UNIVERSAL AUXILIARY POWER UNIT SYSTEM

SPECIFICALLY DESIGNED FOR R-134a REFRIGERANT ONLY

1-800-275-7524
P/N 057-00323 09/2005

IMPORTANT RESTRICTION
THE INFORMATION CONTAINED HEREIN IS FOR EXCLUSIVE USE OF THE MANUFACTURERS CUSTOMERS. NEITHER THE SHEETS NOR THE INFORMATION CONTAINED THEREIN ARE TO BE COPIED OR REPRODUCED WITHOUT THE PRIOR WRITTEN CONSENT OF THE MANUFACTURER. ALL RIGHTS WHICH THE MANUFACTURER HAS OR OBTAINED THEREIN, INCLUDING PATENT RIGHTS ARE EXPRESSLY RESERVED BY THE MANUFACTURER.

IMPORTANT NOTICE
IF AN INSTALLATION IS MADE ON ANOTHER VEHICLE OTHER THAN SPECIFIED, THE FACTORY WILL NOT INCUR ANY EXPENSE FOR LABOR, TIME AND MACHINE EXPENSE TO MAKE THAT PARTICULAR INSTALLATION. ANY DEVIATION FROM PRODUCT DESIGN COMPONENT OR THE USE OF OTHER MATERIAL, PARTS AND/OR SYSTEM COMPONENTS WILL BE WITH THE INSTALLER'S RESPONSIBILITY FOR ANY SUCH CHANGE OR DEVIATION.

MADE IN U.S.A.

CAUTION
Before beginning this installation, take a few minutes to read these instructions. Check that all necessary materials, units and accessory kits that are listed in the application guide are on hand.

RECOMMENDED STANDARD TORQUE SPECIFICATIONS FOR STANDARD FITTINGS

O-RING CONNECTIONS
TUBE O.D. 1/4 3/8 3/8 1/2 5/8 3/4 THREAD SIZE 7/16 5/8 11/16 3/4 7/8 1-1/16 FT./LB. 5-7 11-13 11-13 15-20 21-27 28-33

NOTES Unless otherwise specified, all instructions are given from the drivers seat position facing forward with the engine radiator being the front or forward direction of vehicle. IMPORTANT: Truck air conditioning installation requires a basic knowledge of refrigeration systems and services of a qualified mechanic. These instructions explain the steps necessary for the installation of this unit but do not detail standard workshop procedures or safety practices. NOTE: For the air conditioner to operate properly, it must not contain moisture or dirt particles. Leave all protective caps in place until final installation of the component. Use clean refrigerant oil on all threads and sealing surfaces when making fitting connections. Use a back-up wrench to avoid twisting fittings. NOTICE: Truck air conditioners operate under high pressures and utilize a refrigerant that can be dangerous if not handled properly. Installation, service and repairs should be performed only by those individuals who possess the mechanical skills required and have a basic understanding of refrigeration systems and their operation and who are familiar with and follow approved safety procedures.

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TABLE OF CONTENTS

I.

INTRODUCTION
ILLUSTRATION INDEX OVERVIEW SYSTEM COMPONENTS COMPONENT LAYOUTS SAFETY ISSUES

II.

PLANNING GENERAL MOUNTING LOCATIONS

LOCATING THE ENGINE UNIT LOCATING THE A/C-HEAT UNIT LOCATING THE CONTROLS LOCATING THE 115 VOLT BREAKER BOX AND OUTLETS LOCATING THE SURGE TANK

III.

PLANNING GENERAL ROUTING PATHS

COOLANT HOSES REFRIGERANT HOSES FUEL LINES ELECTRICAL WIRING

IV. INSTALLING THE ENGINE UNIT

ATTACHING THE ENGINE UNIT TO THE FRAME RAIL INSTALLING THE COOLANT CONTROL VALVES INSTALLING THE EXHAUST SYSTEM INSTALLING THE SURGE TANK INSTALLING THE FUEL PICKUP AND RETURN FITTINGS IN TANK

V.

INSTALLING THE A/C-HEAT UNIT

PREPARING THE VEHICLE PLANNING THE DUCT WORK INSTALLING THE DUCT WORK INSTALLING THE A/C-HEATER

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 VI.

INSTALLING THE CONTROLS

INSTALLING CONTROL HOUSING INSTALLING CONTROL WIRING HARNESS INSTALLING 115V BREAKER BOX AND OUTLETS INSTALLING BATTERY CHARGER

VII. INSTALLING HOSES AND ELECTRICAL WIRING

ROUTING FUEL LINES AND COOLANT HOSES ROUTING REFRIGERANT HOSES AND ELECTRICAL WIRING

VIII. ADDING FLUIDS

CHECKING OIL LEVEL ADDING COOLANT AND PRIMING FUEL PUMP

IX. INITIAL START UP

PURGING AIR FROM THE SYSTEM ADDING REFRIGERANT 134A TO THE SYSTEM CHECKING OUT SYSTEM CONTROLS AND OPERATION

X.

TROUBLE SHOOTING GUIDE

ELECTRICAL DIAGRAMS 110 VOLT POWER CONSUMPTION CHART TROUBLE SHOOTING CHARTS

XI. MAINTENANCE AND SPECIFICATIONS

MAINTENANCE SCHEDULE ENGINE SPECIFICATIONS A/C SPECIFICATIONS

XII. DELIVERY TO FINAL CUSTOMER

REVIEW SYSTEM LAYOUT REVIEW SYSTEM OPERATION DEMONSTRATION OF SYSTEM FEATURES AND OPERATION COMPLETION OF WARRANTY INFORMATION DELIVERY OF MANUALS

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ILLUSTRATION INDEX
FIG. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 PAGE 6 7 7 7 8 8 9 9 9 10 10 11 11 13 14 15 18 22 25 25 26 28 28 30 32 35 36 37 DESCRIPTION ENGINE ASSEMBLY FRONT VIEW ENGINE ASSEMBLY END VIEW ENGINE ASSEMBLY BACK VIEW ENGINE ASSEMBLY TOP VIEW KIT INSTALLATION HEAT COOL ASSEMBLY EVAPORATOR / HEATER ASSEMBLY - 2 VIEWS DUCT KIT HOSE KIT ENGINE / BOX LAYOUT FRONT VIEW ENGINE / BOX LAYOUT SIDE VIEW A/C HEAT UNIT LAYOUT SIDE VIEW A/C HEAT UNIT LAYOUT TOP VIEW TRUCK LAYOUT - ENGINE BOX LOCATIONS TRUCK LAYOUT - COMPONENT LOCATIONS HEAT / COOL LOCATIONS MAIN MOUNT CHANNEL LOCATIONS AIR FLOW DIAGRAM CONTROL ASSEMBLY ASSEMBLED CONTROL ASSEMBLY EXPLODED LOAD CENTER DIAGRAM 110 VOLT WIRING DIAGRAM @ ENGINE 110 VOLT WIRING DIAGRAM @ ENGINE - CONT COOLANT FLOW DIAGRAM ENGINE - BOX ASSEMBLY REAR VIEW A/C-HEAT WIRING DIAGRAM PG 1 A/C-HEAT WIRING DIAGRAM PG 2 START / STOP WIRING DIAGRAM

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I. INTRODUCTION
OVERVIEW
THANK YOU FOR PURCHASING THE ALLIANCE TRUCK CLIMATE SYSTEM. This ALLIANCE system is an auxiliary power system that provides air conditioning, heating, 115-volts, and 12-volts to the truck. This system draws diesel fuel from the truck main tank and operates like any small diesel engine. This system operates independently of the front engine and other air conditioning and heating systems on the truck. The engine drives a generator and a/c compressor. The generator provides 3480 watts of 115-volt electricity to run various appliances in the truck. Included is a 40-amp battery charger, which keeps the batteries in full charge condition while the system is operating. The compressor provides refrigerant flow to the a/c cooling unit on the inside of the cabin. Hot water from the small diesel engine is circulated though a heating coil in a/c heat unit to supply warm air in the cabin. The system temperature is monitored by a thermostat and provides comfortable climate control inside the truck during all seasons.

SYSTEM COMPONENTS
The system is shipped in five packages. Each of these packages should contain a packing list, which describes all the parts it contains. These packages should be opened prior to starting the installation and the contents checked using the packing list included as a guide. These packages contain the following: 1. 2. 3. 4. 5. THE ENGINE UNIT THE INSTALLATION KIT THE EVAPORATOR AND HEATER THE DUCT KIT THE HOSE KIT

ENGINE ASSEMBLY - FRONT VIEW

OIL PRESSURE SWITCH FUEL RETURN FITTING FUEL INLET FITTING 110 VOLT BREAKER RESET BUTTON

A/C COMPRESSOR

110 VOLT GENERATOR

FUEL SOLENOID

OIL FILL OPENING OIL DRAIN PLUG & FILTER SCREEN

FUEL VALVE

OIL DIPSTICK

FUEL FILTER

FIGURE 1

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ENGINE ASSEMBLY - END VIEW

A/C COMPRESSOR

FUEL INJECTOR

GLOW PLUG

FIGURE 2

ENGINE ASSEMBLY - BACK VIEW

BELT TENSIONING PULLEY A/C COMPRESSOR

GENERATOR

ENGINE CRANKSHAFT

FIGURE 3

ENGINE ASSEMBLY - TOP VIEW

CONTROL RELAY (5 EACH)

CIRCUIT BREAKERS 12 VOLT (2 EACH) STARTER AND SOLENOID

SWITCH WATER HIGH TEMPERATURE SHUT DOWN

FIGURE 4

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INSTALLATION KIT
LOAD CENTER SACK ASSEMBLY

METAL FLEX HOSE (8 FT) SACK KIT, SCREWS 3X4 CHANNEL (2)

5/16 FUEL LINE (25 FT)

POWER CORD

BATTERY CHARGER

MUFFLER PARTS

CHARGE WIZARD

#6 RED CABLE (15 FT)

SACK ASSEMBLY CONTROL SWITCH ASSEMBLY PRE-PUMP FILTER

CONTROL BEZEL FUEL PICK-UP TUBE #6 BLACK CABLE (15 FT)

#2 RED CABLE (20 FT) START/STOP WIRE HARNESS

FIGURE 5

HEAT COOL ASSEMBLY

HEAT COOL ASSEMBLY

CONTROL ASSEMBLY

SACK PARTS

TEMPLATE

FIGURE 6

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EVAPORATOR / HEATER UNIT

THERMOSTAT

CONTROL RELAYS (2)

EXPANSION VALVE RESISTOR BOARD

FIGURE 7

DUCT KIT
END ADAPTER 3 (2 EACH)

RETURN AIR GRILLE

DUCT ASSEMBLY (2 EACH)

SACK ASSY 3 ROUND LOUVER

FLEX HOSE 3 (25 FT)

FIGURE 8

HOSE KIT
3/4 HEATER HOSE (15 FT) 5/8 HEATER HOSE (35 FT)

SACK ASSY SMART VALVE

WIRE HARNESS EXTENSION

SACK ASSY

#6 HOSE ASSEMBLY SURGE TANK ASSEMBLY

#10 HOSE ASSEMBLY

FIGURE 9 -9-

COMPONENT LAYOUTS
ENGINE/BOX LAYOUT FRONT VIEW

FIGURE 10

ENGINE/BOX LAYOUT SIDE VIEW

FIGURE 11 - 10 -

AIR CONDITIONING/HEATING UNIT LAYOUT SIDE VIEW

FIGURE 12

AIR CONDITIONING/HEATING UNIT LAYOUT TOP VIEW

FIGURE 13 - 11 -

SAFETY ISSUES
WARNING
CALIFORNIA PROPOSITION 65 WARNING: THIS PRODUCT CONTAINS LEAD, A CHEMICAL KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND BIRTH DEFECTS AND OTHER REPRODUCTIVE HARM.

EXHAUST
Inhalation of gas containing carbon monoxide may cause severe personal injury and/or death. Anyone suspected of suffering from carbon monoxide poisoning should be removed from the hazardous area and be given medical assistance immediately.

FUEL/ BATTERIES
Use extreme caution when working near fuel-filled equipment. Do not operate equipment during engine fueling operations. Use eye protection when working near batteries, which contain acid and can explode. Do not smoke or use open flames near batteries. It is recommended to remove all metal jewelry from hands and wrists while working on electrical components. Jewelry shorting out on these circuits can cause severe burns.

ELECTRICAL
Electrical shock can cause severe personal injury, burns, and death. Before working on any unit, disconnect the batteries. Use only approved materials and methods when working on the electrical system, and follow local electrical codes. Never work on the generator box when standing on wet surfaces or when the engine is running. A licensed electrician should oversee all work on wiring which conducts 115 volts a/c.

MOVING PARTS
Moving parts can cause severe injury or death. Before working on any unit, shut it off and wait for it to cool down. Do not start until all protective covers have been replaced. Loose parts or tools falling into rotating machinery can cause severe injury or death. Be sure all parts and belts are tight and properly torqued prior to starting the engine. Do not wear loose clothing or jewelry while working on the unit.

MISUSE
This generator system is designed to provide electrical power for heating and cooling trucks in normal on-road conditions. Never use the generator to power critical medical or sensitive electronic equipment without manufactures written approval.

REFRIGERANT HANDLING
Do not vent R-134a into the atmosphere; all refrigerants must be recovered according to Federal law. When handling refrigerants always wear safety goggles for eye protection. Do not expose refrigerant containers to heat sources such as space heaters, torches, or hot engine compartments. Possible explosion due to high container pressure could result in personal injury or death.

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II. PLANNING GENERAL MOUNTING LOCATIONS

ENGINE BOX LOCATIONS LISTED BY DESIRABILITY

1. A PASSENGER SIDE 2. A DRIVER SIDE 3. B PASSENGER SIDE 4. B DRIVER SIDE 5. C BETWEEN FRAME RAILS

FIGURE 14

NOTE: THIS IS PLANNING STAGE ONLY. DO NOT BEGIN INSTALLATION UNTIL THE INSTALLATION STAGE

LOCATING THE ENGINE UNIT (See Figure 14)

There are several issues that should be considered when deciding on the engine unit location. A. The drivers usually prefer to sleep with their heads to the drivers side of the bunk. Locating the engine as far as possible from that area will reduce the noise heard in the sleeper area. B. Many modern trucks have side skirts along the lower side areas. These skirts hinder installation time and engine service. C. There may exist pre-drilled holes in the frame rail suitable for mounting the brackets. D. Obstructions beneath or immediately inside the frame rail that will slow or hinder installation for performance. Examples are mufflers, air tanks, or fuel tanks. E. The engine unit should be easily accessed for check out and service.

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SURGE TANK

CONTROL PANEL

115V BREAKER BOX

ENGINE BOX

FUEL PICKUP AND RETURN

CLIMATE CONTROL UNIT A/C-HEAT

FIGURE 15 The preferred location is just in front of the passenger side rear wheels, see figure 14. This places the unit where the least noise reaches the driver and is usually clear of side tanks. The second choice is just in front of the drivers side rear wheels. The third choice is under the passenger door. But, under the passenger door usually requires the addition of an optional lower step (P/N 087-00290) available from SCS TRUCK CLIMATE SYSTEMS. Also under the passenger door requires routing the exhaust to a location at least two feet behind the sleeper according to DEPARTMENT OF TRANSPORTATION LEGISLATION. The last location available may be on the fifth wheel catwalk between the frame rails and behind the sleeper. If catwalk location is chosen, remember to allow plenty of room for trailer clearance while the trailer is turning, and at least six inches clearance between the unit and the back of the sleeper. The engine noise will be the greatest inside the sleeper from this location.

LOCATING THE A/C-HEAT UNIT (See Figure 16)

There are several issues to be considered when choosing the mounting location for the a/c-heat unit. A. The drivers usually sleep with their head to the drivers side of the bunk. The further the a/c-heat unit is mounted from the head position the quieter it will be for the driver. B. The area beneath the floor of the truck may have structural beams, fuel lines, airlines, electrical wiring or other obstructions to the installation. C. There must be six inches of clearance at the air discharge hose adaptors to allow for attaching and turning the flexible air ducts. D. Maximum storage must be left for the storage of the drivers gear. E. The installer must be able to route the wire harnesses, a/c hoses and water hoses to the unit without excessive trouble

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HEAT/COOL UNIT LOCATIONS

FIGURE 16 The preferred location is on the passenger side under the bunk. Many of the truck manufacturers use this area to mount their rear air, and it is unavailable. The second choice is the center storage area under the bunk. The third choice is under the bunk on the drivers side. Once the location has been decided, check carefully the items above before beginning installation.

LOCATING THE CONTROLS

The controls must be located so the driver can reach them easily from a sleeping position whenever possible. The control panel should be located where the discharge air from the ducts does not blow directly on the controls or the thermostat will detect an incorrect temperature and not control properly. The panel should be mounted so the wire harnesses can be routed in a closet, or behind the wall panel to the a/c-heat unit while being hidden from view. Be sure the lower and upper bunk can be raised without interference with the control panel.

LOCATING THE 115 VOLT BREAKER BOX AND OUTLETS (See Figure 15)
The breaker box must be located inside the sleeper underneath the bunk. It should be located near a door so when the driver wants to use shore power, the short extension with the male plug can be plugged into the shore power line. The battery charger is usually located near the breaker box so it can be plugged into the outlet on the side of the breaker box. The two outlet boxes connected by cords to the breaker box are to be located on the front wall of the bunk or on exterior walls of the closets or cabinets. Try to locate the outlets so they are not subject to being accidentally kicked during routine movement in the sleeper area.

LOCATING THE SURGE TANK (See Figure 15)

The surge tank must be located at least two feet above the a/c-heat unit for best performance. The preferred location is the back corner of the truck and the same side as the a/c-heat unit. The surge tank should be easily accessible and positioned so the driver can observe the coolant level within the tank, and add coolant as required.

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III. PLANNING GENERAL ROUTING PATHS

NOTE: NEVER ROUTE ELECTRICAL WIRING OR BATTERY CABLES WITH FUEL LINES. AN ELECTRICAL
SHORT COULD EASILY IGNITE THE FUEL AND CAUSE A LIFE THREATENING SITUATION FOR THE SLEEPING OCCUPANTS. NEVER USE OEM AIR LINES, FUEL LINES OR BRAKE LINES AS SUPPORT OR ATTACHING POINTS DURING INSTALLATION.

COOLANT HOSES (See Figure 24)

1. Use the component locations chosen during the previous stage, and the coolant flow diagram as a reference. Beginning with the engine location, check out the route path to the a/c-heat unit location. 2 Look for OEM holes and fasteners that can be used to secure the 3 x 4 long mounting brackets. Remember coolant hoses require about a six inch bending radius to prevent kinking while hot. Stay away from components that move independent of the frame rails, such as transmission, cables, control levers, and suspension components. Remember when routing from the frame to the cab to allow slack in the hoses for the cab movement and bounce on rough driving surfaces.

3. Next check out the route path from the engine to the surge tank. The hose from the engine to the surge tank is three-quarter inch in diameter and will require a minimum bending radius of eight inches. 4. Checking the water circuit diagram. Note the water Y between the a/c-heat unit and the surge tank, and plan the approximate location for installation. A WATER VALVE ASSEMBLY is shown on the circuit diagram and must be located within three feet of the engine to connect to the wiring on the back of the engine unit. Read the note on the bottom right corner of the circuit diagram. Insulation tubing one inch I.D, forty foot in length, can be purchased at most local hardware stores or from SCS TRUCK CLIMATE SYSTEMS (part number 045-00154 is eight foot in length). During very cold weather (below 20 degs) a lot of heat is lost through the coolant hoses to the atmosphere, the insulation will support much warmer air in the sleeper.

REFRIGERANT HOSES
1. Inspect the back of the unit and locate the #10 (suction) hose fitting and the #6 (liquid) hose fitting on the receiver drier tank (see figure 25) 2. Make certain when the unit is mounted, the #10 and # 6 hoses can be coupled to these fitting without interference with rails, tank, or other objects. 3. Check the routing path from engine location to the A/C - Heat Unit for adequate hose length and hose routing. 4. The #10 hose will require a six inch bending radius. The #6 hose will require a four inch bending radius. 5. Adequate slack in the hoses must be left beneath the A/C - Heat Unit to allow for cabin to rail movement over rough terrain. 6. All refrigerant hoses should be routed at least 10 inches away from hot exhaust components.

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FUEL LINES NOTE: NEVER ROUTE FUEL LINES WITH ELECTRICAL WIRING. FUEL LINES PRESENT THE THREAT
OF FIRE IF THEY ARE RUPTURED. USE EXTREME CAUTION WHEN ROUTING TO PREVENT RUBBING AND CHAFFING OF THE FUEL LINES. The fuel lines should route out of the engine unit through the upper opening near the a/c compressor. Determine the route from the engine unit to the fuel tank to be used. Keep fuel lines at least ten inches away from all truck exhaust and muffler components. There are two fuel lines, a supply to the pump, and a return to the tank. Do not use separate tanks for these lines or one tank may be drained while the other tank may overfill.

ELECTRICAL WIRING
The electrical wiring should be routed out the upper opening of the engine unit nearest the generator. Avoid routing wiring near moving parts and over sharp edges, which may cause chaffing. All electrical wiring should be routed at least ten inches away from all exhaust and muffler parts. When routing through holes in metal, the wiring should be protected by the use of grommets. Remember to leave some slack in the harness when routing from the frame to the cabin to account for cab suspension and bounce over rough terrain. Stretch the extension harness from the engine to the a/c-heat unit locations along the chosen path and check for adequate length. Stretch the control harness from the control location to the a/c-heat unit along the chosen path for adequate length. Check the battery cable length and routing from the battery box to the engine unit. Check the battery cable length and routing from the battery box to the battery charger.

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IV. INSTALLING THE ENGINE UNIT

PRIOR TO STARTING STUDY PHOTOS (#1 - #6) listed in the Installation Photo Guide

ATTACHING THE ENGINE UNIT TO THE FRAME RAIL

Tools that are required are listed below. forklift, hand forklift, or transmission jack two four inch or larger c-clamps torque wrench or impact driver (100 ft-lb or more) portable lighting, extension cord hole saws, three-inch diameter, one and one half inch diameter (1-1/2), one and one quarter inch (1-1/4) in diameter reciprocating saw electric drill and drill set up to five eighths inch (5/8) diameter general hand tools

VARIATIONS OF MAIN MOUNT CHANNELS

DO NOT NOTCH OR MODIFY CHANNELS

BEST

AVOID HARD INTERFERENCE BETWEEN HOSES, WIRING AND CHANNEL

PREFERRED

OR MIRROR IMAGE

AVOID HARD INTERFERENCE BETWEEN HOSES, WIRING AND CHANNEL

OR MIRROR IMAGE

FIGURE 17

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IV. INSTALLING THE ENGINE UNIT (cont)

1. Uncrate the engine unit. Check the unit over for any damage that may have occurred during shipping. Report any shipping damage to SCS TRUCK CLIMATE SYSTEMS for corrective action.

NOTE: Use only a stable lifting device. The engine unit weighs over two hundred and fifty pounds (250lbs), and could cause severe personal injury if dropped on an individual.

2.

Finalize the location of the unit to the vehicle. If the unit is to be located behind a fairing now is the time to confirm the unit will fit behind the fairing and any modifications that might be required to refit the fairing back to the truck. The cover of the unit must be removable on a daily basis for engine service. Refer to figure17 for possible mounting bracket configurations. Remove or adjust any equipment on the vehicle that will interfere with the installation, such as wheel fenders, fairings, fasteners, or studs. If there is room it is best to mount the engine box so that it is located below the bottom of the rail and tucked under the rail as far a possible. The fan on the unit must have plenty of room to move the air, and cannot be exposed to high temperatures from mufflers and exhaust systems.

3.

NOTE: LATER PRODUCTION MODELS MAY HAVE PRE-DRILLED HOLES IN THE MAIN L-CHANNELS AND ENGINE BOX. 4. Fit the main mounting brackets (3x4 inch L-channel, 2 each) to the box and secure them using the two c-clamps. Check that the top will still fit correctly on the box. Check to see that the box and brackets fit to the truck as planned. Mark the brackets if any excess is protruding above the rail. Look into the box and make sure that three bolt holes spread between the bottom and top of the engine box can be drilled without damage to components. Be sure the fasteners can be reached with wrenches on both ends after being placed through the holes to be drilled. Mark the locations for three holes to be drilled on each bracket. Drill a pilot hole through each center marked on the bracket and the engine box side (match or line drill) using a one-quarter inch (1/4) diameter drill.

5.

6. 7.

8. 9.

10. Remove the brackets from the unit and saw off the portion that extended above the rail. 11. Replace the brackets on the unit using the quarter inch (1/4)drill for perfect alignment and secure using c-clamps. 12, Drill each pilot hole out with a one half-inch (1/2) diameter drill (three holes on each side). 13 Secure each bracket to the unit using three each (1/2x1-3/4 in) bolts, washers and nylock nuts. Torque these bolts and nuts to sixty (60) foot-pounds. Move the unit to its mounting position on the frame rail. If any OEM holes are going to be used, align the bracket and mark the bracket through the holes to be used.

14. Mark both brackets with two holes centered on the bracket and a minimum of five and one half inches (5-1/2) apart. 15. Remove the unit and pilot drill the locations with a one-quarter inch (1/4) diameter drill.

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16. Replace the unit on the frame rail and using the four holes in the brackets and a quarter inch (1/4) drill mark the locations on the frame rail. 17. Drill all of these locations on the frame with a quarter inch(1/4) drill. Drill all the pilot holes out using a five-eighths (5/8) diameter drill. 18. Bolt the unit to the frame rail using four each (5/8x2-1/4) bolts, washers, and nylock nuts (torque to 100 ft lbs). 19. Replace and tighten all truck components and fasteners loosened or moved prior to installation.

INSTALLING THE COOLANT CONTROL VALVES

1. Locate the coolant control valve assembly. The wire extension to which the valves attach is found on the back of the engine unit. The wire harness is about three feet long with a mating plug for the valves. Note the yellow labels on the valve assembly and refer to the WATER CIRCUIT DIAGRAM FIGURE 24 for added clarification. The valve assembly should never be mounted with the valves up. The plastic cover should be up to prevent moisture intrusion. The water valves should be mounted near enough to the engine for the harness to reach the assembly. There must be enough room around the valve to allow the coolant hoses to be attached without kinking. Many times the valves can be mounted on the main engine mounting brackets. Secure the valves to the chosen location.

2.

3.

INSTALLING THE EXHAUST SYSTEM

Supplied in the installation kit for the exhaust are the following components used to construct the exhaust system: Muffler Muffler Brackets (2 each) 3/4 x 3 inch Nipple 3/4 x 2 inch Nipple 3/4 inch Elbow 1-1/8 inch Muffler Clamps (3 each) 8 feet Flexible Steel Pipe 1. 2. Locate the above components and set them aside. With the engine unit mounted on the frame rail the exhaust system can be installed. Screw the short nipple into the elbow. Screw the other end of the short nipple into the exhaust header through the three-inch clearance hole in the case bottom. Screw the 3/4 x 3 inch nipple into the elbow. Tighten the elbow and nipple into the exhaust header to a minimum of 25 ft-lbs of torque. The elbow can be rotated to start the exhaust in any desired direction. Slide one exhaust clamp over one end of the 8 foot length of flex pipe, and slide the pipe onto the 3 inch long nipple. Temporarily tighten the clamp to retain the flex pipe on the nipple. From underneath the truck, locate where the muffler is to be mounted. The exhaust must exit the system at least 2 feet behind the cab and be pointed rearward. The muffler works best when it is located as close as possible to the unit. In many cases the muffler can actually be mounted to the main mounting channels. The muffler brackets can be moved along the length of the muffler to match existing holes or drilled holes. Mount the muffler. - 20 -

3.

4.

5.

6.

7.

8. 9.

Route the flex pipe to the inlet. Determine the amount of flex pipe required to make the connection.

10. Remove the flex pipe from the exhaust and cut to proper length. 11. Using two 1-1/8 exhaust clamps secure the flex pipe to the engine and muffler. The excess flex pipe can then be secured to the outlet of the muffler to route the exhaust gases further toward the rear of the vehicle. 12. Tighten all exhaust clamps securely.

INSTALLING THE SURGE TANK

1. The surge tank must be installed at least two feet above the a/c-heat unit, see figure 15. Many times there is a bracket attaching the extended sidewalls to the back of the sleeper. This is a good location to mount the surge tank. Being careful not to strip out the threads, attach the tank using four #14 self-drilling screws, or 1/4-20 bolts and nuts. Locate the tank cap and place it on the tank.

2.

3.

INSTALLING THE FUEL PICKUP AND RETURN FITTINGS IN THE TANK

The following parts are required for this installation. Fuel Pick Up Tube 5/16 x 1/4 x 90 Barbed Fitting 1. 2. Locate the tank that will be used as the fuel source. Around the filler cap there is a reinforcement plate welded to the tank. Two holes must be drilled and tapped though the welded plate to fit the 5/16x 1/4-pipe threads found on the fittings. Be sure to locate the holes far enough from the cap that the fittings can turn while screwing in and the fittings do not interfere with the cap in the closed position. Be sure after one fitting is screwed in, the other fitting is far enough away it does not interfere with the first fitting Look inside the tank before drilling the holes and be sure the fuel gauge float is not going to hinder the insertion of the fuel pick up tube. Do not over torque the fittings or the threads may strip in the aluminum tank material.

3.

4.

V. INSTALLING THE A/C HEAT UNIT

The following items will be needed for this installation. Drill Template for A/C-Heat Unit Portable Light 1-1/4 inch Hole Saw 1-1/2 Hole Saw 2-inch Hole Saw 3-inch Hole Saw Electric Drill

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PREPARING THE VEHICLE

1. 2. If the lower bunk and mattress are removable, remove them from the truck to give more working room. If driver gear is in the storage areas it should be removed completely from the cab area. The installer will have to move in and out of the truck many times and it is a faster install to have a clean area with maximum workspace. If the controls are to be mounted to a closet or cabinet wall, the contents of the area should be removed from the truck cab.

3.

PLANNING THE DUCT WORK

RETURN AIR GRILLE FIGURE 18 1. Locate one of the gray louver towers from the duct kit for test fitting. Refer to figure 18 for clarification. The towers are usually put in the corners of the sleeper area. The front corners are also used if the rear corners are unavailable. Attempt to locate the towers so the discharged air will not blow on the control panel. Air discharged from the towers onto the control panel will give the thermostat a false reading and the unit controls will not function properly. Remember, the towers are easily cut off to adjust their height to different trucks. Plan on the lower tower adaptor being in place and the area for the three-inch diameter hose hooking up. Check to be sure the bunk can be raised and lowered without interfering with the ductwork. Plan on how the flex duct will be routed to the towers. The shorter and straighter the path of the flex duct the better the unit will perform. One round ball louver is supplied to be placed in the forward wall of the bunk area. When locating the point of installation consider what must be done to route the air duct to this louver. The return air grille supplies air to the inlet of the a/c-heat unit. It must be located on the wall that separates the a/c-heat from the main cabin area. - 22 -

2.

3. 4. 5.

6. 7. 8.

INSTALLING THE DUCTWORK

1. Using the end of the tower, mark the area of the bunk support that must be removed to allow the duct to end in the storage area. Cut away the unwanted material. Insert the tower into the storage area and place the lower hose adaptor on the duct. If the tower needs to be shorter, mark the duct at the cut location Remove the duct and cut the duct using a standard hack saw. Replace the tower, and secure the lower hose adaptor using the #10x5/8 drill point screws supplied. Secure the duct tower to the interior wall using the #10x1-1/4 drill point screws supplied. The three-inch ball louver is mounted by using the three-inch hole saw. Drill a three-inch hole in the forward wall of the bunk and secure the ball louver using the #6x5/8 black screws supplied. Route the flex duct from the a/c-heat unit to the towers and ball louver. A three-inch hole saw can be used to cut holes through the walls in the storage area as necessary.

2.

3. 4. 5. 6. 7.

8. 9.

10. Secure the duct hose to the hose adaptors using a seventeen-inch tie-wrap on each hose adaptor. 11. The return air grille is installed in the wall between the unit and the main cabin by marking the location and cutting away the unwanted material using a saber saw. See figure 16. 12. Secure the grille using #6x5/8 black flat head screws.

V. INSTALLING THE A/C HEATER

WARNING: The a/c-heat unit has a plastic drain tube protruding from the bottom surface. Caution should be taken not to break the drain tube off during handling.
1. Gently place the a/c-heat unit in the location chosen and check the fit and orientation. Check for these conditions. Six inches of room in front of the discharge adaptors for hose connection. Structures or components below the floor where hoses and harnesses will penetrate the floor. Access to the refrigerant and heater hose connections on the A/C Heat Assembly. Access to relays, thermostat, and resistor for electrical harnesses 2. 3. Use the a/c-heat unit as a guide and mark the floor through two corner holes. Place the drill template on the floor and align with the two holes previously marked. Tape the template in location. Using a 1/4-diameter drill, drill center pilot holes through the floor at the center of all the large holes on the template, including the drain tube hole (five holes total). Check beneath the floor where the drill penetrated the floor for any problems.

4.

- 23 -

5. 6. 7. 8.

Using a 1-1/4 hole saw drill through the floor at each of the pilot hole locations. Place a skirted grommet in each hole through the floor. Remove the plugs from the expansion valve. Make sure any o-rings in the open side of the expansion valve are removed. Do not attach the unit to the floor until the hoses, the drain tube, and wire harnesses are attached. Route the suction hose through the floor using a small amount of oil on the fitting to make the hose slide through the grommet easier.

9.

10. Using one #10 o-ring on the fitting, lubricate the o-ring and threads with refrigerant oil. 11. Secure the fitting to evaporator and torque to twenty-five foot-pounds. 12 Route the liquid hose through the floor, use one #6 o-ring, lubricate the o-ring and threads with refrigerant oil, and secure to evaporator using fifteen foot pounds of torque.

13. Remove the rubber plugs from the heater coil using a pair of needle nose pliers. Refer to the WATER CIRCUIT DIAGRAM (Figure 24) for more information. 14. Route one end of the 5/8 diameter heater hose through the floor and attach to the heater fitting with the Shrader valve using clamps provided. 15. Route the heater hose to the surge tank along the pre-determined path. Do not attach the hose to the truck at this time. Leaving at least an extra foot in length, cut the heater hose off near the surge tank. 16. Route the remaining 5/8 heater hose through the floor and attach to the heater coil using clamps provided. 17. Route the hose to the valve assembly along the pre-determined path and attach to the valve that is labeled INSTALL HOSE TO HEATER INLET HERE. 18. Drill (2) 1-1/4 Dia holes through the floor near the blower motor for wire harnesses. Install a grommet in each hole. 19. Locate the control extension harness. It will be ten feet long with a white plug on one end and two black plugs on the other end. Route the two black plugs on the extension harness through one of the holes in the floor leaving the white plug inside near the A/C - Heat Unit. 20. Attach the drain hose to the drain stub from underneath the cabin. 21. Do not attach the heat/cool unit to the floor at this time.

- 24 -

VI. INSTALLING THE CONTROLS AND ELECTRICAL SYSTEM

CONTROL ASSEMBLY CONTROL HOUSING

ENGINE CONTROL PANEL CLIMATE CONTROL PANEL

FIGURE 19

FIGURE 20

SCREW, #8 X 1/2 PPH BLACK (8 PLCS)

INSTALLING CONTROL HOUSING (See Figure 19 and 20) 1. 2. Locate the control housing against the wall to which it will mount. Decide the screw locations to be used on the flange of the control housing. It is suggested to use three screws along each side. Mark the desired locations on the housing. Using a 3/16-diameter bit, drill through the marked locations on the control housing. Hold the control housing in position against the wall and using it as a template drill through the wall panel using a 3/16-diameter bit. Install the start/stop panel and the climate control panel in the control housing using eight (8) each #8x1/2 pph screws. The wire harnesses should already be installed on the control panels. Check that the wire harnesses are securely plugged into their mating switches and plugs Observe the location the wire harnesses exit the back of the control housing. Mark the locations on the wall where the harnesses must pass through, and drill a 2-inch hole in those locations. Be careful that the housing will completely cover the 2-inch holes, avoid allowing the holesaw to gather upholstery material during this operation.

3. 4.

5.

6. 7. 8. 9.

10. Install two caterpillar grommets in the two-inch holes drilled. Route the harnesses through the wall and secure the housing using the six (6) screws and nuts provided.

- 25 -

INSTALLING CONTROL WIRING HARNESS

1. Route the control wiring toward a/c-heat unit, tie-wrapping or clamping it about every twenty inches (20) to hold it in position. Drill 1-1/2 inch holes as necessary to pass through compartment walls. Place caterpillar grommets in all holes drilled to prevent chaffing of harness. At the a/c-heat unit, plug the control wire harness onto the thermostat, 2 relays, motor, and resistor board. The white plug on the control harness plugs into wire extension harness previously installed. Route the start/stop harness out through the only remaining hole in the floor. After checking to insure all of the hoses, wire harnesses, and drain hose are properly attached and routed, secure the a/c-heat unit using four screws (#8x3/4 pph blk) through the corner holes in the bottom flanges.

2. 3. 4. 5. 6. 7.

INSTALLING 115V BREAKER BOX AND OUTLETS

FIGURE 21

- 26 -

INSTALLING 115V BREAKER BOX AND OUTLETS (CONT)

1. The breaker box and the battery charger must be located so the battery charger can be plugged in to one of the outlets from the breaker box. Three mounting holes are located in the back of the breaker box. Remove the face of the breaker box. Using self drilling screws, attach the breaker box in the chosen location. Replace the face of the breaker box. The breakers should be easy to see and reset as required. The outlet boxes are attached to different length extensions. The longer extension will be installed on the opposite side of the truck from the breaker box. Route the outlet boxes to the desired location. Do not pinch the cord between structures or route though rough or sharp areas. These cords carry 120 volts and must remain in place for a long time, thus greater care must be used when routing them in confined and tight areas. When these cords are routed through holes a grommet must be used.

2. 3 4. 5. 6.

7. 8.

9.

10. Remove the plastic face of the outlet box and locate the face of the box against the desired location. 11. Carefully mark around the box. 12. Drill each corner with a 3/8-diameter drill (do not drill outside the marked perimeter). 13. Using a saber saw remove the unwanted material. 14. Mount the outlet box to the wall. 15. Replace the faceplate on the outlet box. Repeat this process with the second outlet box assembly. 16. Drill a 1-1/4 hole in the floor near the breaker box. 17. Insert a skirted grommet in the hole. 18. Locate the long blue extension with the plug that mates to the male plug attached to the breaker box. 19. Route the blue extension down through the grommet and floor. 20. Plug the blue extension into the plug from the breaker box. 21. Route the blue extension towards the engine box. 22. Route the blue cable into the engine box through the top opening on the generator side. Route the cable through the clamp securing hoses and wires to the case side. 23. Locate the 115 volt breaker with the red reset button just above the generator (See Figure 23). 24. Remove the two screws holding the breaker shroud. The shroud will stay around the wiring going to the breaker.

- 27 -

ATTACH STARTER CABLE FROM BATTERY HERE

GROUND WHITE & GREEN 120 VOLT WIRES HERE

WHITE CONNECTOR FOR START/STOP HARNESS

FIGURE 22

RED BREAKER RESET BUTTON

CIRCUIT BREAKER SHROUD

ATTACH BLACK 120 VOLT WIRE HERE

FIGURE 23

- 28 -

INSTALLING 115V BREAKER BOX AND OUTLETS (cont)

25. The blue cable should be cut to reach 15 inches past the 115 volt breaker. Strip the outer insulation off for the last 15 inches exposing the black, green, and white wires. 26. See Figure 22 and 23, The black wire should route through the grommet in the breaker shroud previously removed. Cut the black wire to the correct length to reach the empty terminal on the breaker. Strip off 3/8 inch of insulation. Crip the eye terminal supplied onto the wire. Be careful to not let any bare strands remain outside the terminal crimp. Attach the eye terminal to the open screw terminal. Replace the breaker shroud in its original configuration. 27. The white and green wires should grounded back to the generator chassis. See Figure 22, Remove the bolt shown and secure the eye terminals of the white and black wires underneath the bolt. Tighten the bolt to 5ft-lbs torque. 28. Tie wrap the cable to the other wire harnesses and hoses. Keep the wire routed away from the drive belt and other objects which might chaff or wear the insulation.

INSTALLING THE BATTERY CHARGER

1. The battery charger should be installed in a semi permanent manner. It should not be allowed to float around on the floor area. The battery charger is capable of producing forty amps of twelve volt current. This is enough current to cause fires or serious damage if electrical shorts occur. Be sure the service cord will reach one of the 120-volt outlets. Read the owners instructions that come from the battery charger manufacturer. Cover the red charging cable with 1/2-inch diameter auto loom supplied in the kit. Be sure to route the fused end of the red cable to the positive (+) post on the battery, and the black cable to the negative (-) post. DO NOT ATTACH RED CABLE ON THE BATTERY AT THIS TIME. Drill a 1-1/4 inch diameter hole in the floor through which to route the cables to the battery charger. Install a grommet in the drilled hole. Route the cables though the grommet and to the battery charger. Attach cables to charger per manufacturers instructions. Support the cables with tie wraps and clamps approximately every twenty inches (20). Be sure there are no areas that may cause chaffing, especially where entry to the battery box occurs. Attach the charging cables to the battery charger according to the manufacturers directions.

2.

3. 4.

5. 6. 7.

8.

9.

10. Leave four to six inches excess at the battery end. 11. Cut the cables to length, strip off one half inch (1/2) of insulation, slide shrink sleeve over each cable, crimp the eye lug onto each cable and cover area between lug and cable with shrink sleeve. 12. When all routing has been completed, attach the black cable to the neg (-) battery post. Connect the red cable to the positive (+) post.

- 29 -

VII. INSTALLING HOSES AND ELECTRICAL WIRING

ROUTING FUEL LINES AND COOLANT HOSES WARNING: Do not bundle electrical harnesses or electrical cables with fuel lines!

COOLANT FLOW DIAGRAM

FIGURE 24
1. 2. On the side of the surge tank, attach the 5/8-diameter heater hose previously routed using a clamp provided. Follow the route of the 5/8 diameter hose between the surge tank and the a/c-heat unit and determine the best location to install the plastic Y in the hose. Cut the hose and install the Y with the bottom leg of the Yinserted in the hose going to the surge tank. Use figure 24 as a guide for routing coolant hoses. Attach the remaining 5/8 diameter heater hose to the third leg of the Y. Install the Y using three hose clamps provided. Locate the 3/4 diameter heater hose and attach it to the bottom fitting of the surge tank using a clamp provided. Route the 3/4 diameter hose to the engine unit. Starting at the a/c-heat unit bundle the hoses and harnesses going to the engine box. Bundle them together, and secure them to the truck, while advancing toward the engine box. Using the general purpose mounting brackets (yellow zinc finish) and P-clamps, tie-wrap and secure the bundle to the truck. The mounting brackets can be bent to match the needs of the installation. Look for OEM fasteners and holes in the frame that can be used to secure the general-purpose brackets. When one hose can be secured to the truck with a P-clamp, the rest of the bundle can be tie-wrapped to it.

3. 4. 5. 6.

7.

8.

- 30 -

ROUTING FUEL LINES AND COOLANT HOSES (cont)

9. Route the control extension and the start/stop harness to the engine box in the same bundle.

10. Route the harnesses into the engine box through the upper opening on the generator side. 11. Inside the engine box are located two black plugs that mate to the two black plugs on the extension harness. 12. Route the extension harness and the start/stop harness through the clamp retaining the other wire harnesses near their entry point into the box. It may be easier to remove and replace the clamp retaining the wire harnesses. 13. Plug the extension harness into the mating plugs in the engine box. 14. The start/stop harness has a mating white six-pin plug in the engine box. Be sure the locking devices engage when the plugs are mated together. See figure 22 15. Tie-wrap the harnesses to the refrigerant hoses in the box for proper support away from the drive belt area. 16. Attach the 3/4 diameter heater hose to the lower coolant hose coming from the water pump in the engine box using the splicer and clamp provided. 17. Route the 5/8 diameter heater hose from the plastic Y in the surge tank line to the top fitting on the radiator. 18. Remove the cap on the top radiator fitting and attach the heater hose with a clamp provided. 19. Attach the remaining 5/8 heater hose to the plastic Y on the coolant control valve using a clamp provided. 20. Route this heater hose into the engine box through the upper opening on the side nearest the compressor. Cut the hose to length. 21. Using a splicer and a clamp attach this hose to the coolant hose coming from the top of the engine. 22. Remove the cap from the bottom radiator fitting. Attach the remaining 5/8 diameter heater hose to the bottom radiator fitting. 23. Route this hose to the control valve assembly and attach to valve labeled INSTALL HOSE FROM BOTTOM OF RADIATOR HERE. 24. Cut the hose to proper length and attach to valve using the clamp provided. 25. Attach the #10 suction hose from the a/c-heater to the suction hose from the engine using one #10 o-ring and refrigerant oil on the o-ring and threads. See figure 25. Torque the suction fittings to 25 foot-pounds. 26. Remove the cap from the receiver drier fitting. Attach the #6 liquid hose from the a/c-heater unit to the receiver drier fitting using one #6 o-ring and refrigerant oil. See figure 25. Torque the fitting to 15 foot-pounds. 27. At the fuel tank attach the fuel line to the pickup tube installed earlier using a small gear clamp provided. 28. Route the fuel line to the engine box. The fuel line should be cut to length (+4 inches), and attached to the fuel pump on the back of the box using a small gear clamp provided. See figure 25 29. Install the in-line fuel filter at this time. Locate the in-line filter near the fuel source and where it is easy to see when filling the truck tank. Be sure to install the filter using the clamps provided, and the flow direction is as shown on the filter body.

- 31 -

ROUTING FUEL LINES AND COOLANT HOSES (cont)

ENGINE - BOX ASSEMBLY REAR VIEW

TRINARY PRESSURE SWITCH INLET FITTING FUEL PUMP

#6 REFRIGERANT FITTING

#10 REFRIGERANT FITTING

RECEIVER DRIER TANK

RADIATOR FAN SWITCH

FIGURE 25

30. Attach the remaining fuel line to the return fitting installed in the tank using one small gear clamp provided. Route this hose to the engine box and install on the fuel return fitting. See Figure 2. Installing this hose is easier if the air filter housing is removed by loosening the clamp at the lower neck of the housing. Bundle the fuel lines and attach to truck being careful to avoid items that could rub or chaff the hose. The fuel lines should be routed at least 10 inches away from all hot components like exhaust systems. 31. The starter cable (large red #2 gage) should install next. Cut the cable to length so it will reach the starter solenoid. Strip the insulation back one half inch on end of the cable. Slide a piece of shrink tubing onto the cable and crimp the eye lug onto the bare wire. It is suggested to solder the lugs onto the ends of this wire. Slide the shrink sleeve over the neck of the lug and shrink tight around the wire/lug junction. 32. Remove the large nut on the starter solenoid and fasten the eyelug onto the stud using the OEM nut. Torque the nut to 15 foot-pounds. 33. The wire harness for the coolant control valves should be plugged into the mating plug on the valve assembly. All hoses and harnesses that remain unattached to the truck should be attached to the truck at this time. Take a few minutes and visually inspect all work completed up to this point. Correct anything that appears to be questionable to safety, reliability, or performance.

- 32 -

VIII. ADDING FLUIDS

CHECKING OIL LEVEL
1. Locate the oil dipstick. Check the oil level. The oil should be to the top mark on the dipstick. Add oil about two ounces at a time until the system is full.

ADDING COOLANT AND PRIMING FUEL PUMP

*coolant required, 50/50 mix of antifreeze and water *premixed coolant required, two gallons 1. Remove the cap from the surge tank and add one half gallon of coolant. Visually inspect beneath the truck for leaks. Check a/c-heat unit area and engine box, Add coolant to surge tank until tank is half full. At the engine box, turn the fuel valve to the on (O) position. Jump across the terminals on the oil pressure switch. See Figure 1. The fuel pump and the water pump will engage and run as long as the oil switch is jumped. Run the fuel pump long enough to fill the fuel filter plus one minute. See Figure 1. Remove jumper. Inspect all fuel connections for leaks or wet areas. Repair any fuel leaks. At the surge tank add coolant until the tank remains half full.

2.

3.

4.

IX. INITIAL SYSTEM START UP

NOTE: The air condition is designed to force the compressor clutch off when cabin temperature is less than 60 degrees, and force the compressor clutch on when cabin temperatures are above 90 degrees. In shops with cold environments, the system heater can be used to raise the cabin temperature above 60 degrees to engage the compressor clutch.

PURGING AIR FROM SYSTEM

1. At the control panel, set the mode switch to heat, set the fan switch to low, rotate the temperature knob fully clockwise to maximum heat. Press the start/stop switch to the preheat position for ten seconds.

2.

Rock the start/stop switch up into the start position. The engine should begin turning over immediately. If the engine does not start, hold the start button in for ten seconds, then release. If the engine has not started repeat the steps above at least two more times, before attempting any repairs. If the engine stumbles and quits, the fuel line may not be totally purged. 3. After the engine has started, let it run, and briefly check under truck for coolant/fuel leaks. With the engine running begin adding coolant to the surge tank. When the coolant level in the tank has stabilized at half full, turn the temperature control fully counter clockwise, max cold position. At the surge tank add coolant until the level has stabilized at half full. Let the engine run for about five minutes moving the temperature knob back and forth between hot and cold, and checking the surge tank to add coolant as needed. Turn the engine off by pressing the start/stop button in on the lower end.

4.

5.

- 33 -

ADDING REFRIGERANT 134A TO THE SYSTEM

1. 2. Hook refrigerant gauges to the high and low side ports located on the fittings connected to the compressor. Evacuate the refrigerant system for a minimum of thirty minutes using a vacuum pump or charging station. The low side gauge should indicate a pressure lower than -27 inches. Turn gauge handles off for 20 minutes and check for rising pressure, an indication of leaks in the system. If the system is sealed, begin the charging process. Start the engine, press the mode switch to the a/c position, set the fan speed to high, and rotate the temperature knob to max cold.

3.

4.

5.

Charge the system with one pound eight ounces (1lbs-8oz.) of refrigerant R-134a. The pressure switches will allow the compressor clutch to turn on at about 30 psi. With the a/c charged a complete system check out can be conducted. Follow the steps below.

CHECKING OUT SYSTEM OPERATION 1. 2. 3. 4. 5.

Turn the engine off. Check the coolant, the surge tank should be half full, add if required. Turn the engine on. Check the fan control for all four speeds. Check the heat controls. Switch the mode control to the heat position. Rotate the temperature knob fully clockwise and run the heater in the max cold position until the discharge air is cool, rotate the temperature knob fully counter clockwise to maximum heat, the discharge air should rise to a warmer temperature. Check the a/c controls. To run this test the cabin temperature must be between 60 and 90 degrees. Switch the mode control to the a/c position. Turn the temperature control fully clockwise to the maximum hot position. Check the compressor clutch, it should be disengaged. Slowly advance the temperature control knob counter clockwise. The compressor clutch should engage when the set point drops below the cabin temperature. Check under the truck for coolant, fuel and oil leaks.

6.

7.

Clean the truck. Vacuum the metal shavings. Replace all the materials removed from the truck preparing for the installation.

- 34 -

PREMIUM SYSTEM WIRING DIAGRAM A/C-HEAT CONTROLS

- 35 -

FIGURE 26

PREMIUM SYSTEM WIRING DIAGRAM A/C-HEAT CONTROLS (continued)

- 36 -

FIGURE 27

ENGINE START / STOP WIRING DIAGRAM

- 37 -

FIGURE 28

POWER CONSUMPTION

- 38 -

- 39 -

- 40 -

- 41 -

- 42 -

- 43 -

- 44 -

- 45 -

- 46 -

XI

MAINTENANCE SCHEDULE

- 47 -

ENGINE SPECIFICATIONS

- 48 -

AIR CONDITIONER SPECIFICATIONS TESTED TO IMACA STANDARDS

- 49 -