 01221 eg LEL 01 46 4 09 66 08 onum 061 01591 858 261 01821 Bisd 0161 Bisd 8 0 OL 4 02 991 0 9 0181 OL pZLL 9901 01 88 221 01121 06 01 69 Dako HH HHUDiH HH HH MOT HH aimesoduie 9JnjeJeduie 95 eunssaJg APIS YBIH INSS ld 9piS juaiquiy SIPPOW IIV LYVHO 3unssaad ddniva3adial ONINOILIGNOD FL 28 LEAK DETECTION WARNING Never leak test with an open flame or a flame type detector M816 WARNING When refrigerant comes in contact with an open flame it can form dangerous gas Never breathe these fumes SM109A Two methods are recommended to test the A C system for refrigerant leaks electronic leak testing with FNH00855 and UV florescent leak detecting Whatever method is used the following components or areas should be checked always looking for signs of leakage oily residue dust accumulation A Compressor li
5. Recovery Station Dye Injector Tool with Charged System o VIS e RROOF101 Valves Shown in OPEN Position 1 VALVE TOWARD 3 RESERVOIR RECYCLING STATION 2 RESERVOIR CAP 4 VALVE TOWARD TRACTOR The R134a dye injector tool is designed to be used with the OEM1598 recycling station 1 Disconnect the low pressure hose blue from the 1 2 inch Acme flare fitting on the rear of the station 2 Connect the dye injector to the fitting 3 Connect the low pressure hose to the dye injector NOTE The dye injector can be permanently mounted on the recycling station with the two threaded holes on the bottom of the reservoir 4 Open the valves on either side of the reservoir on the dye injector 5 Recover 0 5 Ib 0 23 kg of refrigerant from the system This amount of refrigerant will act as a carrier to inject the dye 6 Close the valve on the tractor side of the dye injector and continue to recover This will draw the refrigerant out of the reservoir on the dye injector 7 Close the valve on the station side of the dye injector and stop recovering 8 Remove the cap from the reservoir and fill the reservoir with the contents of one bottle of fluorescent dye Reinstall the cap on the reservoir and tighten securely 9 Open the valve on tractor side of the reservoir on the dye injector 10 Recharge the A C system with the proper amount of refrigerant removed earlier 0 5 Ib 0 23 kg Start the rechar
6. STEP 10 A22111 Record the amount of oil in the reservoir This amount of new oil should be added back to the system Dispose of any oil in the bottle in an appropriate manner and return the bottle to the station STEP 11 All refrigerant has been removed from the A C system replace components or make any repairs at this time 15 RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 IMPORTANT When contaminated refrigerant is discovered with Refrigerant Identifier OEM4450 additional care is necessary to protect your safety and prevent the contamination of service equipment and your refrigerant supply Recover the refrigerant with OEM1691 station to a recovery tank reserved for contaminated refrigerant Do NOT use OEM1598 to recover the contaminated refrigerant Preparing the Tank STEP 12 RR00E127 The tank for the station may be filled with 10 to 15 psi of dry nitrogen which must be removed before it can be used Remove the cap from the red valve outlet Open the tank valve to release the nitrogen Close the tank valve STEP 13 RROOE153 1 VACUUM PUMP 2 CONNECTOR Use the vacuum pump on OEM1598 to pull a 5 minute vacuum on the tank IMPORTANT Head all safety warning and maintenance sections of the operators manual before operating the station WARNING Do NOT use a tank without a limit switch to recover contaminated A refrigerant with OEM1691 The limit switch prevents overfilling of the tank
7. 4 Remove the four screws across the top of the motor assembly and two screws at the sides and remove the assembly 5 Install a new motor assembly with the existing hardware and connect the motor to the harness RH01G097 1 HARNESS CONNECTOR 2 MOUNTING SCREW HEATER CONTROL VALVE REPLACEMENT STEP 184 To replace the heater control valve 1 See ACCESSING THE HVAC BOX page 77 2 Move the controller mounting plate forward to gain better access to the valve RD99N053 3 Disconnect the control valve from the harness NOTE Be prepared to collect a small amount of coolant when the valve is disconnected T 14 RD99N052 Pinch the clamp and disconnect the inlet hose shown to the core from the valve Pinch the clamp and disconnect the supply hose at the bottom of the valve Remove the valve Install a new heater control valve to the same connecting hoses Connect the valve to the harness 80 EVAPORATOR HEATER ASSEMBLY Evaporator Heater Assembly Removal NOTE thermal expansion valve heater valve and evaporator heater assembly are located under the operator seat See ACCESSING THE HVAC BOX page 77 STEP 185 RD99N047 1 THERMAL EXPANSION VALVE Remove the thermal insulation tape from the expansion valve and the evaporator lines To test the valve see thermal expansion valve testing in this section Recover the A C system to remove the evaporator heater core STEP 18
8. Avoid heat sparks and open flame 2 Use only in a well ventilated area Mechanical exhaust and an appropriate respirator may be needed in warm and confined areas to protect your safety Avoid breathing mist and vapor Wear chemical splash safety goggles Wear rubber gloves and a rubber apron when handling the solvent or flushing components 6 Observe all local state and federal regulations regarding the safe disposal of used flushing solvent M802 AC The goal of flushing is to remove contaminants from the A C system Your shop air must be properly filtered and dried with coalescing filter or you will simply replace one source of contamination with another using dirty moisture saturated air The compressor receiver drier and thermal expansion valve must be bypassed removed when performing circuit flushing The compressor and receiver drier may never be flushed the thermal expansion valve can be back flushed Keep the lid on the flushing recovery bucket closed when flushing to minimize the circulation of solvent vapors Never allow the flushing solvent to remain in or on the hoses for an extended period of time Overexposure of the hoses to the solvent especially the exterior may cause hose swelling Do not open the fill cap on the flush reservoir when the reservoir is under pressure Release pressure before removing cap 39 Component Flushing Procedure with Power Flush 17550 STEP 52 All refrigerant
9. Direct the air flow from the inside of the filter outward IMPORTANT maximum air pressure at the nozzle must not be more than 35 PSI 242 kPa Too much air pressure will cause damage to the filter IMPORTANT Do not use a washing method with filter washing compound to clean the filter 93 RECIRCULATION AIR FILTER SERVICE STEP 225 Remove the cab recirculation air filter behind the operator seat STEP 226 Clean the filter as frequently as required by operating conditions Use mild soap and water Rinse with clear water and tap out the excess Or use low pressure shop air to blow out the filter STEP 227 Install the filter behind the operator seat 94 CAB PRESSURIZATION TEST NOTE Perform the cab pressurization test whenever unusual amount of accumulates in the cab or in the evaporator box or if the evaporator core is plugged NOTE When performing this test the door and service door must be closed and latched STEP 228 y RD99N110 Location shown from under the cab RD99N181 Insert the sensing tube from a a digital manometer through the monitor cable access opening behind and below the fuse and relay panel in the electronics compartment in the cab NOTE Do not attempt this test through the door or service door seal since the metal reinforcement in the seal will pinch off the sensing tube STEP 229 RD99N176 Start the engine and run at minimum of 600
10. Do not work with the lamp ON for more than 5 minutes If the lamp heats up uncomfortably cease operation IMPORTANT Do not expose eyes or skin to ultraviolet light Do not stare into an ultraviolet light beam or operate the lamp without the ultraviolet lens filter in place 6 In direct sun sunlight or very bright ambient light use a cover of any type over the suspected area to reduce this light 7 the lamp cannot be directed straight at suspected leak location use a mechanics mirror to reflect the light at the location Or wipe the suspected leak site with a clean shop cloth and shine the lamp at the cloth to check for traces of fluorescent dye 8 The exact location of a small leak at a connection point or sealing point can be further narrowed by daubing a wet film of soap solution over the suspected area Watch for bubbles to confirm the exact point of leakage 9 Repair all leaks and recharge the system 10 Use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future 36 A C SYSTEM FLUSHING PROCEDURE When flushing is necessary all affected components should be flushed to eliminate the possibility of contaminants remaining in the system There are two methods of A C system flushing individual component flushing and complete circuit flushing The complete circuit is the system minus the compressor receiver drier and thermal expansion valve
11. The compressor receiver drier and thermal expansion valve are always bypassed removed during circuit flushing and serviced individually The receiver drier is always replaced anytime a system is flushed The expansion valve due to its small orifices is removed from the system and cleaned or replaced The compressor is either replaced or reused but is NEVER flushed The preferred method of system flushing is individual component flushing Given the size of New Holland equipment and the distance between components individual component flushing will dislodge and flush out more contamination than complete circuit flushing Which individual components are flushed will depend on the source of the contamination and is left to the discretion of the technician For mildly contaminated systems complete circuit flushing may be used where the contamination is oxidized refrigerant oil or small amounts of receiver drier desiccant Complete circuit flushing requires little system disassembly minimal special connectors and the least amount of service time The most likely sources of contamination are compressor failure and receiver drier failure Compressor Failure A failed compressor generally sends debris downstream to the condenser the receiver drier and towards the thermal expansion valve If the compressor fails internally it must be replaced Also individual flushing of the hose between the compressor and condenser of the hose
12. been drained Or use the dipstick to measure and match the replacement compressor oil level to the old compressor oil level STEP 130 If the oil level is not correct add or subtract oil to the correct level described above Always add oil in small quantities to avoid overfilling to subtract oil the compressor must be removed and drained IMPORTANT Use only SP 20 PAG oil STEP 131 RD99N135 Check O ring on the oil filler plug and replace if necessary Install the plug and tighten to a torque of 11 to 18 Ib ft 15 to 24 Nm IMPORTANT For all TJ tractors move the charge air cooler line back into position and reconnect with the clamps The charge air cooler lines are stamped for proper alignment Tighten the clamps to 100 in Ibs 11 3 Nm Compressor Removal TJ 275 325 132 RD00B023 Disconnect the compressor clutch wire from the engine harness assembly STEP 133 RDOOB024 Remove the bolt nut and washers holding the bracket to the top mounting leg of the compressor to move the hoses out of the way 67 STEP 134 RD00B025 Remove the bolt and nut from the hose clamp to move the hoses out of the way STEP 135 RD00B026 Disconnect the high pressure line from the discharge port and the low pressure line from the suction port on the compressor Immediately install protective caps on the open ports and lines 68 STEP 136 STEP 138 RD00B027 0008028 Loosen the
13. Test the clutch belt for correct tension using a belt tension gauge Check the belt to the following specifications New 95 to 115 16 422 to 516 Used 90 to 100 Ibs 400 to 489 N Tighten the adjusting strap hardware on the upper compressor leg STEP 145 RD00B026 Slowly remove the protective cap install new O ring and connect the high pressure line to the discharge port on the compressor Carefully remove the protective cap install new O ring and connect the low pressure line to the suction port on the compressor IMPORTANT Use caution when removing cap as new compressors are under pressurization when shipped STEP 146 RDOOBO25 Reinstall the hose clamp on the bracket with hardware removed earlier STEP 147 P RD00B024 Install the bracket on the compressor leg with hardware removed earlier NOTE Mount the bracket on the right hand side of the leg STEP 148 RD00B023 Connect the compressor clutch wire to the engine harness assembly Compressor Removal TJ 375 425 450 STEP 149 RD99N132 RD99N130 Use a 1 2 inch ratchet drive in the belt tensioner to relieve pressure on the belt and remove the belt from the compressor pulley STEP 150 RD99N147 Disconnect the compressor clutch wire from the engine harness assembly 71 STEP 151 n RD99N148 Disconnect the high pressure line from the
14. between the condenser and receiver drier of the condenser itself and replacing the receiver drier are appropriate service actions for compressor failure For most New Holland condensers with a single flow path flushing effectively removes debris For condensers with parallel flow paths since flushing takes the path of least resistance around any blockage condenser replacement may be the only option The receiver drier has a fine mesh screen to capture contaminants but the contaminants may penetrated the screen Check the discharge port of the receiver drier to see if contaminants have penetrated the screen If so individual flushing of the hose between the receiver drier and the expansion valve and cleaning the thermal expansion valve are appropriate If the thermal expansion valve is damaged replace it as well Additional flushing of the system beyond the thermal expansion valve is at the discretion of the service technician who can best judge how far the contamination has traveled Receiver Drier Failure Receiver driers should not normally fail if replaced A when system has been opened before B when receiver drier has been in service two or more years C when the system has been open for a long period of time because of a leak broken hoses loose connection that has permitted air and moisture to enter the system D when contaminated refrigerant was recovered from the system However if the desiccant pouch
15. clutch front plate STEP 97 21256 Remove the shim s from the shaft 57 STEP 98 21257 Carefully remove the dust cover STEP 99 21258 Remove the key from the rotor shaft STEP 100 A21260 Remove the external snap ring for the bearing and pulley assembly 58 STEP 101 STEP 104 Fr 21261 E 21265 Install the special puller internal collars into the groove in the pulley Install the special tool onto the shaft Tighten the mounting screws finger tight Remove the snap ring for the clutch coil assembly STEP 105 STEP 102 21264 Disconnect the clip for the lead wire A21262 Turn the center screw on the puller STEP 106 STEP 103 21266 Remove the clutch coil assembly A21263 Remove the pulley and bearing assembly 59 STEP 107 21267 Remove the internal snap ring and remove the bearing from the pulley Exploded View of Clutch 1016L9 1 COIL ASSEMBLY 4 BEARING DUST COVER 7 DUST COVER 2 PULLEY 5 FRONT PLATE 8 COMPRESSOR 3 BEARING 6 SHIM S 60 Compressor Clutch Replacement STEP 108 102L7 1 AMMETER 2 12V BATTERY Method 1 Use a ammeter voltmeter and a 12 volt battery to check the amperage of the clutch coil The current draw must be 3 6 to 4 2 amperes at 12 volts A reading of more than 4 2 amperes indicates a short within the coil No amperage reading indicates an open circuit in the Coil Replace
16. compressor pivot bolts Push the compressor down toward the engine Remove the clutch belt STEP 137 139 RD00B014 1 ADJUSTING STRAP NUT RD00B029 Remove the compressor pivot bolts and nuts Remove the bolt from the adjusting strap 4 Slide the compressor out of the bracket and out of the tractor Remove the adjusting strap from the compressor Compressor Installation TJ 275 325 IMPORTANT f a new compressor is to be installed its oil level must be adjusted to match the removed compressor See Oil Level Check or Adjustment page 64 IMPORTANT Use caution when removing protective compressor caps as new compressors are under pressurization when shipped STEP 140 80008029 Install the adjusting strap the compressor Install the compressor in the bracket on the tractor with pivot hardware removed earlier Do not tighten at this time STEP 141 80008028 Install the drive belt on the compressor clutch pulley in the front groove 69 STEP 142 5 80008014 1 ADJUSTING STRAP NUT Install the bolt in the adjusting strap Do not tighten STEP 143 RD00B016 Use a 1 2 inch ratchet drive with the belt tensioning tool to pull the compressor forward and tension the belt Or use a pry bar on the compressor legs only not the compressor body to tension the belt 70 STEP 144 RD00B027 Tighten adjusting bolt Tighten the pivot bolts and nuts when completed
17. evacuate the system 6 With the system in a vacuum close the valves on either side of the reservoir on the dye injector 7 Remove the cap from the reservoir and fill the reservoir with the contents of one bottle of fluorescent dye Reinstall the cap on the reservoir and tighten securely 8 Open the valve on tractor side of the reservoir on the dye injector 9 Recharge the system with the proper amount of refrigerant Start the recharging process and immediately open the valve on the station side of the dye injector to prevent drawing the dye into the charging station The dye will be injected into the system while recharging 10 Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports This will alert service personnel in the future to the presence of the dye in the system 11 Operate the A C system for about 15 minutes to circulate the dye throughout the system Turn off the system and use the UV lamp and goggles to locate leaks The exact location of the leak will be shown by a bright yellow green glow of the dye NOTE The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak A very small leak could take hours or days of system operation to appear 12 After repairing the system use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future 31
18. hoses loose connection that has permitted air and moisture to enter the system E If contaminated refrigerant was recovered from the system TJ 375 425 450 shown The receiver drier orientation is critical Make sure the outlet flange is within 5 degrees of true level the decal should face up The receiver drier must be installed with the inlet connected to the hose from the condenser and the outlet connected to the hose going to the thermal expansion valve The receiver drier is normally the last item replaced when servicing the system just before the system is evacuated This prevents saturating the drier with moisture NOTE Always install new O rings when the receiver drier is connected to the system Lubricate the O rings with clean mineral oil RD99N129 Use the two hand two wrench method to prevent damage to the tubes and fittings when you loosen or tighten the tube connections 77 ACCESSING THE BOX STEP 178 NOTE The following procedure applies to both the standard units and Automatic Temperature Controlled ATC systems STEP 175 Disconnect the harness to the right hand control console STEP 176 RD99N151 For tractors equipped with mechanical remote hydraulic controls the right hand control console must be disconnected from the seat A Loosen the 13 mm nut at the front of the right hand side of the seat B Remove the 18 mm bolt at the right hand rear of the seat and
19. initial air gap in the field Slip the wire between the clutch plate and the pulley and check the gap at the three rivets The gap must be 0 016 to 0 031 inch 0 41 to 0 79 mm The gap must be even all the way around the plate If necessary lightly lift or push down on the plate to make the gap even 63 NOTE f the gap does not meet the above specifications remove the front plate and add or subtract clutch shims as required STEP 124 A21252 Install the clutch dust cover STEP 125 21251 Install and tighten the three Torx screws that attach the dust cover to the compressor clutch Torque to 5 to 8 Ib ft 7 to 11 Nm 64 A C COMPRESSOR Oil Level Check or Adjustment Since the refrigerant is recovered as a gas during a typical recovery only about 25 of the oil in the vehicle s A C system is recovered and separated The other 7596 remains in the closed system normally on the low pressure side These percentages are representative and will vary from recovery unit manufacturer to manufacturer The only reliable method for determining if the A C system has the correct amount of oil is the dipstick method Too much oil in the closed system causes poor condensation and reduced cooling since the oil accumulates on the evaporator and condenser surfaces Too little oil in the system causes poor lubrication which equates to poor refrigerant circulation and reduced compressor efficiency and high pressures Bot
20. is punctured by a debris from a failed compressor or fails from age desiccant particles may flow downstream toward the thermal expansion valve and the evaporator An indicator of receiver drier failure is soft golden brown particles found at its outlet The thermal expansion valve should always be checked after receiver drier failure If the receiver drier fails it must be replaced Also individual flushing of the liquid hose between the receiver drier and the thermal expansion valve and cleaning the valve are appropriate Check the suction line from the valve to the compressor and the compressor suction port If golden brown particles is found flush the evaporator and suction line individually The compressor may be reused AFTER all contaminants are removed 1 Use the dipstick to measure the compressor oil level 2 Drain and refill the compressor with PAG oil until the drained oil is free of particles 3 Rotate the compressor clockwise to check for binding caused by the presence of particles 4 Drain or add PAG to return the compressor to measured dipstick level IMPORTANT Flushing solvent CANNOT be used to remove compressor contaminants Required Tools 37 Additional system flushing is at the discretion of the service technician who can best judge how far the contamination has traveled and what components may have been damaged and require replacement The following tools are required when flushing an A C system
21. must be recovered from the system before flushing STEP 53 RP00G013 Evaporator and Universal Fittings Shown The 17550 power flush unit uses shop air to atomize the flushing solvent and a pulsing action to scrub residue and contaminants out of components Attach flushing adapters to the component to be flushed These adapters can be shop built or a universal A C flushing fitting set is available Model 17582 STEP 54 RDOOH200 Fill the flushing reservoir 3 4 full with approved New Holland flushing solvent Do not overfill the reservoir or you will restrict the pulsing action of the unit STEP 55 asl 33 RDOOH201 1 AIR VALVE 2 FLUSH VALVE Close the air and the flushing valves STEP 56 338 RP00G018 Remove the flushing tank hose quick coupler from the evaporation plug 40 STEP 57 RDOOH2OS Connect the flushing tank hose quick coupler to an extension or an adapter hose STEP 58 RDOOH202 Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve STEP 59 RDOOH204 1 FROM THE FLUSH PUMP 2 TO THE RETURN BUCKET Connect flushing and drain hoses to flushing adapters on component being flushed so the flushing solvent moves in the opposite direction of refrigerant flow back flushing Reinforced clear hose is preferred to monitor the condition and removal of the used solvent IMPORTANT Secure the lid on the return bucket so all flush va
22. the evaporator core and thermal expansion valve Connect the new valve to the evaporator using the two hand two wrench method STEP 170 RD99N049 Lubricate new O rings with clean mineral oil and install in the fittings on the suction and liquid lines Connect the liquid and suction lines to the expansion valve using the two hand two wrench method STEP 171 Remove air and moisture from the system and charge the system Leak test all connections with FNHO00855 before reapplying any thermal insulation tape STEP 172 Replace all thermal insulation tape and reconnect the low pressure cutout switch 76 CONDENSER AND RECEIVER DRIER STEP 173 NOTE See A C SYSTEM COMPONENTS page 50 Keep the condenser fins clean and straight to make sure that there is maximum air flow though the condenser and radiator at all times Use compressed air or a soft brush to clean the condenser Also check and clean the grille screen and radiator Maximum air flow prevents engine overheating and offers the most efficient A C operation IMPORTANT Because the condenser fins bend easily and are sharp be careful when cleaning the condenser STEP 174 Replace the receiver drier if A System has been opened before B Receiver drier has been used two or more years C Disassembly show small particles of moisture removing material gold or brown particles D If the system has been open for a long period of time because of a leak broken
23. the low pressure hose valve and remove the hose from the port at the compressor STEP 32 RROOE133 Disconnect the compressed air line from the inlet on the regulator STEP 33 RROOE134 Disconnect the black ground lead Disconnect the red power lead from the 12V power source STEP 34 F Bn RR00E137 After each recovery carefully open the accumulator oil drain and drain any collected compressor oil in a proper container NOTE Small amounts of refrigerant may remain in the accumulator and build a slight pressure Drain the accumulator when the inlet pressure gauge shows a vacuum There may or may not be any oil to drain this will vary from tractor to tractor Dispose any oil drained in a proper manner NOTE f any significant amount of oil is drained measure and record that amount Add that equivalent of new SP 20 PAG oil back into the system at the end of the evacuation process IMPORTANT f the oil is suspected to be other than SP 20 PAG oil 1 See the flushing procedures in this Chapter for complete circuit flushing to remove the oil 2 Drain all oil from the compressor and add back to the compressor 8 5 oz 250 ml of new SP 20 PAG oil 3 Back flush the thermal expansion valve 4 Reintroduce the fluorescent dye for R 134a in the system 5 Replace the receiver drier before evacuating and recharging the system 6 Operate the system for 15 minutes to circulate the new oil throughout the circui
24. the oil injection valve to add the oil into the system Close the valve when the oil level reaches the O ring IMPORTANT Do not let oil level fall below the dip tube in the return bottle or air will be introduced into the refrigerant circuit STEP 44 A22115 Press the CHARGE key PROGRAM and CHARGE will appear on the display STEP 45 rgin 22113 Program the proper refrigerant amount for your tractor and press the ENTER key All TJ Tractor Models 4 2 lbs 1 9 kg The display will flash once indicating the programmed data has been accepted STEP 46 A22115 Press the CHARGE key to begin refrigerant charging AUTOMATIC and CHARGE will appear on the display The display shows the programmed amount and counts down to zero as charging proceeds When charging is completed the display shows CPL IMPORTANT Check the OEM equipment manual before performing Step 47 to avoid damaging recovery unit Pressure reading should be obtainable with valves closed Damage may occur if the tractor is started with the valves accidently open or if either or both valves are opened while the A C system is operating STEP 47 A22114 Completely close the high and low pressure manifold valves 25 STEP 48 MK99J200 RD00CO070 Standard A C System 1 BLOWER CONTROL 3 TEMPERATURE CONTROL 4 LCD DISPLAY 2 A C OR ATC SWITCH Start the tractor and run the engine at 1500 RPM Opera
25. with a Charged System 32 Gomipressor 33 SP 20 PAG Oll Ret rm Bottle 34 Fluorescent Leak T stirig etre teen etin 35 SYSTEM FEUSHING PROGED U RE 5 nere eit e tea P ran erecto 36 RHequired Tools nep a rh qi Bir euius 37 i e 38 Component Flushing Procedure with Power Flush 17550 nennen 39 Complete Circuit Flushing Procedure with Power Flush 17550 1 42 Back Flushing the Thermal Expansion Valve or Refrigerant Line n 46 Post Flushing Procedures ne t tme regen rie ae rtm eerte tet ete 48 t roD et dot erp 49 A G SYSTEM GOMPONENCS ax sube d esed beue Ee 50 Cab HVAC Box Components Automatic Temperature Control 50 Cab HVAC Components Standard Systems sse enters 51 TJ 275 925 Ghassis Combporiehts ite rele teer e tr pee orbe Ert eee pe EE edat eden 52 TJ 375 425 450 Chassis Components 54 A G COMPRESSOR GEUTGE EH iste a ies tesa 56 56 Exploded Wiew of ER URINE 59 Compresso
26. 6 RD99N049 Using the two hand two wrench method disconnect the air conditioning suction and liquid lines at the thermal expansion valve Remove and discard the O rings Cap and plug the lines to prevent dirt and moisture from entering the system NOTE Clean packaging tape may be used to seal the expansion valve ports STEP 187 RD00A016 TJ 375 425 and 450 Shown 1 HEATER SUPPLY HOSE Use a vise clamp to clamp off the heater supply hose Make sure the heater control switch in the cab is fully open NOTE Location of the hose differs for TJ 275 325 and TJ 375 425 450 tractors See pages 53 and 55 STEP 188 RD00A015 2 NE TJ 375 425 and 450 Shown 1 HEATER RETURN HOSE Use a vise clamp to clamp off the heater return hose NOTE Location of the hose differs for TJ 275 325 and TJ 375 425 450 tractors See pages 53 and 55 STEP 189 RD99N052 1 CLAMP 2 SHORT HOSE Loosen the clamp and disconnect the short hose between the heater valve and evaporator heater core Be prepared to collect a small amount of coolant that will drain into the HVAC box STEP 190 RD99N052 81 1 CLAMP 2 HEATER RETURN HOSE Loosen the clamp and disconnect the heater return line from the evaporator heater core STEP 191 mmm mo w TH 110109 TL 0 RD99NO056 1 EVAPORATOR TEMPERATURE SENSOR Remove the evaporator tempe
27. BUCKET 1 FROM THE FLUSH TANK Connect flushing and drain hoses to adapters on compressor lines so flushing solvent moves in the opposite direction of refrigerant flow back flushing Connect the hose from the flush tank to the suction line connect the hose to the return bucket to the discharge line Reinforced clear hose is preferred to monitor the condition and removal of the used solvent NOTE Back flushing is done first to dislodge any contaminants and then forward flushing is performed to remove the contaminants NOTE 7he suction and discharge ports on the compressor are marked with the letters S and D respectively IMPORTANT Secure the lid on the return bucket so all flush vapors pass through the bucket filter STEP 75 RD00H205 1 AIR VALVE 2 FLUSH VALVE Open the air valve 1 2 to 3 4 turn IMPORTANT Do not exceed this rate of air delivery This rate delivers one gallon per minute of flush solvent which is ideal for the orifice openings in the circuit being flushed Turn the flushing valve to the FLUSH position and flush the circuit until the solvent appears clear at the return hose to the solvent waste container STEP 76 RHO1F112 2 TO RETURN BUCKET 1 FROM THE FLUSH TANK Close the flushing and air valves Reverse hose connections for forward flushing Connect the hose from the flush tank to the discharge line connect the hose to the return bucket to the suction line Open flushing and air
28. G DEFROST Standard A C switch to ON and check the low pressure gauge reading Under normal operating conditions the low pressure reading will range from 10 to 47 PSI 69 to 324 kPa when the compressor is operating STEP 163 RD99N047 1 EXPANSION VALVE CAP Remove thermal insulation tape from top of valve Use the palm of your hand to warm the expansion valve and watch the low pressure gauge The valve will open and pressure should rise STEP 164 Use ice to cool the expansion valve and watch the low pressure gauge Within seconds the expansion valve will close and the pressure must drop at the low pressure gauge STEP 165 If there is little or no change at low pressure gauge the thermal expansion valve must be replaced 75 THERMAL EXPANSION VALVE REPLACEMENT STEP 166 Recover all refrigerant from the system Remove the thermal insulation tape from the fittings and expansion valve to replace the expansion valve STEP 167 RD99N048 Using the two hand two wrench method disconnect the liquid and suction lines from the thermal expansion valve Discard the O rings in the fittings STEP 168 RD99N048 Using the two hand two wrench method disconnect the thermal expansion valve from the evaporator tubes Discard the O rings on the tubes STEP 169 T97366 IMPORTANT Lubricate O rings with mineral oil 20 PAG Lubricate new O rings with clean mineral oil and install between
29. N HOSE EVAPORATOR TEMPERATURE SENSOR RIOOA009 BASE WELDMENT EVAPORATOR BOX ASSEMBLY CAB TEMPERATURE SENSOR COMPRESSOR CLUTCH RELAY THERMAL EXPANSION VALVE DRAIN HOSE CHECK VALVE Cab HVAC Components Standard Systems 2 5 LID ASSEMBLY STANDARD A C CONTROLLER BLOWER ASSEMBLY RESISTOR ASSEMBLY A RESISTOR B MOUNTING BRACKET WIRE HARNESS NOT SHOWN LOW PRESSURE SWITCH HEATER EVAPORATOR COIL ASSEMBLY HEATER CONTROL VALVE ASSY A C SUCTION LINE TUBE A C LIQUID LINE TUBE HEATER SUPPLY HOSE HEATER RETURN HOSE RI99M043 EVAPORATOR TEMPERATURE SENSOR BASE WELDMENT EVAPORATOR BOX ASSEMBLY THERMAL EXPANSION VALVE CLUTCH RELAY DRAIN HOSE CHECK VALVE 52 AATWA NOISNVdX3 TVINH3H L HOSSdHdWOO 8 OL v HOLIMS SYNSS3Yd HOIH 4 ISOH HOSSHHd OO OL JAYA NOISNVdX3 TVINH3HL 9 OL lt 3SOH H3SN3QNOO OL HOSSdHdlNOO 5 SLNANOdWOD SISSVHO 965 ANV 922 c 48 77 n M TJ 275 325 Chassis Components RH99D048 53 275 AND 325 HEATING COMPONENTS 2 HEATER RETURN TUBE AND HOSE 1 HEATER SUPPLY TUBE AND HOSE Meseeeeeaespecesseceed
30. P 23 WARNING Do not operate the vehicle or the A C system if the refrigerant identifier shows more than 2 hydrocarbon in the mixture M801 Start the tractor and run the engine at 1500 RPM If possible operate the air conditioner for a few minutes at maximum cooling and maximum blower speed with ATC switch set to DEFOG DEFROST or standard A C switch to ON Tests have shown that more refrigerant will be recovered if this action is performed NOTE Turn the system and tractor OFF before connecting the station 17 STEP 22 RR00E145 Disconnect the R134a hose from the adapter Disconnect the adapter from the tank and store for future use Reinstall the cap on the red valve outlet port The tank is now prepared See the operators manual to prepare the recovery station for use STEP 24 RROOE131 Remove the cap on the low pressure port at the compressor Connect the blue R134a recovery hose from the station to the low side service port at the compressor 18 STEP 25 RROOE159 Open the tank valve for the R134a hose Open the valve at the service port STEP 26 RECOVERY e RROOE132 Turn the control panel valve to START NOTE This will equalize pressure on both sides of the compressor for easier starting STEP 27 RROOE133 Connect a compressed air line to the air inlet on the regulator at the rear of the station NOTE The air system must offer a minimum of 120 psi 827 kPa and a maximu
31. RPM Take a reading from the digital manometer Cab pressurization must be between 0 25 6 mm and 1 inch 25 4 mm of H20 STEP 230 RD99M029 If a digital manometer is not available a simple one can be made with 8 ft 2 8 m of 3 8 inch OD clear vinyl tubing and a yard stick Tape the vinyl tubing to a yard stick as shown STEP 231 RD99M025 Partially fill the looped section of tubing with water Food coloring may be added to the water to improve visibility STEP 232 RD99N181 Install the long end of the tubing through the monitor cable access opening located behind and below the fuse and relay panel in the electronics compartment in the cab 95 STEP 233 RD99M027 Hold the yard stick vertical Record the water level reading without the engine running Start the engine and measure the movement of water on one side of the yard stick Multiply that value by two Cab pressurization must be between 0 25 6 mm and 1 inch 25 4 mm of H20 STEP 234 If the reading is below 0 25 inch of H5O check the following seals and retest Door and service door seals Window seals Customer supplied radio telephone antenna cable routing If the reading is above 1 inch 25 4 mm of check for extra cab sealing missing filter or broken fresh air inlet 96 PRESSURIZER MOTOR REPLACEMENT STEP 235 The cab pressurizer motor is accessed under the instructional seat in the cab T
32. SP 20 PAG oil needed and no further adjustment is required If the compressor is not to be replaced and the entire system was flushed drain the oil from the compressor to remove any remaining contaminants Add back to the compressor one container 8 5 oz 250 ml of new SP 20 PAG oil Some oil about 1 2 07 35 ml will remain in the compressor even after it has been drained If the entire system was not flushed drain the oil from the compressor to be installed Add back new SP 20 PAG oil equal to 8 5 oz 250 ml minus oil amounts still in the components that were not flushed Use the table below NOTE Total system PAG oil should be 9 6 oz 285 ml and about 1 2 oz 35 ml will remain in a drained compressor Flushing Solvent Disposal Never reuse contaminated flushing solvent Good stewardship of our natural resources is everyone s business New Holland flushing solvent is a hazardous material Never dispose of this solvent by pouring it down the drain or treating it as water soluble waste Observe all local state and federal regulations when disposing the solvent 49 Component Flushed Ambunt OF Sr 20 PAG Oil To Add Condenser 1 7 oz 50 ml Evaporator 1 4 oz 40 ml Receiver Drier 0 85 oz 25 ml 0 34 oz 10 ml Each Hose Because the system has been open for a prolonged time it is very important to draw the system to a deep vacuum to remove all moisture Evacuate the system for at
33. Section 50 Chapter 2 AIR CONDITIONING COMPONENT SERVICE All TJ Series Tractors 2001 Printed in U S A 7 90941NH September 2001 TABLE OF CONTENTS SPEGIEIGATIONS wae sce wat aaa ok 4 SBEGIAESTOBOUES Mu LM 4 SREGIAL TOOLS sis eet D tton 4 SAEETY PROGEDURBES 7 de Sea se ta ee 8 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY sse 9 RECOVERING PURE 134A REFRIGERANT entren nnnm rennen 11 RECOVERING CONTAMINATED REFRIGERANT WITH 1691 15 Preparing the iode at ee ate See eee be desee ees 15 Recovery Process aiii testet obe ates tees hc 17 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING sese nennen nene 22 TJ AIR CONDITIONING TEMPERATURE PRESSURE CHART sess nnne 27 BAK DETECTION S iiti etii tiet ees vit tee Lr Iste etl 28 Electronic Testing NBHOO855 ie eee ete tte iore e edt e tet eigen lies 29 Florescent Leak Detection en ee oie delet eed eei n beatles 29 FluorescentiDye Injectiorni 30 Recovery Station Dye Injector Tool with a System a Vacuum sss 30 Recovery Station Dye Injector Tool with a Charged System sse 31 Quick and Easy Dye Injector Tool
34. Temperature Control RD00CO070 Standard A C 1 BLOWER CONTROL 3 TEMPERATURE CONTROL 2 ATC OR STANDARD A C 4 LCD DISPLAY SWITCH Start the tractor and run the engine at 1500 RPM If possible operate the air conditioner for 15 minutes at maximum cooling and maximum blower speed ATC switch set to DEFOG DEFROST standard A C switch set to ON STEP 2 MK99J191 RD99N133 Clean the external surfaces of the compressor and hoses Remove the caps from the service ports on the suction and pressure lines MK99J192 RD99N138 TJ 375 425 450 IMPORTANT Use Hefrigerant Identifier OEM4450 to verify refrigerant purity If refrigerant is 9896 pure HFC 134a and or the only non condensables test as air and moisture then proceed with Step 4 If not go to Step 12 With the charging station manifold gauge valves in the closed position connect the hoses from the test gauges to the service ports Connect the hose from the low pressure gauge to the port on the suction hose Turn in valve depressor Connect the hose from the high pressure gauge to the port on the discharge hose Turn in valve depressor MK96C017 A22111 1 DRAIN VALVE 2 OIL RESERVOIR Open the drain valve to make sure that the oil separator is drained prior to recovery Oil may have mistakenly been left in the recovery unit itself from the previous service job An oily mist will discharge if the separator has been drained Check that
35. and protects your safety M797 STEP 14 RROOE144 A 1 4 inch FFLX to 1 2 inch Acme adapter OEM1693 should have been ordered with the unit Connect the adapter to the red tank valve STEP 15 RROOE152 Connect the 96 inch 2 4 m blue hose with the R134a service coupler to the adapter 16 STEP 16 Connect the R134a service coupler to the tee fitting on top of the vacuum pump on OEM1598 Open the valve on the service coupler by turning it clockwise RROOE154 STEP 17 RROOE155 Open the valve on the tank STEP 18 RROOE156 Open the low side manifold on the control panel of OEM1598 STEP 19 ROOE141 Press SHIFT RESET and ENTER at the same time Press 1 The vacuum pump starts and runs continuously until any other key is depressed Run the vacuum pump for a minimum of 5 minutes Then press 1 to stop the pump STEP 20 RROOE155 Press SHIFT RESET again to return to the normal display mode Close the valve on the tank Close the valve on the service coupler by turning it counterclockwise and disconnect the blue hose from the vacuum pump STEP 21 RROOE143 Set the tank on the platform at the rear of the station Tighten the black strap securely around the tank Recovery Process IMPORTANT f a recovery tank becomes full during a recovery the float switch will automatically turn off the scavenger See Step 35 for changing tanks in the middle of a recovery STE
36. ate leaks The exact location of the leak will be shown by a bright yellow green glow of the dye NOTE The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak A very small leak could take hours or days of system operation to appear 9 After repairing the system use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future 34 SP 20 Oil Return Bottle MK96C043 NOTE This is the least preferred method for injecting the dye since it requires very careful measurement of the PAG oil in the bottle and risks the introduction of air into the system if the dip tube in the bottle is exposed 1 Recover the refrigerant from the A C system 2 Carefully measure the amount of SP 20 PAG oil in the reservoir which was separated from the refrigerant 3 Pour the new replacement oil into the oil return bottle plus some additional oil to prevent uncovering the dip tube 4 Pour the contents of one bottle of fluorescent dye into the oil return bottle and seal the bottle 5 Evacuate the system and inject the oil and dye mixture into the system making sure the oil level in the oil return bottle does not drop below the dip tube 6 Recharge the A C system with the proper amount of refrigerant 7 Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports Thi
37. can form when refrigerant comes in contact with an open flame Never inhale fumes M745 7 Never leak test with compressed air or flame tester Tests have indicated that compressed mixtures of HFC 134a and air can form a combustible gas M746 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY IMPORTANT There are no repair procedures for the compressor or compressor clutch If the clutch or compressor are defective replace them WARNING 134a is the only refrigerant approved in 134a systems Alternative refrigerants which boast better cooling capabilities are in most cases highly flammable Do not expose contaminated refrigerant to spark flame or yourself M748 IMPORTANT Refrigerant contamination has become an issue since the introduction of 134a as a replacement for R 12 Contamination refers to a refrigerant blend and or mixture of alternative refrigerants and 134a Typically R 12 systems which are in need of repair or recharge are suspect to refrigerant contamination due to the number of so called drop in replacements or substitutes for 134a Systems designed for 134a such as the TJ may be at lower risk for contamination but precautions should be taken to prevent contamination of service equipment and or other A C systems IMPORTANT A refrigerant identifier should be used to determine refrigerant contamination prior to recovery New Holland recommends using the OEM4450 refrigerant identifier If a refrigerant conta
38. d install directly on the harness connectors to perform mode door tests 91 RD99N166 2 MOUNTING SCREW 1 HARNESS CONNECTOR To replace the mode door motor disconnect the harness to the motor Remove the two mounting screws and remove the motor STEP 221 Reverse Steps 212 219 to reinstall the steering console cover 92 CAB INTAKE AIR FILTER SERVICE NOTE 7he cab intake air filter will need service at different intervals according to local operating conditions Clean the filter as required Replace the filter if there is damage or when the filter cannot be cleaned for efficient operation STEP 222 MK98C028 The cab intake air filter is located under the cab rear The cab pressurizer blower draws outside air from the vents in the cab cap through the filter and feeds it directly to the HVAC box Unclamp the retaining clamp and lower the cover STEP 223 MK98C029 Pull the filter straight out Clean the inside of the filter housing Install a new filter by pushing straight in until it seats in the upper gasket Close the cover and the retaining clamp STEP 224 Clean the filter element by one of two methods A Tap the outside of the filter This method can be used to clean the filter when most of the dirt is dust Tap the filter against a flat surface Do not use force that can cause damage to the filter B Clean with compressed air The compressed air method is used if most of the dirt is dust
39. discharge port and the low pressure line from the suction port on the compressor Immediately install protective caps on the open ports and lines STEP 152 T RD99N150 Remove the four mounting bolts and remove the compressor 72 Compressor Installation TJ 375 425 450 IMPORTANT f a new compressor is to be installed its oil level must be adjusted to match the removed compressor See Oil Level Check or Adjustment page 64 STEP 153 Install the compressor the mounting bracket with the four bolts removed earlier Torque to 29 4 ft Ib 39 4 Nm STEP 154 RD99N149 Slowly remove the protective cap install new O ring and connect the high pressure line to the discharge port on the compressor Carefully remove the protective cap install new O ring and connect the low pressure line to the suction port on the compressor NOTE Use caution when removing cap as new compressors are under pressurization when shipped STEP 155 T RD99N136 Reconnect the compressor clutch wire to the engine harness STEP 156 RD99N132 Use a 1 2 inch ratchet drive on the belt tensioner to release tension and install the belt NOTE 7he belt should be installed on the six grooves on the pulley nearest the cab 73 Compressor Belt Installation and Adjustment TJ 275 325 STEP 157 RD00B027 RD00B014 Loosen the two pivot bolts and the adjusting bolt Check a new bel
40. ency for regulations on the proper disposition of contaminated refrigerant NOTE n the United States EPA regulations require that tanks of contaminated refrigerant be sent to a refrigerant reclaimer for the contents to be purified or destroyed Call 1 800 296 1996 to locate a reclaimer in your area WARNING Do NOT use a tank without a limit switch to recover contaminated refrigerant with OEM1691 The limit switch prevents overfilling the tank and protects your safety M797 WARNING When working with SP 20 PAG oil follow these safety precautions 1 Avoid contact with eyes skin and clothing 2 Avoid breathing vapor aerosol and mist 3 Do not swallow 4 Use only with adequate ventilation 5 Wear protective safety goggles and non permeable gloves when handling SP 20 PAG oil M798 10 Overview In many countries recovery recycling and reclamation have legal definitions and standard meanings in the mobile A C industry Recovery is transferring refrigerant in any condition from a system to a storage container without testing or purifying the refrigerant in any way Recycling is the cleaning of refrigerant for reuse by oil separation non condensable gas removal and single or multiple passes through filter moisture absorption devices Reclamation is processing refrigerant to a level equal to new product specifications as determined by chemical analysis testing to ARI 700 A22094 OEM1598 In servicing Ne
41. ervice before B Receiver drier has operated two or more years C Disassembly of compressor shows small particles of moisture removing material gold or brown particles D Large system leak broken hose break in line E Too much air or moisture in system F Removal of compressor or any other component caused the system to be open uncapped longer than 5 minutes G Testing with refrigerant identifier OEM4450 showed contamination STEP 38 MK99J192 RD99N138 TJ 375 425 450 With the charging station manifold gauge valves in the closed position connect the hoses from the test gauges to the service ports as follows 1 Connect the hose from the low pressure gauge to the port on the suction hose blue 2 Connect the hose from the high pressure gauge to the port on the discharge hose red 3 Turn in both thumbscrews to depress the service valves Removal of air and moisture from the system is necessary after the system has been opened for maintenance A vacuum pump must be used to lower the pressure enough to change the moisture to vapor which can be removed from the system NOTE Refer to the vacuum pump manufacturer s user manual for additional information STEP 39 rgin A22113 Connect the main power plug to a 115 volt AC outlet Move the main power switch to the ON position If program and vacuum do not appear at the top of the display press the VACUUM key Program a minimum of 45 min
42. frees the controller mounting plate C Disconnect the 18 pin and 5 pin wiring harnesses connected to the ATC controller Or disconnect the 8 pin wiring harness to the blower speed driver IMPORTANT Do not touch exposed pins on ATC controller or blower speed driver to avoid static electricity voltage spikes Voltage spikes may result in equipment damage D Remove the six screws securing the ATC controller and remove the controller Or remove the four screws holding the blower speed driver and remove the driver E Install a new ATC controller or blower speed driver using the existing hardware Reconnect the harness es Align the controller mounting plate with the cover holes Reinstall the seat with existing hardware STEP 211 RIOOA035 1 STANDARD CONTROLLER The standard A C controller is located behind the evaporator and is mounted to the rear of the HVAC upper case With the ignition switch in the OFF position to replace the standard controller A See ACCESSING THE HVAC BOX page 77 B Disconnect the 6 pin and 5 wiring harnesses connected to the standard controller IMPORTANT Do not touch exposed pins on the controller to avoid static electricity voltage spikes Voltage spikes may result in equipment damage C Remove the single nut securing the controller to the mounting stud and remove the controller D Install a new controller using the existing hardware Reconnect the harnesses Reinstall t
43. ging process and immediately open the valve on the station side of the dye injector to prevent drawing the dye into the charging station The dye will be injected into the system while recharging 11 Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports This will alert service personnel in the future to the presence of the dye in the system 12 Operate the A C system for about 15 minutes to circulate the dye throughout the system Turn off the system and use the UV lamp and goggles to locate leaks The exact location of the leak will be shown by a bright yellow green glow of the dye NOTE The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak A very small leak could take hours or days of system operation to appear 13 After repairing the system use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future 32 Quick and Easy Dye Injector Tool with a Charged System w Rez S RDO1F247 1 QUICK COUPLER 2 VALVE 3 T HANDLE 4 SUPPLY CAN The quick and easy R134a dye injector tool is designed to insert the dye in a charged system The dye injector tool has a quick coupler for connecting to the low pressure port of the tractor A C system and a valve with T handle on the other end 1 Examine the threaded end of the
44. h conditions cause more system wear and shorter system life These conditions are not self correcting During normal servicing recovery evacuation and recharge oil is simply injected back into the system during the recharge process Use the dipstick method to check the compressor oil level or to adjust oil level when any of the following occurred A Broken refrigerant hose Large refrigerant leak Compressor leak Damage to or replaced system components W New compressor installed IMPORTANT f a new compressor is to be installed its oil level must be adjusted to match the oil volume of the removed compressor NOTE SP 20 PAG oil must be added whenever a component is replaced Injection Method STEP 126 MK96C043 2 OIL INJECTION VALVE 1 OIL RETURN BOTTLE OEM1598 has an injection system to return new SP 20 PAG oil equal to the amount recovered at the end of the evacuation process To add the new oil adjust the O ring around the oil return bottle to the required oil charge level NOTE f 2 4 oz 71 ml was recovered in the oil reservoir 2 4 oz 71 ml of new SP 20 PAG must be returned Open the oil injection valve to add the oil into the system Close the valve when the oil level reaches the O ring IMPORTANT Do not let oil level fall below the dip tube in the return bottle or air will be introduced into the refrigerant circuit Dipstick Method STEP 127 IMPORTANT For a
45. he seat with existing hardware 89 ACCESSING AND REPLACING THE MODE DOOR MOTOR STEP 212 d RD99N164 Have an assistant help pull back the floor mat from around the steering console base about 6 inches 152 mm STEP 213 RD00A014 RB00A026 1 SCREW 4 BUSHING 2 FLAT WASHER 5 DECELLERATOR ROD 3 BRACKET Remove the decelerator pedal by removing the screw and two flat washers Remove the decelerator bracket from the slot in the rod but keep tension on the bracket to prevent the spring from disconnecting Remove the bushing and slide the decelerator rod out of the right side of the steering console 90 STEP 214 STEP 216 d lia 2 RD99N163 RD00A012 Position the steering wheel so that it is straight and Remove the three screws on top of the steering fully extended console cover STEP 215 STEP 217 RD004A01 1 RD00A013 Remove the two bolts holding the clutch pedal stop bracket RD00A010 Remove the screw from the top of the steering column shroud and remove the two shroud halves STEP 218 RR01G012 Slide the console cover up the steering column as far as it will go to access the mode door motor on the left hand side STEP 219 RD00A009 NOTE The harness connectors to the ignition switch as well as the ether start switch will disconnect from the rear of the switch when the cover slides up the steering column Remove the ignition switch from the cover an
46. in the tank during storage See Post Flushing Procedures page 48 42 Complete Circuit Flushing Procedure with Power Flush 17550 STEP 65 STEP 68 refrigerant must be recovered from the system before flushing STEP 66 RDOOH209 The 17550 power flush unit uses shop air to atomize the flushing solvent and a pulsing action to scrub residue and contaminants out of components 1002018 Remove the thermal expansion valve and use adapters to connect the hose lines to the evaporator Fill the flushing reservoir 3 4 full with approved New Holland flushing solvent Do not overfill the reservoir or you will restrict the pulsing action of the unit STEP 69 STEP 67 1002029 Remove the receiver drier and join the hoses together with an adapter hose Discard the receiver drier RHO1F112 Universal A C Flush Fittings Shown Disconnect the suction and discharge lines from the compressor Attach flushing adapters to the lines STEP 70 RDOOH200 1 AIR VALVE 2 FLUSH VALVE Close the air and the flushing valves STEP 71 ac 338 RPOOGO18 Remove the flushing tank hose quick coupler from the evaporation plug 43 STEP 72 Connect the flushing tank hose quick coupler to an extension or adapter hose STEP 73 RD00H202 Connect CLEAN and DRY shop air supply to the quick coupler on the flushing valve 44 STEP 74 RHO1F112 2 TO RETURN
47. least 45 minutes to a vacuum of 29 5 inches 0 75 mm of mercury Final System Oil Check After the system has been drawn to a deep vacuum and recharged 1 Operate the A C system for 15 minutes to thoroughly circulate the PAG oil throughout the system 2 Install the gauge set and test the A C system for proper operation referring to the pressure temperature table on Page 27 IMPORTANT f oil level was measured and adjusted properly according to the guidelines Steps 3 and 4 are unnecessary 3 Recover refrigerant from the system Use the dipstick method to check the PAG oil level in the compressor If needed adjust the oil level See Dipstick Method page 65 For TJ 275 325 tractors the oil should cover eight lines on the dipstick for TJ 375 425 450 tractors the oil should cover five lines on the dipstick 4 Evacuate and recharge the system In the United States SAFETY KLEEN will recycle used flushing solvent For more information on SAFETY KLEEN s recycling program call 800 323 5040 50 SYSTEM COMPONENTS Cab HVAC Box Components Automatic Temperature Control 1 LID ASSEMBLY 2 CONTROLLER BLOWER DRIVER MOUNTING PLATE ASSEMBLY A ATC CONTROLLER B BLOWER SPEED DRIVER 3 BLOWER ASSEMBLY 4 WIRE HARNESS NOT SHOWN 5 A C LOW PRESSURE SWITCH 9 10 11 12 HEATER CONTROL VALVE ASSY HEATER EVAPORATOR ASSEMBLY A C SUCTION LINE TUBE A C LIQUID LINE TUBE HEATER SUPPLY HOSE HEATER RETUR
48. ll TJ tractors disconnect the charge air cooler line at the clamps and move the line out of the way to insert the dipstick Do not allow any debris to get into the charge air cooler line MK99J195 TJ 375 425 450 RIP UR When all refrigerant has been recovered remove the oil filler plug 65 STEP 128 RD99N144 Use socket to remove the three screws and remove the dust cover from the clutch Use a wrench to rotate the compressor shaft clockwise until the internal parts are in a position to allow dipstick insertion ALTERNATE METHOD Use a jumper wire to supply 12V to the compressor clutch and rotate by hand 66 STEP 129 RB99N062 RB99N057 TJ 375 425 450 Put the dipstick in the oil filler hole to the stop position Make sure the dipstick is inserted all the way to the stop The dipstick stop should be flush with the filler hole boss Take several readings for accuracy For TJ 275 325 tractors the oil level should cover eight lines on the dipstick for TJ 375 425 450 tractors the oil level should cover five lines on the dipstick NOTE The illustrations show the front view of the compressor with the dust cover removed and the proper positions of the counterweight for insertion of the dipstick IMPORTANT When compressor is replaced the old compressor oil should be drained and the oil volume measured This amount of new oil should be put into the replacement compressor after it has
49. m of 200 psi 1379 kPa at sustained volume of 10 cfm 0 28 cmm STEP 28 RROOE134 RROOE138 Connect the red power lead to the positive post of the vehicle s battery or to another 12V DC power supply Connect the black ground lead to an engine ground NOT the battery negative post The compressor should start idling NOTE Batteries generate explosive gases during normal battery operation Use the engine ground to reduce the risk of sparks around the contaminated system NOTE Use a jumper cable to extend the negative lead if necessary to reach an engine ground 19 STEP 29 e 39 RECOVERY START fi RROOE135 Turn the control panel valve to RECOVERY The compressor sound should change Inlet pressure gauge should decrease and tank pressure increase on the gauges STEP 30 TANK PRESSURE RECOVERY START RROOE157 1 A C SYSTEM PRESSURE 2 TANK PRESSURE GAUGE GAUGE When inlet pressure gauge shows a vacuum disconnect the air line Wait five minutes If inlet pressure rises above 0 psi repeat Steps 33 and 35 NOTE Refrigerant may pool inside the system When the station is turned off the refrigerant will vaporize in the ambient heat causing the system pressure to rise again Repeat the recovery process until the system remains at a vacuum for at least two minutes 20 STEP 31 RROOE159 When the recovery process is complete close the valve on the recovery tank Close
50. mination level of 2 or greater is discovered do not recover the system to a tank with pure 134a refrigerant Recover only to a tank reserved for contaminated refrigerant with the air powered station OEM1691 WARNING OEM1598 were designed for the recovery and recycling of pure 134a refrigerant Do NOT use OEM1598 to A recover contaminated refrigerant you will void your warranty you may damage the compressor and filter drier in the recovery station and you may expose yourself to the danger of an explosion M795 WARNING f the refrigerant identifier indicates the system contains more than 296 hydrocarbon propane butane or isobutane the system and its contents must be treated as flammable if more than 4 hydrocarbon the system and its contents must be treated as explosive Do not operate the vehicle or the A C system Do not recover this contaminated refrigerant with an electric powered unit OEM1598 Use the air powered station OEM1691 to recover this refrigerant Avoid heat sparks and open flame when working with this contaminated refrigerant M796 IMPORTANT f contaminated refrigerant is discovered and recovered with OEM1691 replace the receiver drier in the tractor being serviced BEFORE you recharge the system with pure 134a refrigerant OEM1598 should be used to evacuate and recharge the system after the contaminated refrigerant has been safely recovered NOTE Check with your local environmental ag
51. n 79 EVAPORATOR HEATER ASSEMBLY 80 Evaporator Heater Assembly Removal a ETAS AAE 80 Evaporator Heater Assembly Installation 83 Post Replaceimient Procedures eme a intet ee R 85 EVAPORATOR HEATER ASSEMBLY SEALING AND CLEANING eee 86 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION sese nnns nennen 87 CONTROLLER BLOWER SPEED DRIVER amp STANDARD A C CONTROLLER REPLACEMENT 88 ACCESSING AND REPLACING THE MODE DOOR MOTOR sese enne nnns 89 GAB INTAKE AIR FIETER SERVIGE rer ertet er vrl vec bt ertt rto eorpore 92 CAB RECIRCULATION AIR FILTER SERVICE iniseti aiia a aa aa 93 GAB PRESSURIZATION TPEST et tb e Eh cete rado t 94 PRESSURIZER MOTOR REPLACEMENT 96 VISCOUS EAN DRIME rrt tv E uror o vepres 96 7 90941NH Issued 9 01 SPECIFICATIONS Air Conditioning System Refrigerant Capacity All TJ Tractor Models 4 2 Ib US 1 9 kg Compressor Belt Tension New nnne 95 t
52. ne connections surfaces where parts are joined compressor to clutch seal NOTE When checking compressor seal for a leak remove the dust cover and rotate the compressor shaft clockwise B Condenser line connections all welded joints any visible damage C Receiver drier line connections D Thermal expansion valve line connections NOTE Remove the thermal insulation tape to check the expansion valve for leaks replace the tape when completed E Service ports valve core under the caps F Low and high pressure switches Check around the entire switch body where it is threaded into the line Hoses line connections where the hose end meets a metal connector any area that shows damage or rubbing contact RD00B022 FNHO00855 RROOF098 UV Leak Detecting Lamp and Goggles Electronic Testing with FNH00855 RD00B022 4 RD99N140 TJ 375 425 450 Florescent Leak Detection Fluorescent tracer or dye solutions are now commonly used to detect refrigerant leaks Your TJ tractor had an ultraviolet fluorescent tracer or dye introduced into the A C system at the time of manufacture This dye will glow a bright yellow green at a leak location under ultraviolet light The dye has been tested for compatibility with HFC 134a systems and approved for use in all New Holland HFC 134a A C systems Special tools are also available to aid in injection and leak detection See SPECIAL TOOLS page 4 in this Section
53. netrate a leak and show will depend on the size of the leak A very small leak could take hours or days of system operation to appear 9 After repairing the system use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future Compressor Oil Port RD99N135 Recover the refrigerant from the A C system For all TJ tractors disconnect the charge air cooler line at the clamps and move the line out of the way to access the oil filler port on top of the compressor Remove the oil filler plug and pour the contents of one bottle of fluorescent dye into the compressor Check the O ring on the oil filler plug and replace if necessary Reinstall the oil plug on the compressor and torque to 11 to 18 Ib ft 15 to 24 Nm 33 5 For all TJ tractors move the charge air cooler back into position and reconnect with the clamps The charge air cooler lines are stamped for proper alignment Tighten the clamps to 100 in Ib 11 3 Nm 6 Evacuate and recharge the A C system with the proper amount of refrigerant 7 Install the dye identification sticker on a clearly visible area on the compressor body close to the service ports This will alert service personnel in the future to the presence of the dye in the system 8 Operate the A C system for about 15 minutes to circulate the dye throughout the system Turn off the system and use the UV lamp and goggles to loc
54. ng brackets STEP 199 a RD99N045 1 BLOWER MOTOR SCREW Install the blower motor plate with blower motor in the unit with four screws Reconnect the blower harness 84 STEP 200 m ni MAN AN WO m merci Ieri TALI RD99N056 Install the temperature sensor 4 2 inches 107 mm from the left hand rear side of the evaporator The sensor must be installed below the second refrigeration tube row at a 30 downward angle Insert the sensor in the evaporator up to the angled section being careful not to kink the sensor STEP 201 D Wwe i 1 RD99N054 Reinstall the sensor harness through the slot and reinstall the grommet Reinstall the top gasket on the evaporator NOTE gasket seals the top of the evaporator and forces the air to move through the core rather than around it Replace the gasket if it is worn or damaged STEP 202 E RD99N052 Install the heater return line on the evaporator heater core and install the clamp STEP 203 RD99N052 Install the short hose between the heater valve and evaporator heater core and install the clamp STEP 204 T97366 Lubricate new O rings with clean mineral oil and install on the liquid and suction lines at the expansion valve STEP 205 RD99N049 Using the two hand two wrench method reconnect the suction and liquid lines at the thermal expansion valve See the following on leak te
55. o 115 Ibs 422 to 516 Compressor Belt Tension Used Belt 90 to 110 16 400 to 489 Front Plate Alr Gap ice nti dote 0 016 to 0 031 Inch 0 41 to 0 79 mm SPECIAL TORQUES Compressor Clutch Retaining 1 4 enema 15 to 20 Nm 11 to 15 Ib ft OIF MS re PUG MI EE 15 to 24 Nm 11 to 18 lb ft Dust Cover eet ces zio bep divi 7 to 11 Nm 5to 8 lb ft SPECIAL TOOLS 109L7 A22094 Combination Impact and Chemical Splash Refrigerant Recovery Station OEM1598 Safety Goggles 29917 gt RD99K079 Belt Tension Tool CNH299147 1 COMPRESSOR DIPSTICK Compressor Tool Set FNH02343B The compressor dipstick can be found in the Compressor Tool Set or purchased separately FNHO02343B 19 RD01E190 Compressor Belt Tightening Tool RROOE140 Additional 50 Ib Contaminated Refrigerant Tanks OEM1692 RROOE139 RR99M070 1 4 Inch FFLX to 1 2 Inch Acme Adapter Refrigerant Identifier OEM4450 OEM1693 22090 Electronic Leak Detector FNH00855 RR00D078 Air Powered Recovery Station with Tank OEM1691 RROOF098 UV Leak Detection Lamp and Goggles BSL750 RROOF 101 Recovery Station UV Dye Injector for R 134a Refrigerant BSL734 mam STAY BRITE _ es wu has CO TRC TON Drt PERCENT Df SunT Cox ENTRATE RROOF 102 UV Leak Detection Dye for R 134a Refrigerant B726012 RDO1F248 R134a Quick and East Dye injector T
56. o replace the motor 1 Incline the instructional seat forward and remove the storage compartment 2 Remove the trim panel at the rear of the seat cavity 3 Disconnect the motor assembly from the harness 4 Remove the five screws securing the motor assembly to the mounting bracket and remove the motor Inspect the seal and replace if required 5 Install a new motor assembly with the existing hardware and connect the motor to the harness RH01G100 1 MOTOR ASSEMBLY 3 MOUNTING BRACKET 2 SEAL VISCOUS FAN DRIVE Since the viscous fan creates air flow at the condenser a properly functioning fan drive is essential to proper air conditioning performance A defective fan drive can cause engine overheating and or high pressure switch activation But a plugged grille radiator condenser and oil cooler can also cause the same To separate a fan drive problem from other possible causes perform the test in Viscous Fan Drive Test in this manual NOTE When performing the viscous fan drive test the air conditioning system should be OFF
57. ool BSL738 RD01F249 Quick and Easy R134a Charge Cans 6 Pack BSL634 RROOF 100 UV Fluorescent Dye Cleaner B795016 RROOF093 Power Flush Model 17550 BS33801 A C Flushing Solution case of six 1 gallon containers RP00G007 Flush Gun Kit Model 17585 BS33801 A C Flushing Solution case of six 1 gallon containers RROOF 148 17582 Universal Flush Fitting Kit RIOOF041 Coalescing Air Filter Dryer Similar to Ingersoll Rand Model IR5CHE or Grainger Model 4KR65 RIOOF042 Pressure Regulator Capable of Providing 45 psi at 4 0 cfm 310 kPa at 0 11 cmm with Integrated Pressure Gauge SAFETY PROCEDURES THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL WHEN YOU SEE THIS SYMBOL CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALEHT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH M171B ATTENTION Only authorized technicians certified by an approved training and certification organization may service or repair motor vehicle or mobile air conditioning systems Refrigerant HFC 134a is the most stable and easiest to work with of the refrigerants now used in air conditioning systems Refrigerant HFC 134a does not contain chlorofluorocarbons CFC s which are harmful to the earth s ozone layer Safety procedures must be followed when working with refrigerant HFC 134a to prevent possible personal injury 1 Always wear combination impact and chemical splash safe
58. or components RROOF093 Power Flush 17550 RP00G007 B Flush Gun Kit 17585 New Holland A C Flushing Solvent one case of six one gallon containers BS33801 E Dry shop air source use filter below or equivalent Coalescing air filter dryer Ingersoll Rand IRBCHE or Grainger 4KR65 Desiccant type air driers should not be used Adapters to connect flush unit to the various A C system components These adapters can be purchased in kit form or built in the shop Clear Plastic Reinforced Hose to connect the tank to various components and small lengths for bypassing components like the receiver drier or thermal expansion valve See SPECIAL TOOLS page 4 in this Section Optional tools include Pressure regulator to control flow to the flush unit regulator must be capable of delivering 45 90 psi 810 620 kPa at 4 0 cfm 310 kPa at 0 11 cmm Do not exceed 90 psi 620 kPa B Pressure indicator gauge which may be integrated into the pressure regulator 38 Precautions WARNING Do NOT use solvent containing alcohol lacquer thinner brake cleaner or other non approved solvents Use only New Holland approved flushing solvent Other flushing agents or solvents may damage A C system components M815 New Holland A C flushing solvent is a hazardous material Read all warnings on the flushing solvent container prior to use and observe these safety precautions 1 The flushing solvent is combustible
59. perly sealed to allow air movement through the assembly but not around it Check the condition of the foam seal on the top of the assembly where it seals with the HVAC box cover Check the condition of the sealing strip at the front of the evaporator heater bottom Replace repair any seal which has deteriorated with age or which no longer seals properly Cleaning If the evaporator heater assembly is plugged with dirt and debris locate the source of the debris correct and then clean the assembly See CAB PRESSURIZATION TEST page 94 If the assembly is dry clean with low pressure compressed air If the assembly is wet flush with water using a low pressure hose NOTE Check that the condensate drain valves are not plugged before cleaning the assembly with low pressure wash RH01G098 1 TOP FOAM SEAL 2 SEALING STRIP 87 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION RI99D080 1 THERMAL EXPANSION VALVE 4 CHECK VALVE 7 EVAPORATOR TEMPERATURE 2 BLOWER MOTOR 5 CONDENSATE DRAIN TUBE SENSOR 3 BOX DRAINAGE 6 EVAPORATOR BOX ASSEMBLY 8 EVAPORATOR CORE 88 CONTROLLER BLOWER SPEED DRIVER amp STANDARD A C CONTROLLER REPLACEMENT STEP 210 RH99D214 3 ATC CONTROLLER 1 MOUNTING PLATE 2 PWM MODULE With the ignition switch in the OFF position to replace the ATC controller or the blower speed driver A See ACCESSING THE HVAC BOX page 77 B Inclining the seat also
60. pors pass through the bucket filter NOTE Back flushing is done first to dislodge any contaminants and then forward flushing is performed to remove the contaminants STEP 60 RDOOH205 1 AIR VALVE 2 FLUSH VALVE Open the air valve 1 2 to 3 4 turn IMPORTANT Do not exceed this rate of air delivery This rate delivers one gallon per minute of flush solvent which is ideal for the orifice openings on the components being flushed Turn the flushing valve to the FLUSH position and flush the component for 30 seconds STEP 61 RD00H206 2 TO THE RETURN BUCKET 1 FROM THE FLUSH PUMP Close the flushing and air valves Reverse hose connections for forward flushing Open flushing and air valves and repeat flushing until the solvent is clear STEP 62 RD00H207 Turn the flushing valve to the AIR position Allow air to flow through the component until no noticeable mist is discharged NOTE Air pressure is the only means to remove the flushing solvent from the A C system and no solvent must remain in the system when it is evacuated and recharged Turn the component so gravity can assist in solvent removal 41 STEP 63 gt D00H208 Turn the flushing valve to the CLOSED position Disconnect the flushing and drain hoses and adapters from the component STEP 64 asl 33 RP00G018 Install the flushing tank hose quick coupler on the evaporation plug to prevent evaporation of the solvent remaining
61. r Clutch Replacement 60 7 90941NH Issued 9 01 A G COMPRESSOR nonas t iai i eie id dcn edd eise tus 64 Oil Level Check or Adjustment sin tens nenas snnt nnns 64 injection E 64 Dipstick Method c 65 Compressor Removal TJ 275 825 1 nenas nnns 67 Compressor Installation TJ 275 325 sse enne eene nnne entres nennen nenne nnns 69 Compressor Removal TJ 375 425 450 0 71 Compressor Installation TJ 375 425 450 sse entnehmen nri 72 Compressor Belt Installation and Adjustment TJ 275 325 sse nennen 73 THERMAL EXPANSION VALVE TESTING 74 THERMAL EXPANSION VALVE REPLACEMENT 75 CONDENSER AND RECEIVER DRIER ivesti iaiia iai nennen tenens sns inns tassi tens e senten ens 76 ACCESSING THE HVA C BOX o esee adit Rea a D rape 77 EVAPORATOR TEMPERATURE SENSOR LOCATION nennen nnns nnn enn nene 78 BLOWER MOTOR REPLACEMENT 79 HEATER CONTROL VALVE REPLACEMENT sess in
62. rature sensor from the evaporator heater assembly STEP 192 RD99N045 1 BLOWER MOTOR SCREW Disconnect the blower motor from the harness Remove four screws and blower motor plate with blower motor from the box assembly 82 STEP 193 RD99N054 1 TOP GASKET 2 GROMMET Remove the evaporator top gasket and save for reinstallation Remove the grommet and remove the sensor harness from the evaporator by sliding it through the slot opening NOTE gasket seals the top of the evaporator and forces the air to move through the core rather than around it Heplace the gasket if it is worn or damaged STEP 194 T97367 Slide the assembly out of its side mounting brackets STEP 195 197373 Put the assembly on a clean bench Remove the expansion valve from the evaporator heater core Use the two wrench two hand method when removing the thermal expansion valve to prevent damage to the tubes Evaporator Heater Assembly Installation STEP 196 T97376 Lubricate new O rings with clean mineral oil and install new O rings on the evaporator suction and discharge lines STEP 197 leet F ani Wn T97372 Install the expansion valve Tighten the fittings to a torque of 18 to 25 Ib ft 25 to 34 Nm Use the two wrench two hand method when installing the expansion valve to prevent damage to evaporator lines 83 STEP 198 T97367 Install the evaporator heater assembly into the slide mounti
63. remove the console STEP 177 Tilt the steering wheel to the full upright position Adjust seat to the full upright and back position RD99N152 Remove four bolts in the seat base corners STEP 179 RD99N153 1 SEAT HARNESS Disconnect the seat harness STEP 180 Hinge seat forward and rest on steering wheel STEP 181 After completion of service reinstall the seat harness Realign ATC controller mounting plate if equipped with mounting holes and reinstall seat mounting hardware Reinstall right hand control console if applicable Reconnect right hand control harness Ensure cab recirculation air filter is properly installed 78 EVAPORATOR TEMPERATURE SENSOR LOCATION STEP 182 at BY kd 7 RH99D218 Rear View 1 EVAPORATOR TEMPERATURE SENSOR The evaporator temperature sensor MUST be installed 4 2 inches 107 mm from the left hand rear side of the evaporator The sensor must be installed below the second refrigeration tube row at a 30 downward angle RI00A055 Side View 2 4 2 INCH 107 mm 3 EVAPORATOR CORE Insert the sensor in the evaporator up to the angled section being careful not to kink the sensor 79 BLOWER MOTOR REPLACEMENT STEP 183 To replace the blower motor 1 See ACCESSING THE HVAC BOX page 77 2 Move the controller mounting plate forward to gain better access to the motor 3 Disconnect the blower motor assembly from the harness
64. s will alert service personnel in the future to the presence of the dye in the system 8 Operate the A C system for about 15 minutes to circulate the dye throughout the system Turn off the system and use the UV lamp and goggles to locate leaks The exact location of the leak will be shown by a bright yellow green glow of the dye NOTE The operating time needed for the dye to penetrate a leak and show will depend on the size of the leak A very small leak could take hours or days of system operation to appear 9 After repairing the system use fluorescent dye cleaner to remove any traces of dye from around the leak location to avoid false diagnosis in the future Fluorescent Leak Testing RROOF098 To perform UV fluorescent leak testing 1 Operate the tractor long enough to circulate the refrigerant and produce normal system pressures 2 Shut the tractor and system off when leak testing 3 Always wear fluorescent enhanced safety glasses when leak testing 4 Attach the lamp to a fully charged 12V battery or an alternate 12V power supply for best lamp performance 35 5 Shine the high intensity ultraviolet light at the various A C components hoses and lines to search for a glowing fluorescent trail or puddle which identifies the leak location The ultraviolet lamp is intended for intermittent use only The lamp has a momentary contact push button switch to briefly light suspected leak locations IMPORTANT
65. sting replacing thermal insulation tape and recharging the unit Post Replacement Procedures STEP 207 MK99J192 TJ 275 325 Shown Since the evaporator assembly has been replaced adjust compressor oil level Evacuate and charge the air conditioning system Test system performance following procedures on the foldout Leak test the valve and evaporator connections with FNH00855 85 STEP 206 RD00A015 TJ375 425 450 shown 1 HEATER RETURN Remove the vise clamps from the heater supply and return hoses located on the engine NOTE Location of the hose differs for TJ 275 325 and TJ 375 425 450 tractors See pages 53 and 55 STEP 208 i RP99E004 1 INSULATED VALVE CONNECTIONS The thermal expansion valve and line along with the inlet and outlet to the evaporator must be insulated for maximum evaporator performance Apply thermal insulation tape around the expansion valve connectors and the inlet and outlet lines of the evaporator 86 STEP 209 To remove air from the cooling system after installation of a replacement evaporator heater assembly A Fill the radiator completely and fill the coolant recovery bottle to the full line B Operate the engine for 10 minutes C Stop the engine and allow the radiator to cool D Top off radiator and recovery bottle EVAPORATOR HEATER ASSEMBLY SEALING AND CLEANING Sealing The top and bottom of the evaporator heater assembly must be pro
66. system However due to a large refrigerant leak system flush or major component failure it may become necessary to reintroduce the dye into the refrigerant circuit 30 Fluorescent Dye Injection Many methods are available to introduce the dye to a System for the first time or to reinject the dye into an A C system Select the method most appropriate to the needs of the A C system and where you are in the service process 1 Recovery Station Dye Injector Tool with a System in a Vacuum 2 Recovery Station Dye Injector Tool with a Charged System 3 Quick and Easy Dye Injector Tool with a Charged System 4 Compressor Oil Port 5 SP 20 PAG Oil Return Bottle Recovery Station Dye Injector Tool with a System in a Vacuum o LEL RROOF101 Valves Shown in OPEN Position 1 VALVE TOWARD 3 VALVE TOWARD RECYCLING STATION TRACTOR 2 RESERVOIR CAP 4 RESERVOIR The R134a dye injector tool is designed to be used with the OEM1598 recycling station 1 Disconnect the low pressure hose blue from the 1 2 inch Acme flare fitting on the rear of the station 2 Connect the dye injector to the fitting 3 Connect the low pressure hose to the dye injector NOTE The dye injector can be permanently mounted on the recycling station with the two threaded holes on the bottom of the reservoir 4 Open the valves on either side of the reservoir on the dye injector 5 Recover and recycle the refrigerant from the A C system and
67. t STEP 35 If a recovery tank becomes full during a recovery the float switch will automatically turn off the station To change a full tank in the middle of a recovery A Close the blue tank valve and the valve on the black hose from the station B Unscrew and remove the float cable from the tank C Disconnect the hose from the tank valve D Remove the tank from the station E Replace the tank with a properly prepared tank dry nitrogen charge released and vacuum drawn and held for five minutes F Connect the tank valve hose and the float cable G Open the tank valve and the tank hose valve Recovery will continue as soon as both valves are open IMPORTANT Do not use recovered contaminated refrigerant in any A C system Send full tanks to a reclamation center for purifying or disposal of the contents 21 STEP 36 All refrigerant has been removed from the A C system replace components or make any repairs at this time IMPORTANT Replace the receiver drier on the tractor being serviced before you evacuate or recharge the system with OEM1598 STEP 37 See evacuation and recharging in this Chapter to recharge the A C system with pure R134a refrigerant using OEM1598 22 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING IMPORTANT Replace the receiver drier if one or more of the following conditions occurs before you remove the air and moisture from the system A The system has been opened for s
68. t after the first 50 hours and then use the regular check interval 300 hours STEP 158 RD00B016 Use a 1 2 inch ratchet drive with the belt tensioning tool to pull the compressor forward and tension the belt Or use a pry bar on the compressor legs only not the compressor body to tension the belt STEP 159 RD00B013 Measure the compressor belt for correct tension using a belt tension gauge Check the belt to the following specifications New 95 to 115 Ibs 422 to 516 Used 90 to 100 Ibs 400 to 489 NOTE Adjust new belts to the used specifications after a 10 minute run in WARNING Aotating fans and belts Contact can injure Keep clear M150A Tighten adjusting bolt Tighten the pivot bolts and nuts when completed 74 THERMAL EXPANSION VALVE TESTING IMPORTANT The following test is performed with the thermal expansion valve mounted in the system No repair or adjustment is recommended for the valve STEP 160 Y RD99N153 Remove the seat mounting bolts and lean it against the steering column See ACCESSING THE HVAC BOX page 77 STEP 161 RD99N046 Disconnect the low pressure cutout switch Install a jumper wire across the harness leads STEP 162 Start the tractor and run the engine at 1500 RPM Turn blower speed control to maximum position temperature control valve fully clockwise ATC rocker switch to DEFO
69. te the air conditioner system at maximum cooling setting and blower speed with the door and service door open Standard A C switch ON or ATC switch in DEFOG DEFROST position NOTE The compressor does not operate if the system pressure is too low or too high because the clutch is latched off by the controller Standard A C units blink the indicator light on the A C ON OFF switch indicating a system pressure problem To restart the compressor the switch must be turned to the OFF position and then ON ATC units display a fault code on the LCD display indicating a pressure problem To restart the compressor the ATC switch must be turned to OFF and then A or snowflake position 26 STEP 49 22117 MK99J201 Observe the pressure gauge readings to determine that the correct amount of refrigerant has entered the system See chart on page 27 for temperature and pressure variations Check louver temperature for proper cooling at the mid cab vents STEP 50 TJ 275 325 Shown SONS Close any open valves on the couplers and carefully remove the gauge hoses from the ports on the suction and discharge lines STEP 51 MK99J191 RD99N137 TJ 375 425 450 Install the caps on the service ports on the suction and discharge lines 27 uedo sJeAno euiBue 1e pue Ajddns seui POOH dn peys uaye
70. the clutch coil if the amperage reading is not correct OR Method 2 Measure resistance Resistance must be 2 86 to 3 3 ohms Replace the clutch coil if the resistance reading is not correct STEP 109 A21266 Install a new clutch coil assembly Align the coil so the lead wire is next to the clip mounting hole STEP 110 A21264 Install the clip for the coil lead wire STEP 111 Fr 21265 Install the snap ring for the clutch coil assembly STEP 112 A21267 Install the bearing in the pulley and install the internal snap ring STEP 113 D RR99D245 Put the pulley and bearing assembly on the front housing hub Install a driver on the pulley assembly Make sure that the tool is on the inner race of the bearing STEP 114 D RR99D245 Support the compressor on the four mounting ears at the compressor rear Press the pulley assembly on the front housing hub Make sure the bearing is against the bottom of the hub 61 A21260 Install the external snap ring on the front housing hub STEP 116 A21259 Install the key in the rotor shaft STEP 117 me A21269 Place the bearing dust cover in the bore Place driver from special tool kit over the dust cover 62 STEP 118 21270 Install the dust cover STEP 119 21256 Install the shim s on the rotor shaft STEP 120 ani A21271 Install the front plate on the rotor shaft Make sure the keywa
71. the oil reservoir has been drained prior to recovery to avoid returning additional oil to the system 22114 Open the high and low valves STEP 6 22107 Make certain the refrigerant tank gas and liquid valves are open 13 A22112 Connect the main power plug to a 115 volt AC outlet Move the main power switch to the ON position and depress the RECOVER switch The compressor will shut OFF automatically when recovery is complete Wait for 5 minutes and observe the manifold pressure gauges for a pressure rise If no pressure rise recovery is complete If pressure rises above 0 PSI depress the HOLD CONT switch and repeat until pressure holds for two minutes Then wait for the compressor to automatically shut OFF NOTE Refrigerant may pool inside the tractor s A C system When the recovery unit s compressor is turned off the refrigerant will vaporize in the ambient heat causing the system pressure to rise again Hepeat the recovery process until the system remains at a vacuum for at least two minutes STEP 8 TO THE Mis OF reve A22108 Some recovery units require a manual air purge to remove non condensables from the recovery tank Refer to the operators manual for your unit Air purge is automatic on an OEM1598 when it evacuates the A C system MK96C017 Slowly open the oil drain valve and drain the oil into the reservoir When the oil stops draining close the oil drain valve completely
72. ty goggles when doing any service work near an air conditioner system Liquid refrigerant in the eyes can cause serious injury Do the following if you get refrigerant near or in your eyes A Flush your eyes with water for 15 minutes B See a physician immediately M779 2 Always recover all refrigerant prior to opening an A C system A drop of liquid refrigerant on your skin may cause frostbite burns Open fittings carefully and slowly when servicing the air conditioning system Your skin must be treated for frostbite burns or a physician must be seen if you get refrigerant on your skin M799 3 Keep refrigerant containers in correct upright position Always keep refrigerant containers away from heat and sunlight The pressure in a container will increase with heat M743 4 Always check refrigerant purity with the OEM4450 Refrigerant Identifier before recovering refrigerant and before testing the system M777 5 Use the air powered OEM1691 ONLY to recover contaminated refrigerant Do NOT use 1598 recycling station to recover contaminated refrigerant If contaminated refrigerant contains more than 2 hydrocarbon propane butane or isobutane the mixture must be treated as flammable if more than 4 hydrocarbon the mixture must be treated as explosive in both cases an electric powered recovery station may NOT be used Avoid heat sparks and flame when working with this contaminated refrigerant M800 6 Dangerous gas
73. ush gun to the canister 47 STEP 83 STEP 84 Use CLEAN and DRY shop air to purge the solvent and dry the valve RP00G011 Back flush the discharge port RP00G012 Back flush the suction port NOTE prevent sprayback press the rubber nose cone on the gun into the opening on the refrigerant line or thermal expansion valve when flushing When back flushing the thermal expansion valve the suction and discharge ports must be flushed in different directions Collect used solvent in a container for proper disposal 48 Post Flushing Procedures STEP 85 Identify and remove the source of the contamination STEP 86 RP00G006 Reconnect all fittings using new HNBR green HFC 134a compatible O rings Lubricate the O rings with mineral oil prior to installation STEP 87 RP00G002 Install a new receiver drier NOTE 7he receiver drier should be replaced just before the system is drawn to a deep vacuum to avoid saturating it with moisture STEP 88 RP00G011 Clean or replace the thermal expansion valve STEP 89 RD00B029 Install a new compressor if required STEP 90 m RD99N134 Adjust the level of SP 20 PAG oil in the system When each component was flushed some SP 20 PAG oil was removed from the system Use the following guidelines when adjusting PAG oil If the compressor is to be replaced and the entire system was flushed the new compressor will contain all the
74. utes and press the ENTER key The display will flash once indicating the programmed data has been accepted STEP 40 A22114 Fully open the low and high pressure valves 23 STEP 41 22107 Open the red vapor and blue liquid valves on the tank STEP 42 FOR R 134a USE ONLY A22123 Press the VACUUM key Automatic will show on the display VACUUM will appear on the display and after a slight delay the vacuum pump will start The display will show the amount of time programmed and begin a countdown to zero When the programmed time has elapsed an automatic hold occurs Check the low pressure gauge to see that the A C system maintains a 28 to 29 1 2 inches of mercury Hg NOTE The low pressure gauge must not increase faster than one inch of mercury Hg in 15 minutes If the system will not hold vacuum a leak exists that must be corrected before recharging can begin See leak testing in this chapter 24 STEP 43 MK96C043 1 OIL RETURN BOTTLE 2 OIL INJECTION VALVE IMPORTANT Do not inject the PAG oil until the system will hold a proper vacuum OEM1598 has an injection system to return new SP 20 PAG oil equal to the amount recovered at the end of the evacuation process To add the new oil adjust the O ring around the oil return bottle to the required oil charge level NOTE f 2 4 oz 71 ml was recovered in the oil reservoir 2 4 oz 71 ml of new SP 20 PAG must be returned Open
75. valve to see if the point of the valve stem is flush with the rubber washer If not turn the T handle until the point is flush 2 Screw the Quick and Easy can and the valve together until the can seats on the rubber washer NOTE Do not turn the T handle at this time to tap the can 3 Connect the quick coupler to the low pressure service port under the instructional seat in the cab 4 To purge air from the hose slowly unscrew the untapped can a half turn or more Allow refrigerant from the A C system to force the air out of the hose and then retighten the can on the valve 5 Turn the T handle clockwise to tap the can 6 Hold the can upside down to allow the can contents to enter the A C system When complete turn the T handle counterclockwise to close the valve Disconnect the tool from the low pressure port NOTE You may have to operate the tractor and the A C system for a few minutes to completely empty the can 7 Install the dye identification sticker on a clearly visible area on the compressor body close to the service port This will alert service personnel in the future to the presence of the dye in the system 8 Operate the A C system for about 15 minutes to circulate the dye throughout the system Turn off the system and use the UV lamp and goggles to locate leaks The exact location of the leak will be shown by a bright yellow green glow of the dye NOTE The operating time needed for the dye to pe
76. valves and repeat flushing until the solvent is clear 45 STEP 77 RD00H207 Turn the flushing valve to the AIR position Allow air to flow through the circuit until no noticeable mist is discharged NOTE Air pressure is the only means to remove the flushing solvent from the A C system and no solvent must remain in the system when it is evacuated and recharged STEP 78 22 33 RP00G018 Turn the flushing valve to the CLOSED position Disconnect the flushing and drain hoses and adapters from the compressor lines Install the flushing tank hose quick coupler on the evaporation plug to prevent evaporation of the solvent remaining in the tank during storage See Post Flushing Procedures page 48 46 Back Flushing the Thermal Expansion Valve or Refrigerant Line STEP 79 RP00G007 Flush gun 17585 can be used to back flush the thermal expansion valve or a refrigerant line Solvent is added to the canister and then the canister is pressurized with CLEAN and DRY shop air Pulse the trigger on the flush gun for greater flushing effectiveness STEP 80 RP00G008 To fill the canister remove the cap assembly Add no more than 20 oz 590 ml of New Holland flushing solvent to the canister Replace the cap assembly STEP 81 4 7 RPO0GO09 Pressurize the canister to a maximum of 90 psi 620 kPa with CLEAN and DRY shop air STEP 82 E RP00G010 Connect the hose with fl
77. w Holland A C systems with OEM1598 when recover is depressed the refrigerant in the vehicle is transferred to the recovery tank on the unit without testing or purifying At the same time SP 20 PAG oil is separated from the refrigerant and stored separately in the reservoir This oil requires proper disposal and should never be returned to the vehicle When vacuum is depressed the vacuum pump on OEM1598 evacuates the atmosphere in the vehicle A C system to a vacuum of 28 to 29 1 2 inches of mercury Hg Air and moisture are removed in the process and only SP 20 PAG oil remains in the vehicle s A C system When recycle is depressed the entire contents of the recovery tank on OEM1598 are recycled The refrigerant in the tank is passed through a filter drier in OEM1598 and cleaned non condensables are removed and air is purged automatically Older recovery units have manual air purge NOTE n automatic operation recycling begins about 5 seconds after the vacuum pump starts NOTE During recycling some additional SP 20 PAG oil is separated from the refrigerant and stored separately in the reservoir Only new SP 20 oil is added to replace the oil which was separated during recovery and when recharge is depressed only clean recycled refrigerant is returned to the vehicle s A C system OEM1598 does not perform reclamation 11 RECOVERING PURE 134A REFRIGERANT MK99J200 ATC Automatic
78. y in the plate is aligned with the key in the shaft Install the driver over the shaft STEP 121 21272 Use hammer to tap the plate onto the shaft sure the plate is against the clutch shims As the plate is tapped onto the shaft you can hear the difference in sound when the plate is fully installed STEP 122 w 21253 Install the nut on the rotor shaft Use the spanner wrench and a torque wrench to tighten the nut to a torque of 11 to 15 Ib ft 15 to 20 Nm STEP 123 MK98E341 RD99M052 Two methods can be used to measure and adjust the air gap between the clutch plate and pulley Magnetic Dial Mount a magnetic base dial indicator on the outer face of the pulley so that there is no interference with the clutch plate Apply battery ground to compressor body and 12V B to clutch wire lead Position the dial indicator pointer on the flat surface on the outer diameter of the clutch plate midway between any two outer rivets or on one of the outer rivet heads Clutch plate travel should measure from 0 016 to 0 031 inch 0 41 to 0 79 mm This measurement should be taken between each of the three rivets or on each outer rivet head to get an average measurement If necessary lightly lift or push down on plate to even the gap Spark Plug Gauge If a dial indicator is not available to check air gap clearance a spark plug gauge with 90 wire feelers may be used to check

Chapter 2 -- Air Conditioning Component Service

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