Cabina y Aire Acondicionado LH 60

Service Manual
Installation instruction for air-conditioning 160.001.1 LH 60 C

hose fittings LH 60 M
Mounting of operator's cab elevation 160.002.1 LH 60 C

LH 60 M
Lift frame without cab control (Option) 160.010.1 LH 60 C 64724-

LH 60 M 56721-
Height adjustable operator's cab with cab 160.015.1 LH 60 C 64724-

control (option) LH 60 M 56721-
Auxiliary heater 160.030.1 LH 60 C 56140-

LH 60 M 56721-
Air-conditioning system 160.040.1 LH 60 C 64724-

LH 60 M 56721-
Air-conditioning system service 160.045.1 LH 60 C 64724-

LH 60 M 56721-
LHB/en/Edition: 11/2015
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Service Manual
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Service Manual Installation instruction for air-conditioning hose fittings
Tightening torques for air-conditioning hose fittings
In order to prevent malfunctions and ensure that the air-conditioning system is properly installed, it is
important that all a/c hoses are correctly laid and connected.
Before installation, apply a little a/c compressor oil (8504414 (PAG SP20) or 10017679 (PAG
SP10)) to all sealing rings.
Fig. 1 Compressors
3/4" 25 Nm
7/8" 35 Nm
3/4" 35 Nm
7/8" 40 Nm
Risk of damage to a/c hoses when tightening hoses.

When tightening the fittings, hold the hoses.
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Installation instruction for air-conditioning hose fittings Service Manual
Fig. 2 Condensers
3/4" 25 Nm
5/8" 16 Nm
Risk of damage to dryer-collector unit fittings when tightening hoses.

Fig. 3 Dryer-collector unit
5/8" 16 Nm
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Risk of damage to hoses during tightening.

Fig. 4 Hose fittings
3/4" 35 Nm
5/8" 16 Nm
7/8 40 Nm
1/16 45 Nm
Fig. 5 Expansion valve

M6x16 5.5 ± 1 Nm
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Fig. 6 Bending radius
Hose DN 8 50 mm
Manuli/RefrieMasterPlus
Hose DN 10 60 mm
Hose DN 13 80 mm
Hose DN 16 90 mm
Hose DN 8 60 mm
Eaton / HG 134
Hose DN 10 70 mm
Eaton / HG 134
Hose DN 13 90 mm
Eaton / HG 134
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Hose DN 16 110 mm
Eaton / HG 134
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Service Manual Mounting of operator's cab elevation
General
Special screw connections must be released or tightened exclusively by LIEBHERR customer

service or an authorised specialist workshop. Special screw connections are identified with an
adhesive label in this area.
Fig. 1 Identification of special screw connections
The tightening torques for angle-controlled assembly (torque value number) can be found in table
LH standard 10650522. The torque value number is included in the spare parts drawing (Lidos).
The valid torque value number must be obtained exclusively from spare parts drawing and must
not be transferred to apparently similar geometries.
Fig. 2 Design of special screw connection
Standard nut Washer (disc)

Threaded bolt Lift frame
Washer is a backing washer with press-mounted threaded segment which is inserted below
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Mounting of operator's cab elevation Service Manual
Assembly instruction for special screw connection
standard nut in screw connection.
Fig. 3 Screwing in special screw connection
When tightening screw connection (threaded bolt with washer and nut), ensure that it is fully screwed
into the component.
Threaded bolt must be at least flush with standard nut and must not protrude by more than approx.
2-3 mm, see Fig. 3.
All separating surfaces where components are to be tensioned against each other with screw
connection must be cleaned and degreased.
Fig. 4 Preparation of contact surface
Clean and degrease all contact surfaces, in particular the contact surfaces of the screw head and
the nut, prior to tightening.
Remove all residue of tinder, burrs and welding splashes with a scraper.
Carefully clean the flat-bottom holes.
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Special screw connections that have been tightened once in an angle-controlled tightening
procedure must not be reused.
Fig. 5 Preparing/checking special screw connections
Keep special screw connection (threaded bolt with washer and nut) ready. For type and quantities,
see parts list.
Carry out visual inspection of screws for serious damage to the surface.
Incorrectly mounted components can cause serious damage to machine.

Adhere to installation position of components.
Fig. 6 Positioning operator's cab elevation
Make sure that the parts to be secured with screws are flush with each other before tightening the
special screw connections.
For special screw connections, the parts to be tensioned can be secured with one or more suitable
screws.
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Fig. 7 Applying special screw connection
Apply special screw connection (threaded bolt with washer and nut ) and turn in by hand
(open-end spanner).
If threaded bolt does not move freely, lock nut with a second nut and screw in threaded bolt.
If an electric or air-powered screwdriver is used to insert screws, ensure that prescribed joining
torque is not exceeded.
Adhere to LH standard 10650522.
The tightening torques for angle-controlled assembly (torque value number) can be found in table
LH standard 10650522. The torque value number is included in the spare parts drawing (Lidos).
Observe tightening sequence for special screw connections, (see “Tightening sequence of
screws” on page 7).
Electric and hydraulic screwdrivers can cause serious injury to hands from crushing.
Observe operating manual of manufacturer.
Keep hands out of danger zone when operating screwdriver.
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Fig. 8 Tightening with electric or hydraulic screwdriver
Observe manufacturer instructions for electric or hydraulic screwdriver.

See spare parts drawing (Lidos) for torque value number.
Tighten special screw connection according to LH standard 10650522.
Screw special screw connection fully into component.
Threaded rod must be flush or protruding by no more than 2-3 mm, see Fig. 3.
Mark tightened screws.
When tightening screws manually using torque wrench, exclusively tighten nut as washer acts as
expansion sleeve (not as nut or lock nut!). If necessary, hold washer with open-end spanner.
Fig. 9 Tightening with torque wrench
See spare parts drawing (Lidos) for torque value number.

Tighten special screw connection according to LH standard 10650522.
Tighten nut with a suitable torque wrench according to LH standard.
Hold washer with open-end spanner.
Screw special screw connection fully into component.
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Threaded rod must be flush or protruding by no more than 2-3 mm, see Fig. 3.
Mark tightened screws.
As soon as nut of special screw connection is released, entire screw preload is lost. Washer has
no fixing function on its own!
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Fig. 10 Tightening sequence of screws
Operator's cab elevation, rigid LFC 80-200 Operator's cab elevation, hydraulic LHC 340
Operator's cab elevation, hydraulic LHC 255 Operator's cab elevation, hydraulic LHC-D
(two cylinders in operator's cab elevation) 730
Operator's cab elevation, hydraulic LHC 255
(one cylinder in operator's cab elevation)
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Fig. 11 Tightening sequence of screws
Operator's cab elevation, rigid LFC 250 - Operator's cab elevation, hydraulic LHC-D
LFC 350 1090T
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Service Manual Lift frame without cab control (Option)
The design of the hydraulic system is described in

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Lift frame without cab control (Option) Service Manual
Hydraulic schematic
Fig. 1 Hydraulic schematic Lift frame without cab control
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Service Manual Lift frame without cab control (Option)
Key of hydraulic schematic
Return block / control pressure

Return block / return oil
Input plate with priority function
Pilot control valve / grapple rotation
Control axle / lift frame
Secondary pressure-relief valve
Spool / lift frame
Pressure balance / lift frame
Pressure balance / lift frame
Load holding valve
Pilot control valve / lift frame
Accumulator
Emergency discharge
Emergency discharge
Load holding valve
Hoist cylinder
Solenoid valve / lift frame UP
Solenoid valve / lift frame DOWN
Shift valve / lift frame
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Lift frame without cab control (Option) Service Manual
Key of hydraulic schematic
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Service Manual Height adjustable operator's cab with cab control
The design of the hydraulic system is described in .

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Height adjustable operator's cab with cab control Service Manual
Hydraulic schematic
Fig. 1 Hydraulic schematic height adjustable operator's cab with cab control (option)
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Service Manual Height adjustable operator's cab with cab control
Key for hydraulic schematic
Return block / control pressure

Return block / return oil
Input plate with priority function
Servo control valve / turning grapple
Control axle/ height adjustable operator's cab
Control spool/ height adjustable operator's cab
Pressure balance/ height adjustable operator's cab
Pressure balance/ height adjustable operator's cab
Servo control valve/ height adjustable operator's cab
Valve unit
Piston
Filter
Pressure relief valve
Restrictor check valve
Bleeder valve
Accumulator
Throttle
Shuttle valve
Check valve
Emergency discharge
Emergency discharge
Shuttle valve
Stop valve, releasable
Hoist cylinder
Solenoid valve/ height adjustable operator's cab up
Solenoid valve/ height adjustable operator's cab down
Shift valve/ height adjustable operator's cab down
Tab. 1 Key for hydraulic schematic

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Height adjustable operator's cab with cab control Service Manual
Key for hydraulic schematic
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Service Manual Auxiliary heater
Design
The auxiliary heater is connected to the cooling system, the fuel system and the electrical system of
the machine. The water heater is mounted on the uppercarriage below the diesel engine .
The check valve and the thermostat valve are integrated into the heating circuit of the auxiliary
heater.
The auxiliary heater consists of the following main components:
– Water heater
– Fuel system, see Fig. 3
– Silencer
– Timer , see Fig. 2
Fig. 1 Design of auxiliary heater
Check valve Diesel engine

Thermostat valve Water heater
Silencer
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Auxiliary heater Service Manual
Design
Fig. 2 Electrical system of the auxiliary heater
Electric cabinet Timer

Central electrics motherboard Plug connection, 2-pin
Fuse (20A) Plug connection, 12-pin
Time relay 0.5-5.0 seconds Plug connection
Relay Plug connection
Relay Plug connection
Water heater Plug connection
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Technical data
Fig. 3 Fuel system with metering pump and fuel filter
Water heater Thermo 90 ST

Heat flow
Maximum kW 9.1
Control range kW 1.8 – 7.6
Fuel Diesel
Fuel consumption
Maximum l/h 1.1
Control range l/h 0.19 – 0.9
Rated voltage V 24
Operating voltage range V 20 - 30
Rated power consumption of recirculation pump
Maximum W 90
Control range W 37 – 83
Permissible operating pressure bar 2.0

Heat exchanger filling volume l 0.15
Maximum combustion air intake temperature °C +40
Minimum volume in cooling circuit l 6.0
Volumetric flow rate of recirculation pump
l/h 1650
Thermostat valve flow rate l/min 2.667
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Function
Tab. 1 Technical data
The auxiliary heater complements the standard heating system of the machine and serves for
– Heating of the operator's cab
– Defrosting of vehicle windscreen and windows
– Preheating of water-cooled diesel engine
Fig. 4 Water heater
Control unit Cooling fluid inlet

Fuel connection Recirculation pump
Combustion air fan Fastening clamp

Cooling fluid outlet Exhaust gas outlet
Temperature sensor Combustion air inlet
Temperature limiter Water heater
Heat exchanger
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Functional description of the components, see Fig. 4
The electrical components and connections are shown in the circuit diagram of group 110.
The control unit controls the functions of the burner and monitors its operation.
The combustion air fan provides the air required for combustion from the combustion air inlet to
the burner gun .
The temperature sensor records the cooling fluid temperature at the cooling fluid outlet of the water
heater by measuring its electric resistance. This signal is processed by the control unit .
The temperature limiter serves as an overheating protection device and protects the water heater
against excessively high operating temperatures. The overheating protection responds the
moment the heat transfer temperature exceeds 127 ±7°C, switching off the water heater.
In the heat exchanger , the heat produced through combustion is transferred to the coolant circuit.
The recirculation pump transfers the coolant through the circuit. The recirculation pump is switched
on through the control unit and remains switched on while the water heater is in operation.
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Functional description of the components, see Fig. 4
Fig. 5 Glow pencil and flame detector
When the water heater is started, the air-fuel mixture is ignited by the glow pencil. The glow pencil
designed as an electrical resistor is installed in the burner gun on the side facing away from the flame.
The flame detector is a temperature-controlled resistor whose resistance changes depending on the
heat produced by the flame. The resistance signal is fed to the control unit where it is processed. The
flame detector monitors the flame across the entire operating time of the burner.
Fig. 6 Burner gun with inlet guide plate and burner tube
In the burner gun with the inlet guide plate , the fuel is distributed across the burner cross-
section in the burner tube . The air-fuel mixture is combusted in the burner tube.
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Function of auxiliary heater
Fig. 7 Thermostat valve 30
The thermostat valve controls the coolant circuit based on the temperature in the circuit.
Fig. 8 Metering pump
The fuel supply and the supply to the water heater is controlled by the external metering pump
. In addition, it serves as a shut-off device when the water heater is switched off. The pulses
that control the magnetic coil of the metering pump are sent by the control unit .
If the ignition is off, start the auxiliary heater through the instant heating function or the pre-
programmed heating operation. The recirculation pump , the glow pencil and the combustion air
fan are started.
Combustion begins approx. 60-140 seconds after the system is started. From this point, the heating
operation is controlled automatically. The auxiliary heater can be operated at full load for maximum
2 hours.
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Maintenance
The air-conditioning system of the machine is only switched on when the coolant has reached the
necessary temperature.
If the temperature of the coolant increases to the threshold for pause, the water heater is
temporarily switched off. During this break, the recirculation pump , the heater fan of the machine
and the indicator at the timer remain however in operation.
After the coolant temperature has dropped to the programmed re-start temperature, the water heater
is automatically switched on again.
If the water temperature in the water heater is above the set temperature but does not reach the
pause threshold, the temperature is reduced so that it reaches the set temperature within 10 minutes.
The water heater is switched to 9.0 kW heating level.
If the set temperature is reached, it is automatically restarted to max. 7.6 kW heating level.
When the auxiliary heater is switched off, the operating indicator and the timer are no longer
displayed. Combustion is stopped and the system is operated in afterrun mode. The recirculation
pump and the combustion air fan remain however in operation. The water heater is cooled
(afterrun) and automatically shuts down after approx. 105 seconds. During the afterrun period, the
water heater can be switched on as normal.
Risk of injury from burns when touching hot components!

Allow the components to cool down.
Prior to the start of the cold season or if the auxiliary heating system has become dirty, perform the
following maintenance tasks:
– Clean the outside of the water heater.
– Check the electrical connections for proper tightening and contact corrosion.
– Inspect the exhaust gas and combustion air lines for damage and blockage and clean them, if
necessary.
– Check the fuel line and the filter for damage and leakage.
– Change the fuel filter.
– Check the coolant circuit and the recirculation pump for leakage.
– Check the coolant hoses for cracks, etc.
In order to prevent the diesel fuel becoming viscous, it is necessary to change to winter diesel. Ensure
that all summer diesel is flushed from the system,
before the cold season begins.
Start the diesel engine and let it run for 10 minutes.
Lines are flushed with winter diesel.
Shut down the machine and let it cool down.
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Repair
Switch on the auxiliary heater (see “Adjustment” on page 15) and let it run for approx. 60 minutes.
Lines are flushed with winter diesel.
Switch off the auxiliary heater.
All repair work must be performed by specially trained maintenance personnel.

Observe the documentation of the manufacturer.
Prior to commissioning, after installation or repair, observe the following:

Carefully bleed the coolant circuit and the fuel supply system.
Open the coolant circuit before performing a test run.
During the test run of the heater, check all water and fuel connections for leakage and proper
fixture.
Check the cooling water level in the expansion tank.
When operating the auxiliary heater, adhere to the following instructions:

Before refuelling, switch off the water heater.
The water heater must never be operated under conditions where flammable fumes or dust could
occur.
The mounting recess for the water heater may not be used for the storage of other items.
Do not store
– fuel canisters
– oil or spray cans
– gas cartridges
– fire extinguishers
– cleaning cloths
– items of clothing
– paper
or similar material on top of or beside the heater.
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Repair
Fig. 9 Installation and dismantling of the water heater
Bracket Hose clamp

Screw Water heater
Washer
Risk of injury from dropping components.

Secure the components in their position.
Open the hose clamps around the coolant hoses.

Remove the coolant hoses from the water heater .
Let the coolant flow into a suitable container.
Seal the coolant hoses.
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Repair
Fig. 10 Installation and dismantling of the water heater
Remove the hose clamps from the fuel line at the water heater .
Collect the escaping fuel in a suitable container.
Seal the fuel line.
Loosen and remove the screws , see Fig. 9.
Remove the water heater together with the bracket from the uppercarriage by pulling it
down.
To install the water heater , perform the above steps in reverse order.
After installation, check the coolant level.
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Troubleshooting
Fig. 11 Installing metering pump
When installing the metering pump E30.Y1 and laying the fuel lines, observe the following:
– Cut the fuel hoses and pipes with a sharp-edged knife. Ensure that the cutting edges are not
squeezed or burred.
– Do not lay fuel lines near the waste gas duct from the water heater or near the diesel engine.
– All fuel lines must be installed with butt joints to prevent bubbles in the system.
– Install the metering pump in such a way that the pressure side is located at the top. Ensure that
the angle of installation is approx. 20°.
F 00 Heater locking or control unit not working

F 01 No start (after 2 attempts)
F 02 Flame interruption
F 03 Overvoltage or undervoltage
F 04 Premature flame detection
F 05 Flame detector wire break
Flame detector short circuit
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Troubleshooting
F 06 Temperature sensor wire break

Temperature sensor short circuit
F 07 Metering pump wire break
Metering pump short circuit
F 08 Fan motor wire break
Fan motor short circuit
Incorrect fan motor speed
F 09 Glow pencil wire break
Glow pencil short circuit
F 10 Overheating
F 11 Recirculation pump wire break
Recirculation pump short circuit
Tab. 2 Error messages
After the cause of the fault has been eliminated, the auxiliary heater must be released by switching
it off and on again.
The following faults result in a shutdown of the auxiliary heater:

– If no flame is produced, the fuel supply is shut off after max. 240 seconds.
– If the flame dies, the fuel supply is shut off after max. 240 seconds.
– If the system is overheating (temperature limiter triggered), the fuel supply is interrupted.
– If the undervoltage protection is tripped for more than 20 seconds, the fuel supply is interrupted.
General fault symptoms

Water heater is No combustion after multiple Control unit locked due to fault
automatically start attempts Switch off the heater and switch it on
switched off again.
Flame dies during operation If the heater still fails to work properly,
consult the manufacturer for a service by a
specialist technician.
Heater overheating due to Adding coolant

insufficient coolant/coolant
loss
No voltage for more than 20 Check fuses, plug connections and battery
seconds charge
No flame detected upon start Check flame detector and flame detector
connections
Fault symptoms upon fault shutdown
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Troubleshooting
Auxiliary heater not Electric wiring, fuses Check fuses and plug connections
working Check battery connection
Control device defective Replace control unit
Flash pulse Fuel system Check fuel level
(auxiliary heater Check fuel filter
fails to start) Bleed fuel system
Combustion air/exhaust gas Check combustion air/exhaust gas line for

line blockage and clean, if necessary
Burner Clean burner and replace, if necessary

Flash pulse Fuel supply Check fuel level
(flame dies during Check fuel filter
burner operation) Bleed fuel system
Burner Clean burner and replace, if necessary
Flash pulses Electrical supply Checking battery
(undervoltage) Check electrical connections
Flash pulses Flame detector not working Replace flame detector
(flame detector
continuously hot)
Flash pulses Cabling Check cables for damage and short
(flame detector not circuits
working)
Flame detector not working Replace flame detector
(temperature circuits
sensor not working)
Temperature sensor not Replace temperature sensor
working
Flash pulses Coolant circuit Check coolant level.
(metering pump not Bleed coolant circuit
working /
overheating Cabling Check cables for damage and short
protection not circuits
working)
Metering pump not working Replace metering pump
(combustion air fan circuits
not working)
Combustion air fan not Replace combustion air fan
working
(glow pencil not circuits
working)
Glow pencil not working Replace glow pencil
Flash pulses Water heater overheating Check coolant; if necessary, add coolant
(overheating)
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Adjustment

(recirculation pump circuits
not working)
Recirculation pump not Replace recirculation pump
working
Fig. 12 Timer
Display Instant heating

Feed line Program selection
Return line Time
General The timer allows for the programming of the heating start
within period of 7 days from the time of programming. You
have the option to set 3 switch-on times, whereby only one
can be activated at a time.
The timer comes with an alarm clock function. When the
ignition is on, the clock shows the actual time and the day
of the week. When the heater is on, the display and the
buttons are illuminated.
When the unit is powered, all symbols on the display flash.
Set the time and day of the week.
Operation The timer settings indicated by the flashing symbols can be
adjusted with the buttons and . If no button is pressed
for more than 5 seconds, the set time is saved. If the
buttons and are pressed and held for more than 2

seconds, the system is run in speed mode.
When the ignition is switched off while the water heater
is in continuous heating mode, the display indicates the
remaining runtime (15 minutes), and the water heater
remains in operation.
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Adjustment
Switching on Manual:
– Press the button (continuous heating mode).
Automatic:
– Program heating start.
Switching off Manual:
– Press the button .
Automatic:
– Set the timer while the water heater is running.
– Enter the remaining runtime.
Adjusting the time/weekday settings Press and hold button for more than 2 seconds.
The time display flashes.
Set the time, using the buttons and .
The week day display flashes.
Select the week day, using the buttons and .
Viewing time Ignition off:
Press the button .
Programming heating start Press the button .
The memory slot flashes.
Set the heating start time, using the buttons and .
The week day display flashes.
Select the week day, using the buttons and .
Repeatedly press the button .
Memory slots 2 and 3 can be programmed.
Change to time mode.
Viewing / deleting preset times View/delete preset times:
The desired memory slot is displayed.
Delete preset times:
The preset time is deleted.
Until no memory slot but the time is displayed.
Programming operating time Auxiliary heater not in operation.
Press and hold button for 3 seconds
Operating time flashing
Press the buttons and to set the heater operating
time (10 to 120 minutes).
Setting remaining runtime Press the buttons and to set the remaining
operating time (1 to 120 minutes).
The remaining operating time is the time during which the
water heat remains switched on from the date of setting the

time. It can only be set while the heater is in operation and
the ignition is off.
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Adjustment
Setting alarm clock time The alarm clock time is not linked to a specific week day.
Until the bell symbol is shown in the display .
Set the alarm clock time by pressing the buttons and
.
The alarm clock is automatically switched off after 5
minutes, or when one of the buttons is pressed.
Viewing/deleting alarm clock time Viewing alarm clock time:
Until the bell symbol is shown in the display .
Read the alarm clock time.
Deleting alarm clock time:
Press the button .
Until the bell symbol on the display disappears.
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Adjustment
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Service Manual Air-conditioning system
Design of air-conditioning system
The air-conditioning system is designed to enable the operator to freely adjust the temperature in the
operator's cab. The adjustment must be possible irrespective of the actual ambient conditions.
The air-conditioning system consists of 3 main components that are connected to each other with
refrigerant lines:
A/c compressor - attached to the diesel engine
Condenser - attached to the radiator of the diesel engine and the hydraulic system
Heating/air-conditioning unit - located in the operator's cab below the operator seat
Fig. 1 Main components of the air-conditioning system
A/c compressor Heat exchanger

Condenser Pressure-relief valve
Dryer-collector A/c control unit
Expansion valve Central control system
Evaporator Magnetic clutch
Heating/air-conditioning unit
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Air-conditioning system Service Manual
see Fig. 12
The a/c compressor with the electromagnetic clutch is powered by the diesel engine through
a V-belt and is located near the diesel engine.
The a/c compressor compresses the refrigerant in the circuit.
see Fig. 9
In the air-pressurised fin condenser , the thermal energy of the refrigerant is dissipated into the
ambient air and the gaseous refrigerant becomes liquid under pressure.
The condenser is mounted to the radiator of the diesel engine / hydraulic system. The radiator blower
feeds air through the condenser.
see Fig. 9
The dryer-collector is located behind the condenser . The dryer-collector acts as a compensating
and reserve container for the refrigerant in the cooling circuit. The liquid refrigerant fed by the
condenser enters the dryer-collector . In the dryer-collector, the refrigerant is collected, fed through
the dryer and then released in a continuous flow without air bubbles in the direction of the expansion
valve .
The amount of refrigerant pumped though the circuit is determined by the actual operating conditions,
the heat load at the evaporator, the condenser and the operating speed of the engine.
In the dryer-collector , water that has entered the cooling circuit during assembly is absorbed. In
addition, abraded material from the compressor , dirt that entered the circuit during assembly and
other particles are removed as they settle in the dryer-collector.
Due to its chemical properties, the R134a refrigerant can only absorb very little water. High humidity
in the system can cause corrosion, damaging the system and leading to malfunctions.
To absorb the water in the refrigerant, the dryer-collector contains a desiccant. It removes water as
well contaminants such as acidic substances and dirt particles from the refrigerant. To prevent
desiccant from entering the cooling circuit, a number of sieves or filters are installed at the outlet end
of the dryer.
The dryer-collector is equipped with the pressure-relief valve , (see 1.10.2 on page 5) and Fig. 13.
see Fig. 3
The expansion valve acts as a thermostatic pressure-relief valve.
In the expansion valve , the refrigerant is depressurised and cooled. The valve thus separates the
high-pressure and low-pressure sections of the circuit. The expansion valve also regulates the
refrigerant flow to the evaporator, based on the temperature at the evaporator .
This ensures that only the amount of refrigerant that is required for uniform cooling is depressurised
towards the evaporator .
The expansion valve controls the refrigerant flow based on the temperature:
– if the temperature of the refrigerant leaving the evaporator rises, the refrigerant expands in the
thermostat of the expansion valve .
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The refrigerant flow rate to the evaporator is increased.

– if the temperature of the refrigerant leaving the evaporator drops, the volume of refrigerant in the
thermostat is reduced.
The refrigerant flow rate to the evaporator is reduced.
see Fig. 2
The evaporator consists of an air-pressurised heat exchanger. The warm air is moved through the
fins of the evaporator so that heat is dissipated through the fins and pipe walls to the refrigerant.
The refrigerant evaporates and thus becomes gaseous.
The (liquid) refrigerant released by the expansion valve is depressurised in the evaporator . This
results in the fins of the evaporator being significantly cooled down. The ambient or cab air fed by
the blower ( ) through the evaporator is cooled down so that the necessary cooling effect can be
achieved (e.g. during hot weather and exposure to strong sunlight).
The water in the cooled air condensates at points in the evaporator where the temperature is below
the dew point temperature. The air is thus dried. This side-effect is used to dry fogged windows in the
operator's cab.
see Fig. 2
The coolant of the diesel engine is fed through hoses to the heat exchanger , forming a separate
circuit from that of the air-conditioning system.
The heat exchanger heats the air fed through it. The further the refrigerant valve is opened by
means of the servo motor , the more the air is heated up. Depending on the actual blow level
of the blower motor , more or less warm air flows through the air outlets into the operator's cab.
see Fig. 2
The brushless DC motor drives the low-noise rotor blades whose speed can be steplessly
adjusted.
The double radial blower takes up air through the filter system in axial direction and then feeds it in a
radial direction. The air flow is fed through the heat exchanger and the evaporator and escapes
through the outlets into the operator's cab. Depending on whether heating or cooling operation is
selected, the air is warm or cool.
see Fig. 5
The air necessary for the operation of the air-conditioning system is fed through the filters in the filter
box .
The filter box contains a pre-filter, a fresh air filter and a recirculation air filter. For a description of the
filter unit, (see 3.4 on page 9).
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see Fig. 11
The temperature outside the operator's cab is monitored by the external sensor (temperature
sensor) and signalled to the a/c control unit . The air-conditioning performance is adjusted
depending on the temperature difference between the actual outdoor temperature and the desired
indoor temperature.
The external sensor is mounted at the outside of the operator's cab (below the headlight
housing).
see Fig. 11
The light intensity (intensity of sunlight) is monitored by the sunlight sensor (light sensor) and
signalled to the a/c control unit . The air-conditioning performance is adjusted depending on the
actual light intensity (light = heat).
The sunlight sensor is located at the right rear of the display / control desk.
see Fig. 11
When the air-conditioning system is started, the temperature inside the operator's cab is measured
once by the cab sensor (temperature sensor) and signalled to the a/c control unit . The air-
conditioning system performance is adjusted according to this temperature.
The cab sensor is located to the rear inside the operator's cab to the right of the radio speaker
(see Fig. 11 on page 16).
see Fig. 2
The air outlet temperature is monitored by the air outlet sensor (temperature sensor) and
signalled to the a/c control unit . The air-conditioning performance is adjusted depending on the
actual temperature.
The air outlet sensor is inserted at the bottom into the air outlet of the heating/air-conditioning
unit .
see Fig. 13
The pressure switch sends an electric signal to the central control system , which then
switches off the refrigerant compressor through the electromagnetic clutch when the
permissible maximum pressure is reached.

Possible causes for excessive pressure:
– Excessive amount of refrigerant in the circuit
– Excessive temperature due a dirty condenser or defective fan
– Filter in the dryer-collector dirty
– The expansion valve is iced up (due to excessive humidity in the refrigerant) or dirty (blocked)
The a/c compressor is also switched off when the permissible minimum pressure is reached. This
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is done to prevent dry-running of the compressor (insufficient pressure = insufficient amount of

refrigerant).
see Fig. 13
The pressure-relief valve protects the components of the cooling circuit against excessive
pressure and consequential damage.
see Fig. 2
One anti-icing sensor (evaporator sensor) protects the evaporator against icing. The
second sensor is installed to protect the system in the event of a sensor failure.
The values recorded by the anti-icing sensor are continuously checked and the magnetic
clutch of the compressor is switched on and off accordingly.
The anti-icing sensors are inserted at the bottom of the evaporator .
The lubricant (refrigeration oil) is added to the cooling circuit to minimise abrasion and wear in the
compressor . It also facilitates heat dissipation and abrasive particle transport.
The system is factory-filled with R134a to the recommended level for best operation. As it is not
possible to achieve a completely sealed refrigerant circuit in an a/c system (due to the flexible
connecting hoses from the compressor to the condenser and evaporator), it might from time to time
be necessary to add refrigerant.
Within the refrigerant circuit, the refrigerant constantly changes its physical state:
– in the evaporator, it changes from liquid to gaseous
– in the condenser, it changes from gaseous to liquid
see Fig. 2
Fresh and recirculation air is taken up by the blower through the intake shaft and fed to the
evaporator and the heat exchanger . The conditioned air flows through the outlet shafts
and according to the actual flap position (adjusted through the servo motors ,
into the air channels/air outlets.
The heating/air-conditioning unit is located behind the operator seat.
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..
Fig. 2 Design of the heating/air-conditioning unit 13, part 1
Fig. 3 Design of the heating/air-conditioning unit 13, part 2

Expansion valve Refrigerant return connection

Evaporator Anti-icing sensor
Heat exchanger Air outlet sensor
Fresh/recirculation air intake shaft Blower motor
Front/defrost air outlet shaft Refrigerant valve servo motor
C-columns outlet shaft Servo motor / legroom
Legroom air outlet shaft Servo motor / defrost
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Technical data
Refrigerant feed connection Servo motor / C-columns
Manufacturer Wölfle GmbH

Rated voltage 24 V DC
Refrigerant R134a
Filling volume see group 030
Type Alpha 2006

Rated voltage 24 V
Blower steps 6 (stepless with automatic)
Max. current consumption 8.5 A (unrestricted blowing: 16 A)
Capacity 0.682 l
Filtration up to particle size >7 
Water absorption in drying cartridge 13 g
Opening pressure of pressure-relief valve 15 34.5 - 41.3 bar
Switching pressure of pressure switch B
Low pressure / high pressure 2.0 bar / 28.0 bar
Type SD 7 H 15
Rated voltage 24 V
Max. speed 5000 rpm
Flow rate 154 cm3
Direction of rotation clockwise
Refrigeration oil PAG SP10 or equivalent product
Filling volume 200 cm3
Max. power consumption 42 W

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Functions and principle of operation
see Fig. 4
The compressor compresses the gaseous R134a refrigerant. The hot refrigerant flows through the
condenser . In the condenser , the thermal energy of the refrigerant is dissipated to the air flow
from the cooling blower (engine cooling / hydraulic oil cooling). As the refrigerant is cooled and
compressed, it becomes liquid.
The liquid refrigerant flows into the dryer-collector to the expansion valve . The pressurised
refrigerant is depressurised.
This sudden pressure drop results in the refrigerant evaporating and becoming gaseous. In the
process, it takes up the thermal energy of the air as it is fed through the fins of the evaporator . The
blower feeds the air as it is being cooled down towards the outlets in the operator's cab.
Fig. 4 Diagram of the cooling circuit of the air-conditioning system
A/c compressor Blower motor

Condenser Magnetic clutch
Dryer-collector High-pressure circuit 1
Expansion valve High-pressure circuit 2
Evaporator Low-pressure circuit 1
Engine cooling blower Low-pressure circuit 2
The warm/hot refrigerant is fed through the refrigerant hoses between the diesel engine and the heat
exchanger to the refrigerant valve.
Depending on the desired indoor temperature, the refrigerant valve is opened by the servo motor
so that the required amount of refrigerant is fed to the heat exchanger . The refrigerant is
cooled down as its thermal energy is dissipated through the fins of the heat exchanger .
The blower feeds the air as it is being heated towards the outlets in the operator's cab.
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Functions and principle of operation
see Fig. 6 and Fig. 7

The heating/cooling performance can be regulated at the display , with the rotary encoder
or with the buttons .
see Fig. 5
To clean the incoming air, it is fed through the filter box mounted in the rear right corner of the
operator's cab.
Depending on the position of the recirculation air flap , which is operated by the servo motor
(fresh/recirculated air operation), the air is fed through the fresh air filter or the recirculated
air filter in the filter box and on to the heating/air-conditioning unit .
The filter box is equipped with a filter cassette .
The filter cassette consists of the following components:
The pre-filter cleans the fresh air taken into the system by removing foreign objects and larger
dust particles. The pre-filter must be regularly cleaned (see “Maintenance” on page 13).
The fresh air filter cleans the fresh air by removing fine dust particles.
The fresh air filter must be replaced at set intervals together with the filter cassette (see
“Maintenance” on page 13).
The recirculated air filter cleans the taken-up cab air from fine dust particles. The recirculated air
filter must be replaced at set intervals together with the filter cassette (see “Maintenance” on
page 13).
Fig. 5 View and sectional drawing of the filter box with filter cassette
to heating / air-conditioning unit Fresh air filter
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Operation of air-conditioning system
Filter box Recirculated air filter

Filter cassette Recirculated air flap
Pre-filter Servo motor of fresh air/recirculated air
intake

An indoor climate inside the cab that is adjusted to the operator's needs helps make working with the
machine less tiring and thus enhances safety.
The temperature inside the operator's cab can be adjusted to any value between +16°C and +28°C.
In automatic mode, the air-conditioning system can only perform at its optimum level if all windows
are closed and the air outlets inside the cap are open.
The air-conditioning system is designed for cooling, heating and fan operation.
The heating/air-conditioning system can be controlled at the display , with the control knob
or with the buttons on the main keyboard .
To operate the system through the display , press the icons on the touch screen
interface (see Fig. 7 on page 12).
To control the system with the control knob , turn the control knob and simultaneously
activate the respective icon (highlighted with frame) on the display . To activate/conform the
command, press the control knob .
To control the system with the buttons at the main keyboard , press the respective
button.
The number of indicator LEDs lit in the button indicate the respective operating mode. The
right and the centre LEDs in the button are on = blower set to level 6 (81 - 100 % of max. blower
output)
The air flows through the outlets to the left and right behind the operator's seat and through the
openings below the seat and near the windscreen into the operator's cab, see Fig. 8.
Other functions and possible operating statuses are described in detail in the respective operating
manuals.
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Fig. 6 Control console with monitoring display, control unit and rotary encoder
Display Blower output button

Main keyboard ECON button (no cooling)
Control knob / manual control in display Defrost/dehumidify button
menu
Automatic mode button Recirculated air button
Temperature button
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Fig. 7 Display of main a/c menu
Main menu for heating/air- Air outlet / head area

conditioning
Automatic mode Air outlet / chest area
ECON (operation without cooling Air outlet / foot area
function)
Recirculated air Blower performance display and adjustment + / -
Defrosting / dehumidification Air outlet operating status indicator
Temperature display and
adjustment + / -
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Maintenance
Fig. 8 Air outlets at operator's workplace
To ensure trouble-free operation and a long service life, the a/c system must be regularly and
carefully serviced.
Regularly start the a/c system to prevent the following problems:

– Odour in air
– Malfunctions
– Damage to a/c system
– Seizing of compressor
This requires that the compressor is started as follows:
During the cold season, heat the cab to comfort temperature (20 - 22°C).
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Maintenance
Start the a/c system in automatic mode.

Switch on the defrost/dehumidify function.
Switch on the recirculated air function.
After approx. 15 minutes, the a/c system can be switched off again.
Check the a/c system for proper functioning.

Check the condenser for dirt; blow clean, if necessary.
Clean the preliminary filter, the recirculated air filter and the fresh air filter; replace filters, if
necessary; shorten the maintenance interval if there is excessive generation of dust.
Check the V-belt tension and compressor fixture.
Check the sensors to ensure that they are in working order and are not obstructed (covered) or
dirty.
Check the hose lines and electric cables for chafe marks; if necessary, replace hoses and cables
and check the plug-connections for proper fixture.
The fins of the condenser must be regularly cleaned with great care.
Clean the condenser fins only with pressure-reduced compressed air. Do not clean mechanically
or with a steam jet cleaner.
Fig. 9 Condenser installation
Condenser Diesel engine/hydraulic cooling system

Dryer-collector
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Maintenance
The filters and installed in the filter box must be regularly serviced.
If the pre-filter is very dirty, it can be cleaned by tapping or blowing out the dirt.
Open the access door to the left of the operator's cab (release lever located in left rear corner
of operator's cab)).
Remove the pre-filter from the filter box and clean it.
The recirculated air filter and the fresh air filter must not be cleaned.
If the recirculated air filter or the fresh air filter are dirty, replace the complete filter
cassette .
Remove the filter cassette from the filter box .

Dispose of the filter cassette with the dirty recirculated air filter and the fresh air filter
in a safe way.
Insert the new filter cassette complete with the pre-filter the fresh air filter and the
recirculated air filter into the filter box (correct position of installation is defined by the
outer shape of the filter cassette ).
Close the access door .
Fig. 10 Removing and installing filter element 101
Access door for filter Pre-filter

Filter box Fresh air filter
Filter cassette Recirculated air filter
During each service, the cab sensor the sunlight sensor and the external sensor
must be checked to ensure that they are not obstructed (i.e. covered) or dirty).
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Maintenance
The sensors can only work properly if they are not covered by objects.
Incorrect handling or cleaning of the sensors can damage them. This would lead to malfunction of
the automatic a/c control.
If necessary, remove any covers from the sensors.
Never use pointed or sharp-edged tools to clean the sensors.
If necessary, clean the sensors carefully with compressed air or a soft cloth to remove dust and
dirt.
Fig. 11 Arrangement of sensors
Display Sunlight sensor

External sensor Cab sensor
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Handling of refrigerant
In the event of problems with the air-conditioning system, and in particular if you suspect that there
is a leak in the a/c system, observe the following safety instructions.
All refrigerants displace oxygen in the atmosphere. There is thus a risk of suffocation! R 134a is
heavier than air and displaces it. An acrid smell indicates that the refrigerant is decomposing due to
overheating. Refrigerants are flammable and can be set on fire by glowing cigarette ash. The
substances released by combustion are toxic and must not be inhaled.
Ensure proper ventilation!
Do not work in pits!
Do not smoke when handling refrigerants!
Always seal leaks in the air-conditioning system without delay.
In the event of a sudden rise in the refrigerant concentration in the ambient air (e.g. after a
pipeline rupture), immediately leave the room and only enter it after it has been properly
ventilated!
If the refrigerant concentration in the air is high, use respiratory protection equipment with
separate oxygen supply.
Never inhale refrigerant vapours as they have a narcotic effect in high concentrations. Misuse of
the substance can be fatal!
In the event of , rinse the affected area with plenty of

water and consult an ophthalmologist.
In the event of , remove all contaminated clothing and rinse the affected area
with plenty of water.
After , remove the casualty to fresh air
and keep at rest. Consult doctor. In the event of respiratory difficulties, administer oxygen. In case
of respiratory arrest, resuscitate the casualty.
The inhalation of refrigerant vapours can cause drowsiness or unconsciousness. Refrigerants

sensitise the heart against the effect of catecholamine, thus prohibiting the administration of
adrenaline and similar substances. After inhalation of refrigerant decomposition products, there is an
increased risk of lung oedema even after a prolonged latency period.
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Extraction of refrigerant, filling of air-conditioning system with leakage test
For details, refer to the description and instructions in group 160.045
Risk of injury to service personnel.

If the refrigeration circuit is opened improperly, refrigerant escapes in liquid or gaseous form. The
higher the pressure in the system, the more refrigerant escapes and the faster it is released from
the system.
Before carrying out any maintenance or repair work on the air-conditioning system, always switch
off the electric system.
Set the key of the battery main switch to position .
To check the air-conditioning system after maintenance / repair, turn the key of the battery main
switch to position .
Before removing/dismantling components of the air-conditioning system, you must open the air-
conditioning circuit.
Extract the refrigerant from the air-conditioning system, following the instructions in group
160.045.
Always observe the instructions for the handling of refrigerant in group 160.045.
see Fig. 12
Extract the refrigerant from the air-conditioning system, see group 160.045.
Loosen and remove the fittings/refrigerant lines from the a/c compressor .
Immediately seal the disconnected hoses (to prevent dirt or water entering the hoses).
Loosen the tensioning device of the a/c compressor so that the ribbed V-belt is
loosened.
Remove the ribbed V-belt from the belt pulley of the a/c compressor .
Loosen the hex head screws and remove the a/c compressor .
New a/c compressors are filled the necessary with PAG-10 refrigeration oil, Tabelle 1 auf Seite 7, and
nitrogen (N2).
To distribute the oil in the a/c compressor, rotate it a number of times before installing it.
Secure the a/c compressor with the hex head screws to the bracket of the motor.
(Secure the a/c compressor in such a way that the housing is not under stress).
Place the ribbed V-belt on the belt pulley of the a/c compressor .
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Repair work on components
Tension the ribbed V-belt to the correct tension, using the tensioning device .
Remove the plug from the low-pressure side S(ND) of the a/c compressor , see Fig. 12 (carefully
release the nitrogen!).
Do not inhale the escaping nitrogen.
The special oil in the a/c compressor reacts with the moisture contained in the air.
Refrigeration oil containing water reduces the lubricating capacity of the oil in the a/c compressor,
and can thus damage the compressor.
When assembling the parts, ensure that the individual components remain sealed as long as
possible! Do not let refrigeration oil escape from the unit!
Ensure that all components have the same temperature!
Connect the refrigerant lines at the a/c compressor quickly, and tighten the fittings.
After the refrigerant lines have been connected, the system must be evacuated and subsequently
filled with the prescribed amount of refrigerant, see Tab. 1, see also group 160.045.
Fig. 12 Installing a/c compressor
A/c compressor Holder

Ribbed V-belt Bracket
Tensioning device Pressure / high-pressure side
Hex head screw Suction / low-pressure side
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see Fig. 13
The condenser and the dryer-collector form a unit and are mounted on the cooling system of the
diesel engine and the hydraulic system.
Loosen and remove the screwed fittings/refrigerant lines of the dryer-collector .
Remove the screws and the holder and then remove the dryer-collector .
Remove the clamps and the pressure switch from the dryer-collector .
Dispose of the dryer-collector in a safe way.
New dryer-collectors are clean, dry and sealed air-tight.

Mount the clamps on the new dryer-collector .
Secure the dryer-collector with the screws the washers and the holder to the frame/
radiator.
The connections of the dryer-collector are sealed air-tight with plugs. When mounting the dryer-
collector , remove these only immediately before connecting the respective refrigerant line .
Remove the plugs and quickly connect the refrigerant lines .
Connect the pressure switch to the line at the dryer-collector and establish the electrical
connections.
After the refrigerant lines have been connected, the system must be evacuated and subsequently
filled with the prescribed amount of refrigerant, see Tab. 1, see also group 160.045.
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Fig. 13 Installing dryer-collector 3
Condenser Clamp
Dryer-collector Holder
Pressure-relief valve Refrigerant line
Hex head screw Pressure switch
Washer
see Fig. 14 - Fig. 25
Remove the screws (observe different screw lengths and note down the screw positions).
Disconnect the plug from the servo motors the air outlet sensor
and the control unit .

Remove the control unit .
Put the wire harness to the side.
Lift off and remove the upper part of the housing .
(When lifting the housing part, do not damage the air outlet sensor ).
Remove the holder from the cover (the bottom flap remains connected to the lower part
of the housing or the upper part of the housing ).
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Carefully remove the bottom flap with the bearing.
Fig. 14 Disconnecting heating/air-conditioning unit
Heating/air-conditioning unit Control unit

Upper housing section Air outlet sensor
Lower housing section Servo motor / legroom
Holder Servo motor / defrost
Hex head screw Servo motor / C-column
Bottom flap Plug connection to connected
components
Disconnect the plug from the blower and remove the flat cables .
Remove the blower together with the blower holder.
Fig. 15 Dismantling and installation of the blower
Flat cables Blower motor

Plug connection
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see Fig. 16
Loosen the Allen head screw and remove the plate .
Unscrew the Allen head screws .
Remove the expansion valve .
Pull off the O-rings and remove the plate (only required for the dismantling of the evaporator
).
Fig. 16 Dismantling and installation of the expansion valves
Expansion valve Plate

Allen head screw Refrigerant feed connection
Plate Refrigerant return connection
Allen head screw Hose clamps
O-ring Red ribbon (feed line)
see Fig. 17
Damaged fins prevent proper air flow through the evaporator . As a result, the maximum cooling
performance might not be achieved.
Do not damage the fins when dismantling and cleaning the evaporator.
When servicing the evaporator, check the cooling fins for damage.
Disconnect the plug from the anti-icing sensors .

Lift the evaporator together with the anti-icing sensors from the unit.
If required, dismantle the anti-icing sensors , see Fig. 22.
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Fig. 17 Dismantling of evaporator
Evaporator Anti-icing sensors

Plug connection
Before dismantling the heat exchanger , open the refrigerant circuit between the heat exchanger
and the diesel engine.
There is a risk of serious injury from burns if the refrigerant circuit is opened while it is still hot.
Before dismantling the heat exchanger , allow the diesel engine to cool down, or remove the
heat exchanger when the diesel engine is cold.
Open the cover / pressure-relief valve at the compensation vessel for refrigerant.
Close the refrigerant taps and .
Unscrew the cover plate at the base of the operator's cab.
Place a suitable clean collecting container of sufficient size under the operator's cab.
Fig. 18 Draining / filling in refrigerant
Cover of compensation vessel Refrigerant tap / return line

Refrigerant tap / feed line
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Incorrect connection of the heating circuit to the heat exchanger can lead to insufficient heating
performance of the heating/air-conditioning unit.
The fitting of the heating feed line is labelled with a red of ribbon (arrow).
Before removing the heating hoses, mark the hose / heating feed line.
Damaged fins prevent proper air flow through the heat exchanger . As a result, the maximum
heating performance might not be achieved.
Do not damage the fins when dismantling and cleaning the heat exchanger .
When servicing the heat exchanger, check the fins for damage.
Loosen the hose clamps and disconnect the hoses with the hose clamps from the
refrigerant feed and return lines.
Let the refrigerant in the heat exchanger and the refrigerant lines flow into the collecting
container.
Place the cover onto the compensation vessel for the refrigerant (preventing dirt entering the
liquid).
Lift the heat exchanger by approx. 15 cm.

Disconnect the plug from the servo motor .
Lift the heat exchanger together with the servo motor of the refrigerant valve and the
hoses from the lower part of the housing .
Loosen the hose clamps .

Disconnect the refrigerant hoses from the refrigerant valve.
Remove the refrigerant valve together with the servo motor .
Fig. 19 Dismantling and installing heat exchanger and refrigerant valve
Heat exchanger Upper refrigerant hose

Lower housing section Lower refrigerant hose
Hose clamps Refrigerant valve servo motor
Hose clamps Plug connection
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Disconnect the plug from the servo motors .

Remove the screws .
Remove the servo motors.
Normally, the coupler remains attached to the servo motor.
Fig. 20 Dismantling and installing servo motors
Philips screws Servo motor / defrost

Coupler Servo motor / C-columns
Servo motor / legroom Plug connection to servo motors
Remove the plug from the air outlet sensor .

Remove the screws .
Remove the air outlet sensor together with the holder.
Fig. 21 Dismantling and installing air outlet sensor
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Allen head screws Air outlet sensor

Plug connection
Remove the flat cables from the cable harness of the anti-icing sensors
(arrows).
Pull out the anti-icing sensors together with the cable.
Fig. 22 Dismantling and installing anti-icing sensor
Evaporator Anti-icing sensor

Anti-icing sensor Plug connection
see Fig. 22
Insert the anti-icing sensors together with the cable into the openings provided
on the evaporator .
Secure the cable harness of the anti-icing sensors with cable straps to the
evaporator .
see Fig. 21
Apply Loctite 242 to the screws .
Secure the air outlet sensor together with the holder, using the screws .
Connect the plug of the cable harness to the air outlet sensor .
Align the coupler at the air flap to the servo motor and slide the servo
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motor into its position.

Tighten the screws .
Connect the plug to the servo motors .

Slide the hose clamps onto the refrigerant hoses .
Connect the refrigerant hoses to the refrigerant valve.
Position the hose clamps as shown in Fig. 19 and tighten them.
Connect the plug to the servo motor .
Insert the heat exchanger together with the refrigerant valve (servo motor ) and the
hoses into the lower part of the housing .
Slide the hoses with the hose clamps onto the refrigerant feed and return line (observe marks
applied during dismantling).
Tighten the hose clamps .
Open the refrigerant taps and .
Remove the cover from the compensation vessel for refrigerant.
Add the amount of refrigerant that has been collected during dismantling into the compensation
vessel.
Close the cover of the compensation vessel for refrigerant.
Start the engine and let it run at low idle speed.
Set the heating to maximum heat output.
The refrigerant valve is opened fully by the servo motor .
Any air trapped in the refrigerant hoses and in the heat exchanger is released through the
compensation vessel.
Set the engine to medium speed to heat it to operating temperature.
Run the engine for approx. 15 minutes at maximum speed and set the heating to maximum output.
Check the refrigerant level and inspect the hose connections for leakage. If required, add
refrigerant.
Condensate in the evaporator occurs for physical reasons and must be removed through the drain
connections at the bottom of the housing of the heating/air-conditioning unit .
Condensate that is not drained off can lead to malfunction of the heating/air-conditioning unit.
Ensure that the condensate drain connections are not blocked.
Before installing the evaporator , check the condensate drain connections for blockage.
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Fig. 23 Condensate drain connections 21 in the lower part of the housing seen from the top (a)
and the bottom (b)
Place the evaporator together with the anti-icing sensors in the lower part of
the housing.
Connect the plug to the anti-icing sensors .
see Fig. 16
Improper installation of the plug connection at the expansion valve can lead to leakage and
malfunction of the unit.
Ensure that the O-rings are correctly installed, see Fig. 24.
To prevent dirt from entering the unit, remove the seal plugs of the components only immediately
prior to installation.
Ensure that the expansion valve and the lines are not restricted or kinked when installed.
Fig. 24 Installation instructions
O-ring Incorrect
Crimping Apply refrigeration oil to surface
Correct Defective area
Mount the plate .
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Apply refrigeration oil to the O-rings and the flange area of the expansion valve , Fig. 24.
Mount the O-rings and install the expansion valve .
Tighten the Allen head screws .
Mount the plate and tighten the Allen head screws .
see Fig. 15
Install the blower together with the blower holder.
Connect the plug to the blower and attach the flat cables .

Hold the bottom flap in the lower section of the housing and place the upper part of the
housing on the lower part (the bottom flap must be placed firmly in its bearing; observe
position of the air outlet sensor ).
Slide the holder into position.
Mount the control unit .
Connect the plug to the servo motor and the control unit .
Tighten the screws (observe lengths of screws).
Fig. 25 Assembly of housing
Bottom flap Bearing

Coupler Bearing shell
To dismantle the heating/air-conditioning unit , disconnect the plug connections of the servo
motors. This is also required if you need to replace the control unit and/or a servo motor.
This ensures that no message regarding the position/limit stops of the air baffle flaps is sent.
After installing the heating/air-conditioning unit , you must repeat the teaching procedure of the
control unit .
To teach the control unit at the heating/air-conditioning unit, proceed as follows:
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Connect the central unit of the machine to your PC/laptop, using the respective interface
(diagnostic plug) and suitable connecting cables.
The PC/laptop to be connected must have the "Sculi" program installed.
Connect your USB dongle or your smart card containing the required authorisation data for
(Service/Inspector) to your PC/laptop.
Using the mouse, click the button.
The Sculi screen is displayed.
The Connect submenu is displayed.
Click the button.
The Sculi program is started.
Click .
Your access authorisation is confirmed with message "Connect (Service / Inspector)".
Click the button.
The "MessageAnalyzer" window is displayed.
Click the button.
All variables are displayed.
In the list, select variable , using a search filter.
Set in mode (Status 0) to status and confirm.
The Teach Mode program is activated.
The servo motors adjust the air flaps in the heating/air-conditioning unit.
Return to the "MessageAnalyzer" screen.
A number of messages are transferred.
After completion of the teaching process, the messages "CC01 Air conditioning control unit learning
mode is activated" (indicating start time) and "CC01 Air conditioning control unit learning mode is
finished" (indicating end time) are displayed.
After message "CC01 Air conditioning control unit", message "Teaching successfully completed" is
displayed (message code 0x72000081) and the teaching process is terminated.
Click the button.
The Sculi program is closed.
Disconnect the cable connecting the central unit and the PC/laptop and remove your USB
dongle or smart card.
Switch off the machine ignition.

Remove the boot card from the central control unit .
Insert a boot card with the new air-conditioning software (Wölfle).
Switch on the ignition.
The data transfer is being prepared.

The green and yellow LEDs flash alternately (intervals of 2 seconds).
After completion of the preparation procedure, both LEDs flash synchronised.
The software is now automatically updated at the a/c control unit . During this procedure:
The yellow LED at the bottom is continuously on.
The green LED at the bottom flashes at intervals of 1 second.
After completion of the data transfer:
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Electrical system
The yellow LED at the bottom is off.

The green LED at the bottom continues flashing (indicating that transfer was completed without
errors).
Switch off the ignition.
Remove the boot card with the air-conditioning software.
Insert the boot card into the central control unit .
Switch on the ignition.
The excavator software of the central control unit is loaded.
see electrical system of basic model group 110.
Heating Stop valves of refrigerant Open stop valves.

failure line at diesel engine
closed
Engine has not yet Run engine to operating temperature.

reached operating
temperature
Blower No power Check fuses; replace, if necessary.

failure
Blower motor Replace blower motor .
defective
Tab. 2 Fault diagnosis
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Troubleshooting
No or Faulty electrical Check connections at temperature sensor and

insufficient connections control unit.
cooling
Sensors defective Check sensors and sensor functions using error
codes, see 11.
Electrical control defective Check display, keyboard, rotary encoder.
Econ button pressed Press button at the display / rotary encoder or

control unit.
Fuse defective Activate / .
Repeat compressor shut- Clean compressor and condenser.

down after exceeding of Replace filter cassette.
max. operating pressure Check the system for leakage.
Insufficient refrigerant in Extract refrigerant and refill system according to

the system instructions.
Compressor magnetic Replace coil .

clutch defective
V-belt broken Replace V-belt.
Insufficient air flow rate Clean fins in front of the evaporator and the
condenser .
Expansion valve Clean or replace expansion valve.

blocked or defective
Expansion valve iced Replace the dryer-collector .

over due to excessive
moisture in system
Dryer-collector partly Replace the dryer-collector .

blocked, with icing on
dryer-collector
Air in cooling circuit at Evacuate and refill system.

increased pressure level
Insufficient Blower settings too low Set blower performance to higher level or press
air flow rate AUTO button.
in operator's
cab Air outlet closed Open air outlet.
Fresh air filter / Clean pre-filter and change filter cassette.

recirculated air filter dirty
Loud noise Ball bearing of Replace compressor .

from compressor worn
compressor
Magnetic clutch Replace magnetic clutch .
defective
Whistling V-belt worn Replace V-belt.
noise from V-
belt V-belt loose Tighten V-belt.
Tab. 2 Fault diagnosis
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Code overview
In the event of a malfunction in the air-conditioning system, the a/c control switches from automatic
to manual mode. The display shows the symbols for manual control.
Teach mode activated Teach mode initiated
Excessive voltage detected in Short-circuit to Ubat

line
Overload at output detected Short to ground
Errors in analog output Amplifier defective or interruption
External compressor Compressor cannot be actuated,
actuation defective heating operation only
External condenser actuation Error in condenser fan actuation, condenser
defective shut-down,
heating operation only
External pressure switch External pressure switch defective,
defective heating operation only
CAN bus timeout; No CAN connection to a/c module
a/c module defective or fault
in CAN wiring
Teaching process
successfully completed
Anti-icing sensor 2 Anti-icing sensor 1 is used

Disconnection
Anti-icing sensor 2 Anti-icing sensor 1 is used;
Short circuit if both anti-icing sensors fail at the same time,
the compressor coupling is not actuated
External temperature sensor Change to OFF mode, feature bit "a/c
Disconnection automatic" omitted
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Code overview
Short circuit at external Change to OFF mode, feature bit "a/c

temperature sensor automatic" omitted
Internal temperature sensor Change to OFF mode, feature bit "a/c
Disconnection automatic" omitted
Internal temperature sensor Change to OFF mode, feature bit "a/c
Short circuit automatic" omitted
Blower rotor blocked System set to "OFF" mode
Short to ground at System can continue to run without
compressor coupling output compressor coupling
Flap Error message based on configuration
Front windscreen/defrost Error message preset by machine type
flap; no connection to control configuration
Disconnection
Short circuit
Refrigerant valve
Plug disconnected
Top/defrost flap plug
disconnected
Bottom flap plug
disconnected
Centre flap plug
disconnected
Recirculated air flap plug
disconnected
Deviation between anti-icing
sensor 1 and 2 too large
Disconnection at compressor System can continue to run without
coupling output compressor coupling
Disconnection at the
condenser fan output
Short to ground at condenser
fan output
Teaching process/EEPROM: Use old value or default value (if old value is
maximum value range of not available)
refrigerant valve invalid
Teaching process
successfully completed
Refrigerant valve
Position not reached
Head/defrost flap
Bottom flap
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Code overview
Centre flap
Recirculated air flap
Disconnection at dust filter From hardware revision 3: internal actuation
blower output possible; release by bridging plug pins 20 to
21
Short to ground at dust filter From hardware revision 3: internal actuation
blower output possible; release by bridging plug pins 20 to
21
Short to power at refrigerant
valve servo motor
Short to power at head/
defrost flap servo motor
Short to power at bottom flap
servo motor
Centre flap
Short to power at servo motor
Recirculated air flap
Short to power at servo motor
Short to power at rear panel Error text is determined by configuration of the
flap servo motor device type in the control
Rear panel flap servo motor Error text is determined by configuration of the
No connection to control device type in the control
Rear panel flap
Front/defrost flap position not
reached
Disconnection of air outlet Change to OFF mode, feature bit "a/c
Short circuit at air outlet Change to OFF mode, feature bit "a/c
Teaching process/EEPROM: Use old values or default values (if old values
maximum value range of are not available)

bottom flap invalid
minimum value range of are not available)
centre flap invalid
centre flap invalid
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Code overview
recirculated air flap invalid
recirculated air flap invalid
refrigerant valve invalid
minimum value range of rear are not available)
panel flap invalid
maximum value range of rear are not available)
panel flap invalid
minimum value range of front/ are not available)
defrost flap invalid
front/defrost flap invalid
minimum value range of head are not available)
flap invalid
head flap invalid
bottom flap invalid
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Code overview
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Service Manual Air-conditioning system service
Maintenance
In principle, the intervals specified in the inspection and maintenance schedule apply.
Observe the applicable safety instructions, in particular the instructions for the safe handling of
refrigerants.
Never leave the refrigerant circuit open! Refrigerants are highly hygroscopic, which means that
they absorb moisture from the air at a very fast range (100% saturation within 24 hours).
Always keep all air-conditioning spare parts and components tightly sealed. Only open them
immediately prior to installation.
Every time you open the refrigerant circuit, replace the dryer-collector, see group 160.040.
Avoid carrying out soldering work. If this is not possible, carry it out with extreme caution.
Do not kink refrigerant hoses as this could damage their Nylon core.
Use only new sealing material (only mount Neoporen O-rings and use refrigeration oil).
Prevent refrigerants from escaping when refilling liquid or carrying out repairs. Always collect
liquid in a dedicated recycling container.
The liquid or gaseous refrigerant in the refrigeration unit is under pressure. This fact must be taken
into consideration when carrying out repair work on the system.
Leaks do not only reduce the output rate of the refrigeration unit, but might also cause dangerously
high concentrations of gaseous refrigerant in the air.

If refrigerant escapes from the unit in a closed room, a high concentration of the substance in the air
might be built up, endangering the health and safety of people due to the narcotic effect of the
substance. Before carrying out any repair work on refrigeration systems, collect the refrigerant in the
recycling container where it can be safely stored. After completion of the repair work and
reconditioning of the refrigerant, it can be returned to the system. Alternatively, it can be returned to
the supplier.
To avoid the risk of high concentrations of refrigerant in a room, always ensure proper ventilation.
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Air-conditioning system service Service Manual
Repair
Under certain circumstances, it might not be sufficient to open doors and windows, and it might be
necessary to operate an extractor system that extracts the air near the point where the refrigerant
escapes or at floor level.
Filter masks with A-type filters (for solvents) do not provide sufficient protection and may only be used
in rooms where the refrigerant concentration in the air does not exceed 0.5 % vol/vol (see respiratory
protection sheet). As refrigerant vapours are heavier than air, there is a particular risk of high
concentrations in pits and shafts. If you are not sure whether there is dangerous amount of refrigerant
in the ambient air, use respiratory equipment with oxygen supply that is independent of the ambient
air!
Welding and soldering work on the refrigeration unit must be carried out in well-ventilated rooms!
When refrigerant is combusted in the flame of the soldering iron or the arc of the welding machine,
toxic substance are released that must not be inhaled! Do not inhale these substances!
The substances produced when refrigerant is exposed to heat are not only toxic but also highly
corrosive, causing damage to pipelines and other unit parts. In the case of chlorinated refrigerants,
the decomposition products include hydrogen chloride, hydrogen fluoride and elementary chlorine.
Under certain circumstances, highly toxic phosgene might be produced! When halogenated
fluorocarbons are burnt, hydrogen fluoride might be produced.
Please note that the dangerous decomposition products listed above are already in the air when the
acrid smell occurs. Do not inhale these substances, as they can cause serious damage to the
respiratory passages, the lungs and other organs. The decomposition products are effectively
removed by a filter mask with respiratory filter B (acidic gases). Always observe the user instructions
of the filter!
Immediately leave the room, ventilate it or wear a filter mask / respiratory filter B (acidic gases)!
Leaks often show "sticky" dust deposits formed by the refrigeration oil that has escaped together with
the refrigerant. Please remember: Refrigeration oil and refrigerant form a mixture in the system.
If there is no system pressure, add a small amount or refrigerant. If available, add nitrogen to the
system (do not use compressed air as it contains water!).
Read the operating manual enclosed with the kit.
Additive and refrigeration oil (in the compressor) must be compatible.

Using a special adapter, add additive to the cooling circuit containing refrigerant.
Add additive only to the pressure side (see instructions below for the filling of the system).
Let the system run for at least 1 hour and then examine the cooling circuit with the UV lamp. If the
leaks are tiny, it might take a few days until the contrast agent becomes visible.
Refrigerant escaping at a leak is visible in the form of bright fluorescent spots under the UV
light.
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Repair
Follow the operating instructions of the leak detector you wish to use.
This method might not be successful, for example if gases are removed by air draughts when the
escape or if there are other "foreign gases". In this case, the substance in question must be blocked
and/or the sensitivity of the device must be reduced so that it can distinguish between the refrigerant
and other substances.
A leakage check is required:

• Upon initial assembly (e.g. when a machine is retrofitted with an air-conditioning system)
• After a repair (replacement of components or hoses)
• After change to another refrigerant
Fill cooling circuit with nitrogen (max. 20 bar) and wait for 12 hours (e.g. overnight).
Evacuate circuit and wait for approx. 1 hour.

Check the pressure before and after the test period. The pressure may not change significantly.
In many cases of failure, there is no refrigerant left in the system (leakage, break, etc.).
Extraction is however necessary in the following cases:
• Replacement of components (pressure switch, dryer-collector unit, evaporator, etc.)
• Changeover of air-conditioning system to run with R134a
If the air-conditioning system can be operated, switch it on for approx. 15 minutes before
commencing extraction. This facilitates the extraction process.
Switch off the air-conditioning system.
Connect the extraction device to the intake and pressure parts of the compressor (quick-release
couplings).
Connect a refrigerant bottle with sufficient refrigerant (2 kg) to the suction valve.
Open the manual valves at the quick-release couplings and the extraction device.
The respective pressure values are indicated at the pressure gauges.
Disconnect the hose from the refrigerant bottle, briefly open the outlet tap at the extraction device
(to bleed it) and close and tighten it again.
Open the outlet tap.
Due to the pressure in the air-conditioning system, refrigerant initially flows from the system to
the bottle.
Switch on the extraction device.
The compressor in the extraction device sucks the refrigerant from the system and pumps it
into the bottle.
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Repair
The extraction device is automatically switched ON and OFF, depending on the pressure of
the refrigerant in the system.
To accelerate extraction towards the end of the process, use a hair dryer to slowly heat up the filter/
dryer as refrigerant must evaporate from the filter/dryer (do not heat to more than 30-40°C).
To evacuate the system, use a 2-step vacuum pump that is able to produce a final pressure of 0.05
mbar or lower (see air-conditioning service tools). The evacuation process should not take less than
1 hour.
For new systems (initial installation), the evacuation time can be reduced (to approx. 30 minutes).
– Ensure that no air is trapped in the cooling circuit during filling. Air in the cooling circuit results in
high pressure during operation and can cause malfunctions. The evacuation process ensures that
all air is extracted from the system.
– Evacuation also dries out the cooling circuit. The boiling point of water is lowered by the vacuum
(see table "Evaporation temperature of water"). Water in the form of moisture in the cooling circuit
is extracted during evacuation in the form of water vapour.
– If the system is evacuated for repair after it has been in operation for some time, the evacuation
process must be repeated several times.
– The high vacuum accelerates the subsequent filling process.
– You might also consider evacuating the system for leakage testing. To do this, evacuate the
system, close the manual valves at the pressure gauge bar and then switch off the vacuum pump.
– If the pressure in the system does not change significantly within a period of 1 hour, there is no
leak in the system.
Take into account external factors such as temperature changes (e.g. by direct sunlight).
Evacuation is particularly effective if the cooling circuit is purged with (hot) nitrogen. Its effectiveness
can be further improved by adding a small quantity (approx. 200 g) of refrigerant to the system and
extracting it again (refrigerant is hygroscopic and thus extracts moisture from the system).
To fill the system, use only devices that are compatible with R134a. Observe warning signs and
instructions!
This procedure saves time, as refrigerant in liquid form can be transferred much faster into the cooling
circuit than refrigerant in gaseous form (density 40x higher).
This method must however only be used to fill the refrigerant to the high pressure side if the diesel
engine is shut down.
For liquid filling, the refrigerant bottle must be equipped with a riser pipe. Such bottles are equipped
with two valves (1 red, 1 blue).
To use the liquid filling method with a refrigerant bottle that does not feature a riser pipe, the bottle
must be positioned upside down.
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Repair
Filling with gas can be performed simultaneously at the high pressure and the low pressure side.
Filling with gas takes more time.
Under certain circumstances, filling with gas is required after filling with liquid, if the amount of
refrigerant required in the system is not reached (residual filling). This is for example the case, if the
pressure in the refrigerant bottle and in the cooling circuit reach the same level before the required
amount of refrigerant has been transferred.
For residual gas filling, open only the blue valve at the pressure gauge bar and at the refrigerant
bottle. If the refrigerant bottle is not equipped with a riser pipe, it must be placed upright.
Switch on the air-conditioning system.

The a/c compressor takes up refrigerant from the refrigerant bottle and transfers it into the
cooling circuit.
The amount of transferred refrigerant can be measured by means of weighing scales or with a filling
cylinder.
During the cold season, first warm up the refrigerant bottle using a heating collar (max. temperature
+30°C).
Vapours escaping from the air-conditioning system are highly explosive and poisonous.
Never use naked flames near the unit.
(checklist, refrigerant bottle without riser pipe)

Switch off the diesel engine.
Connect the red filling hose to the pressure side of the a/c compressor (quick-release coupling).
Connect the blue filling hose to the suction side of the a/c compressor (quick-release coupling).
Connect the yellow hose to the vacuum pump. Switch on the pump and open all valves.
Evacuate for 1 hour and then close all valves.
Disconnect the yellow hose from the vacuum pump and connect it to the refrigerant bottle.
Open the valve at the refrigerant bottle.
Place the refrigerant bottle upside down.
Open the red manual valve at the pressure gauge battery.
Liquid filling commences.
Observe the refrigerant flow through the sight glass at the pressure gauge battery.
When the refrigerant flow stops, close the red manual valve.
Place the refrigerant bottle in its upright position and start the diesel engine.
Switch on the air-conditioning system.
Open the blue manual valve at the pressure gauge battery.
Residual filling with gaseous refrigerant commences.
At medium diesel engine speed, check the sight glass of the dryer-collector unit: when the white
fill level bead is lifted by the refrigerant, immediately close the blue manual valve.
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Repair
Let the system run for a few minutes until the refrigerant is properly distributed throughout the
system. Then check again the fill level at the sight glass. The fill level bead must be near the upper
edge of the sight glass.
Perform a test run and check the pressures.
The pressures depend on the ambient temperature. At the pressure side, they should be between 8
bar and approx. 18 bar; at the suction side, they should be between 0.8 bar and approx. 2 bar (see
temperature/pressure diagram of air-conditioning system).
Fig. 1 Filling of air-conditioning system through pressure gauge battery
The function and operation of the a/c service device depends on the actual device make and model.
Certain devices also cater for the evacuation of the system and for refrigerant changes. It is therefore
imperative that you follow the operating instructions of your specific a/c service device.
For the operation of a/c service devices, the operator must normally specify the fill volume of the air-
conditioning system, as the amount of refrigerant is measured by means of weighing scales or with
a filling cylinder.
For suction side filling, this is normally not required, as the system can be fully filled through the pump
of the a/c service device.
After the filling procedure has been completed, the cooling performance of the air-conditioning
system must be checked.
Measuring the temperature in the evaporator is very useful in this context, as it allows for the
measurement of the switching points of the temperature switch or temperature sensor respectively.
For good cooling performance, it is however very important that these switching points are set
correctly. To measure the temperature, you need a temperature gauge with a thin probe. The probe
should be positioned at the exact position of the sensor (capillary tube) of the temperature switch/
sensor between the evaporator elements.

In certain device types, the switching values can be adjusted. For details see the respective service
manual.
The switching hysteresis must not be too narrow, as the compressor would otherwise switch
constantly at short intervals so that the magnetic clutch would be excessively worn. There is also
the risk of ice formation in the evaporator.
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A/c service tools
The above measurements indicate quickly whether the temperature switch works properly. If the ON/
OFF switching points change constantly, the switch is clearly defective (burned-out or dirty contacts).
The repeat accuracy of the temperature switches is approx. .
Correctly set switching points ensure optimum cooling performance: Temperature at the outlet
nozzles (see temperature/pressure diagram of the air-conditioning system). If this temperature is not
reached, check the following:
• The recirculated/fresh air flap must be set to recirculated air.
• The heating is switched off (check refrigerant valve of the heating/air-conditioning unit; if
necessary, close the refrigerant valves at the diesel engine).
• See also a/c service - troubleshooting.
(4-valve version with filling hoses and quick-release couplings)
Fig. 2 Pressure gauge bar, complete
Low pressure gauge Hose to refrigerant bottle

High pressure gauge Hose to vacuum pump
High pressure filling hose Low pressure filling hose
This tool is very useful for filling and evacuation as well as for the monitoring of the pressure during
operation, especially if no a/c service device is available.
Do not confuse the hoses (refrigerant may remain in the hoses, so that there is no need to bleed the
system the next time it is used).
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A/c service tools
Fig. 3 Pressure gauge fitting of pressure gauge bar
Low pressure Valve/vacuum Valve/low pressure

High pressure Valve/refrigerant Valve/high pressure
Fig. 4 Vacuum pump (2-step) RD-4
Model RD-4 ID no. 7027551

Engine power 0.3 kW
Suction performance 3.53/h
End vacuum 0.05 mbar
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A/c service tools
Weight 12.2 kg
Production of high vacuum in cooling circuit (drying of system prior to filling)
Fig. 5 A/c service device
Model 34701 TUV

Weight (without storage bottle) 73 kg
Electrical connection 220-240 V
Pump performance 8.5 m3/h
Suction rate 0.2 kg/min
Recycling rate 0.4 kg/min
Vacuum 20 micron
Suitable for R134a.

With integrated filter and oil separator. Keypad for programming of digital balance and calling up of
parameters.
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A/c service tools
• Extracting refrigerant from cooling circuit

• Recycling = reconditioning of extracted refrigerant
• System evacuation
• Filling
(For detailed information on the a/c service device, see quick guide instructions).
Fig. 6 Leak detector
Model UView
Voltage 12 V (observe polarity)
Accessories:
30 ccm filling cylinder, safety goggles
Detection of small leaks by introducing fluorescent oil into the cooling circuit.
Leaks appear as bright spots under UV light.
– Even very small leaks can be detected.

– Contrast agent is hard to remove from system and "contaminates" the air-conditioning system.
– No compression guarantee.
– Must only be used with compatible contrast oil.
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A/c service tools
Fig. 7 Filling balance
Model CC100 from CPS

Weighing range 50 kg
Scale division 10 g
Accuracy ±
Operating voltage 9V
This filling balance is a service tool replacing the filling cylinder. It can be used for all types of
refrigerants and does not require any pressure/temperature calculations.
The refrigerant bottle is placed on the balance.
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For instructions, see manual of SPX RONBINAIR 34701 TUV service device
– Accurate filling within short time.

– Filling without the need to observe sight glass/fill level bead.
– The device is equipped with a TARE key.
– The actual filled amount of refrigerant is indicated.
– The digital indicating device is equipped with a connecting cable and can be detached from the
unit.
Close the two service hoses to the air-conditioning system.

Open the valves at the storage bottle and the control panel.
Switch on the a/c service device.
Press key First C-CL

At the beginning of the
extraction process, the
extraction amount is
indicated.
Subsequently, the
extraction amount and
CPL flash alternately.
Press key 15.00 minutes Open the drain valve, slowly
drain off the oil and determine
the amount of drained oil.
Enter Evacuation time in
using the numerical minutes and seconds
keys (60 min)
Press key
Press key Evacuation time
countdown.
When completed, CPL
is displayed.
Press key Stored evacuation time Add correct amount of oil
through the fresh oil valve.
Press key 00.00 kg
Enter the Filling amount in kg
using the (2.2 kg) with hose
numerical keys filling
(example: enter 075 =
0.75 kg)
Press key
Press key again The amount yet to be
filled is displayed.
When completed, CPL
is displayed.
Press key Stored evacuation time
Press Disconnect both hoses from
the vehicle.
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Dismantling and installation air-conditioning system components
Close the valves of the storage bottle and at the control panel.
Switch off the device.
Seal the fresh PAG oil with the lid.
If message is displayed, you must add more refrigerant to the storage bottle.
15.00 minutes Connect red bottle hose with

bottle adapter to the refilling
bottle. Open refilling bottle
and blue valve at the storage
bottle. Place the refilling bottle
upside down.
Simultaneously press Display blank
and Message "Add"
Press followed by refilled
quantity
After sufficient
refrigerant has been
added, press
(max. storage
bottle capacity 20 kg)
Close valves and reconnect
red hose to the storage bottle.
Press key 15.00 minutes
Press the key once; the current process is interrupted.

Press the key again; the process is resumed.
Press the key to terminate the current process.
For detailed instructions for the dismantling and installation of individual components in the air-
conditioning system, see group 160.040.
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Dismantling and installation air-conditioning system components
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Service Manual

Installation instruction for air-conditioning 160.001.1 LH 60 C

Mounting of operator's cab elevation 160.002.1 LH 60 C

Lift frame without cab control (Option) 160.010.1 LH 60 C 64724-

Height adjustable operator's cab with cab 160.015.1 LH 60 C 64724-

Auxiliary heater 160.030.1 LH 60 C 56140-

Air-conditioning system 160.040.1 LH 60 C 64724-

Air-conditioning system service 160.045.1 LH 60 C 64724-

Risk of damage to a/c hoses when tightening hoses.

Risk of damage to dryer-collector unit fittings when tightening hoses.

Fig. 3 Dryer-collector unit

Risk of damage to hoses during tightening.

Fig. 4 Hose fittings

Fig. 5 Expansion valve

Fig. 6 Bending radius

Special screw connections must be released or tightened exclusively by LIEBHERR customer

Fig. 1 Identification of special screw connections

Fig. 2 Design of special screw connection

Standard nut Washer (disc)

standard nut in screw connection.

Fig. 3 Screwing in special screw connection

Fig. 4 Preparation of contact surface

Fig. 5 Preparing/checking special screw connections

Incorrectly mounted components can cause serious damage to machine.

Fig. 6 Positioning operator's cab elevation

Fig. 7 Applying special screw connection

Fig. 8 Tightening with electric or hydraulic screwdriver

Observe manufacturer instructions for electric or hydraulic screwdriver.

Fig. 9 Tightening with torque wrench

See spare parts drawing (Lidos) for torque value number.

Fig. 10 Tightening sequence of screws

Fig. 11 Tightening sequence of screws

The design of the hydraulic system is described in

Fig. 1 Hydraulic schematic Lift frame without cab control

Return block / control pressure

The design of the hydraulic system is described in .

Return block / control pressure

Tab. 1 Key for hydraulic schematic

Fig. 1 Design of auxiliary heater

Check valve Diesel engine

Fig. 2 Electrical system of the auxiliary heater

Electric cabinet Timer

Fig. 3 Fuel system with metering pump and fuel filter

Water heater Thermo 90 ST

Permissible operating pressure bar 2.0

Tab. 1 Technical data

Fig. 4 Water heater

Control unit Cooling fluid inlet

Combustion air fan Fastening clamp

Fig. 5 Glow pencil and flame detector

Fig. 7 Thermostat valve 30

Fig. 8 Metering pump

Risk of injury from burns when touching hot components!

All repair work must be performed by specially trained maintenance personnel.

Prior to commissioning, after installation or repair, observe the following:

When operating the auxiliary heater, adhere to the following instructions:

Fig. 9 Installation and dismantling of the water heater

Bracket Hose clamp

Risk of injury from dropping components.

Open the hose clamps around the coolant hoses.

Fig. 10 Installation and dismantling of the water heater

Fig. 11 Installing metering pump

F 00 Heater locking or control unit not working