FREEDOM™ MEDIUM DUTY TRUCKS AIR CONDITIONING SYSTEM SERVICE MANUALry AIR CONDITIONING SYSTEM SERVICE MANUALATTENTION The information in this manual is not all inclusive and cannot take into account all unique situations. Note that some illustrations are typical and may not reflect the exact arrangement of every component installed on a specific chassis. The information, specifications, and iltustrations in this publication are based on information that was current at the time of publication. No part of this publication may be reproduced, stored ina retrieval system, or be transmitted in any form by any means including (but not limited to) electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc.a TABLE OF CONTENTS TABLE OF CONTENTSés TABLE OF CONTENTS SAFETY INFORMATION SAFETY INFORMATION Advisory Labels ... Service Procedures and Tool Usage . TECHNICAL DATA . AIC SYSTEM TECHNICAL ‘DATA Air Conditioner . Consumables : Tightening Torques .. . Personal Precautions OPERATION AIC SYSTEM OPERATION . Heating — Ventilation Maintenance eer Layout of Equipment on Vehicle. ...... cs. ssssse REMOVALIINSTALLATION ....... ‘NC COMPONENTS REMOVAL/INSTALLATION Heating Block Motor-Driven Fan Uni Expansion Valve . Heating Tap Valve . HEATING BLOCK . HEATING BLOCK SERVICE PROCEDURES . To Disassemble the Radiator .. To Disassemble the Evaporator . : TOASSOMbIC wo... eeeeeeec eee Heating Control Panel Board CONDENSER . ce CONDENSER SERVICE PROCEDURES . To Remove ....... we To Install... RECEIVER/DRYER ..... 5 RECEIVER/DRYER SERVICE PROCEDURES. To Remove To Install. COMPRESSOR - COMPRESSOR SERVICE PROCEDURES ToRemove . To Install Checking the Oil Level Clutch 2... HOSES AND UNIONS oe HOSES AND UNION: ICE PROCEDURES To Change a Damaged Hoses. To Assemble Unions ........ REFRIGERANT CIRCUIT ..... noanon0 REFRIGERANT CIRCUIT SERVICE PROCEDURES.TABLE OF CONTENTS Environmental Protection Refrigerant Oil .. Periodically Checking the Charge . ‘Charging the System in Liquid Phase Charging the System in Gaseous Phase . TROUBLESHOOTING ..,... TROUBLESHOOTING DIAGNOSTICS AND TESTING Preliminaries ; ‘Symptom Diagnostics. ELECTRICAL DIAGRAMS ‘NG SYSTEM ELECTRICAL DIAGRAMS TOOLS ... NC SYSTEM TOOLS . -69 7 .78NOTESa» SAFETY INFORMATION SAFETY INFORMATION Pagetas SAFETY INFORMATION SAFETY INFORMATION Advisory Labels Cautionary signal words (Danger-Waming-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the Use of these advisory labels as they appear throughout the manual: py Activities associated with Danger indicate that death or serious personal injury may result from failing to heed the advisory. Serious personal injury may be equated to career-ending injury. from failing to heed the advisory. in this case, personal injury is not equated to career-ending injury, but results in possible change in quality of life. A CAUTION Activities associated with Caution indicate that product damage may result from falling to heed the advisory. Caution is not used for personal injury. NOTE A procedure, practice, or condition that is essential to emphasize. SERVICE HINT A helpful suggestion that will make it quicker and/or easier to perform a procedure, while possibly reducing service cost. Page 2a> SAFETY INFORMATION Service Procedures and Tool Usage Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any mannet ftom the instructions provided assume all risks of consequential personal injury or damage to equipment involved. Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions. transmission in neutral, be sure that parking brakes are set, and disengage the clutch. 2. Betore working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels. 3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts, driveshafts and other related rotating assemblies, can be very dangerous. Do not work on or service engine-driven components unless the engine is shut down. Always keep body parts and loose clothing out of range of these powerful components ta prevent serious personal injury. Be aware of PTO engagement or nonengagement status. Always disengage the PTO when not in use. REMEMBER, SAFETY ... ISNO ACCIDENT! PagesSAFETY INFORMATION Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and tal necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation. ‘The following list of general shop safety practices. can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood. © Perform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling. * DO NOT wear loose-ftting or torn clothing. Remove any jewelry before servicing vehicle. * ALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp comers and jagged edges. Page 4 Use hoists or jacks to lit or move heavy objects. NEVER run engine indoors unless exhaust fumes are adequately vented to the outside. Be aware of hot surfaces. Allow engine to. cool sufficiently before performing any service or tests in the vicinity of the engine. Keep work area clean and orderly. Clean up any spilled oi, grease, fuel, hydraulic fluid, ete, Only use tools that are in good condition, and always use accurately calibrated torque wrenches to tighten all fasteners to specified torques. In instances where procedures. require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions. Do not store natural gas powered vehicles indoors for an extended period of time (overnight) without first removing the fuel. Never smoke around a natural gas powered vehicle.de> TECHNICAL DATA TECHNICAL DATA Page 5ian) AIC SYSTEM TECHNICAL DATA Air Conditioner TECHNICAL DATA Heating power T0KW ‘NG power 72 KW MOTOR-DRIVEN FAN UNIT Supply volage Rv ‘ir conditioner unit total power 300 “ist speed (air inlet) resistance 2.25 Ohm “and speed” (airinlol) or “st speed? (recycling) resistance (065 Ohm “Grd speed? (arilel) or “2nd speed” (recycling) resistance (027 Ohm “ah speed” (ar inkl) or “Grd speed” (recyoing) resistance 00hm Resistance thermal protection (Blown fuse) at 216°C AIC UNIT Tigh pressure salety 28 bar (408.1 psi) Low pressure safely Gircuit bricant total capacity 2 bar (29.0 psi) 165 mil (5.57 02) COMPRESSOR =SANDEN" SD 7115 ‘Number of eyinders 7 Displacement 754.9 m= Refrigerant Rista Recrigerant capacity 1.2 Kg (2.65 16) Lubricant viscosity (@t 100°C) 21.15 Cst Lubricant eapaciy 165 mI (6.5702) CLUTCH ‘Supply voltage TeV Coil power aw (Coil resistance 410hm Air gap 6+ 02 mm * NOTE: A new compressor is filled with 165 ml (5.57 02) of lubricating oil by the manufacturer. This 165 ml of oil is distributed throughout the A/C system during operation. Page 6TECHNICAL DATA Consumables Refrigerant oils with R134a fluid: ‘sP20 ACAUTION Exclusively use SP20 oil for compressor SD ~7H15SQ. Tightening Torques There are several types of tightening: — Tightening to torque (in N-m) — Tightening to angle (in ) — Tightening to torque-angle (in N-m +°) ‘Torques given in N-m are nominal torques (average value calculated on the basis of the minimum torque and the maximum torque). The tightening accuracy class defines the tolerance of this torque in percent as a function of the nominal torque applied. TIGHTENING ACCURACY CLASSES: — Glass l: Special threaded hardware (tolerances variable depending on assembly). — Class Il: Reserved for precise tightening (tolerance + 10% of the nominal torque). — Class Il: Reserved for normat standard tightening (tolerance + 20% of the nominal torque). For standard threaded hardware indicated in the table below, use tightening class I TIGHTENING TORQUES FOR CONVENTIONAL NUT AND BOLT HARDWARE TO “METRIC SYSTEM" ‘STANDARD 01.504.002 Diameter and pitch of nuts Quality ciaas 8 Quality class 10.9 and bolts (in mm) Tightening class MI (= 20%) Tightening class i (= 20%) x10 Zz} 708 TAIO0, Tat 178 81.00 132 282 8x 125 178 263 0x 1.00 ae 8 10x 1.25 aa 55 10x50 ea 5 12x 1.25 Ca = 72x15 oA 4 12x 175 et 20 4x 1.50 05 155. 14x2.00 6 743 T6x1.50 ter 257 7 16x2.00 161 Be 18x 1.50 235 346 18x2.50 210 308 20x1.50 8 481 20x2.50 “208 495 22x50 aA 652 22x250 406 596 NOTE Torque values shown in the chart are in N-m, Page7TECHNICAL DATA Personal Precautions Prior to carrying out any work on the circuit, itis compulsory to take the following precautions: goggles when you open a refrigerant circuit Refrigerant liquid or gas may cause permanent damage to your eyes. — Never heat a closed refrigerant circuit with a naked flame. The refrigerant fluid could cause an explosion (excessive pressure). Take precautions when entering into paint booths (80°C maximum). — Make sure that the A/C system pipes are properly fastened and cannot enter into contact with any metallic parts. — Inthe presence of a flame, the refrigerant produces phosgene (carbonyl chloride), a toxic gas: never inhale it — Do not smoke in the vicinity of a refrigerant circuit. — Donotuse any refrigerant other than what is recommended. FIRST AID —— Ifrefrigerant has splashed into your eyes, you must consulta doctor. — Toalleviate the effect of the refrigerant in your eyes or on your skin, apply a few drops of neutral mineral oil and then wash with a weak solution of boric acid. Page 8 2—HUMIDITY The least trace of humidity in the circuit will risk stopping its operation. In fact, water droplets will freeze at the pressure reducer. The dehydrator cylinder has a very low capacity of 5.5 grams (about 60 drops); beyond this amount, water will Combine with the refrigerant to produce acids which attack metallic components. A mere trace ci humidity is the most frequent cause of intermittent cooling problems. It is necessary to apply compressor oil to each threaded union. 80% of all circuit failure will be eliminated if the system is kept clean. ACAUTION When the refrigerant circuit is opened suddenly (punctured condenser, burst fluid pipe, etc...) itis essential to replace the following parts: — defective component. — _receiver/dryer cylinder. If is essential to drain the fouled oil from the compressor and refill with fresh oil.ds OPERATION OPERATION Page 9OPERATION A/C SYSTEM OPERATION Heating — Ventilation VERSION WITHOUT AIR CONDITIONING 1 — Cab air distribution control knob. 2 ‘Temperature control knob. Ventilation control knob. VERSION WITH NON-REGULATED AIR CONDITIONING 1 — Cab air distribution control knob. 2 ‘Temperature control knob. 3 — Ventilation control knob. 4— Air conditioner control button. Page 10 NOTE So as lo limit risks of feaks due to prolonged standstill itis recommended to run the air conditioning for about 15 minutes at least once a month, mainly during the winter period. AIR DISTRIBUTION CONTROL, The control ites the air between the various outlet ports according to the position chosen, Combined with the temperature control and the ventilation contro, it assures optimized temperature according to the positioning of the outlets.OPERATION a = 2 pa Ww \ IN Position 2 Air directed upwards (dashboard air vents) and downwards (footwelll air vents). — Position 3 Air directed downwards (footwell air vents) with gentle air flow upwards (windshield air vents). gv cw NX a Page ttae Position 4 OPERATION Air directed downwards 50% (footwell air vents) with air flow upwards 50% (windshield and side windows air vents). Position 5 Air directed upwards (windshield and side windows air vents). NOTE When the side and central air vents are open, the air flow is distributed between the different ports selected for each control position. Page 12OPERATION VENTILATION CONTROL ‘This contro} incorporates two functions. External air ventilation function Turn the knob clockwise: — Position STOP: stop (air inlet closed). — Position 0: stop (air intet slightly open). — Position 1: fan control (1st speed). — Position 2: n control (2nd speed). — Position 3: fan control (3rd speed). — Position 4: fan control (4th speed). o2rta Internal air ventilation (alr recycling) function Tum the knob counterclockwise — Position STOP: stop (air inlet closed). — Position 1: fan control (1st speed). — Position 2: fan control (2nd speed). — Position 3 fan control (3rd speed). Air recycling makes it possible to: — avoid breathing in stale air from the ‘exterior (road tunnel, polluted area...), — obtain maximum cooling or maximum heating power from the air conditioner. Only use the air recycling feature in short spells. AIFi CONDITIONER CONTROL (6) With the engine running, tum the ventilation ‘control knob to at least position 1 and press the air conditioner control button to operate the air conditioning A builtin waming light on the switch comes on when the air conditioning feature is activated. Set the temperature contsal to the desired temperature. srezrea Page 13a OPERATION TEMPERATURE CONTROL, Turn the temperature control knob to the desired temperature: — blue zone: cold — blue/red zone: temperate — ted zone: hot. ‘Once you have made the adjustment, wait for a few moments to evaluate the result before changing it slightly, if necessary. USE IN COLD WEATHER: DEFROSTING/ DEMISTING — Close the side and central air vents. — Move the fan control to position “0” (external air side). — Move the air distribution contral knob to the “detrosting/demisting”. — Move the temperature control knob into the “hot” zone. ‘As soon as the temperature rises: — Move the ventilation control knob to position 4 With air conditioning: — Press the air conditioner contro! button, Page 14 With or without air conditioning: — Increase the air flow as the engine temperature rises. When the “defrosting/demisting” action is finished, move the temperature control knob into the desired zone, The reaction time varies according to the position chosen. Maintain a minimum airflow for better efficiency. In order to improve defrosting of the side windows, open the side air vents after demisting the windshield. USE IN HOT WEATHER: If the temperature inside the cab is higher than the outside temperature: — Aerate the cab by driving for a few minutes with the windows down. — Move the temperature control knob to “max. cold” and the ventilation control knob to position 4 to obtain maximum air flow, With air conditioning: — Press the air conditioner control button (6). As soon as the desired level of comfort is, reached With of without air conditioning: — Retum the temperature control knob to ‘a more moderate position. — Choose the air distribution control knob position. — Reduce the ventilation. Maintain a minimum air flow for better efficiency (position 1 minimum). Ifyou wish to increase the heating or cooling power, use the cab air recyciing feature with the air conditioner engaged. Only use the recycling feature in short spells.a SIDE AIR VENTS These are located on each To open: Turn knurled wheel (1), pointer (3) towards mark (4) (solid triangle). To close: Tum knurled wheel (1), pointer (3) towards mark (5). To swivel vertically: Use control (2). Tosi 1 horizontally: Tilt the air vent, ide of the dashboard. OPERATION CENTRAL AIR VENTS ‘These are located in the middle of the dashboard, ‘To open: Tum knurled wheel (1) upwards. To close: Tum knurled wheel (1) downwards. To swivel horizontally: Use control (2). To swivel vertically: Tilt the air vent. NOTE The evolution of climate control and soundproofing have led to cabs becoming more and more hermetically sealed. It is therefore necessary, when you have to stay inside the cab for a long period, to provide adequate ventilation (windows partly open, roof air vent) to avoid confinement of the Page 15ey Maintenance FAN COIL HEATER FILTER Removal Withdraw screws (1). Tilt the front grille and remove filter (2). Page 16 OPERATION Cleaning Atthe scheduled intervals, back-flush the filter (2) with compressed air, directing the jet of air in the direction opposite to that of filtration (7 bars/ 101.5 psi maximum pressure). Then immerse filter (2) in a soapy solution for about 15 minutes. Rinse the filter with plenty of water until the rinsing water remains clear. Dry filter (2) with compressed air. Ifnecessary, replace the filter.OPERATION Installation Position filter (2). Tighten screws (1). Receiver/dryer Whenever you work on the A/C system, replace filter (1) and renew the refrigerant, requires special safety instructions to be observed. Work should be performed by an ASE AJC certified personnel only. Page 17ds OPERATION Layout of Equipment on Vehicle Page 18OPERATION DETAILS OF THE MAJOR A/C SYSTEM COMPONENTS 1— Compressor: ‘The compressor assures circulation of the ‘efrigerant in the system. 2—Condenser: The condenser’s job is to evacuate calories so as, to cause liquefaction of the vapors compressed by the compressor. 3.—Receiver/dryer: ‘The dehydrator’s job is to absorb the humidity in the A/C system. 4— Pressure controller: ‘The pressure controller's job is to protect the AIC. ‘system components. — Expansion valve: The expansion valve's job is to expand the refrigerant at the evaporator inlet and contto! the. fluid flow inside the evaporator. 6 —Thermostat: ‘The thermostat controls the compressor clutch when the evaporator temperature is more than 4°C and cut the compressor clutch when the evaporator temperature is less than 1°C. 7 — Frost sensor: The frost sensor's job is to avoid “icing up” of the evaporator. The capillary tube is placed at the coldest point of the evaporator and is connected to the thermostat, As soon as the temperature drops below 1°C in the evaporator, the thermostat disengages the compressor clutch. — Evaporator: The evaporators job is to produce cold: it is a heat exchanger between the ambient air in the cab that is to be cooled and the boiling refrigerant. The condenser and the evaporator are the two exchange surfaces of an A/C circuit. 9— LP pressure take-off (gaseous charge): The LP pressure take-off serves for diagnostics testing and gaseous charging. 10—HP pressure take-off (iquid charge): ‘The HP pressure take-off serves for diagnostics testing and liquid charging. Pipes: ligh pressure — gaseous state : High pressure — liquid state C: Low pressure — liquid state D: Low pressure — gaseous state Page 19de> NOTES Page 20as REMOVAL/INSTALLATION REMOVAL/INSTALLATION Page 21ies) REMOVAL/INSTALLATION AIC COMPONENTS Remove the sorews holding the refrigerant pipes. REMOVAL/INSTALLATION Heating Block TO REMOVE Open the master switch to cut off the electrical power supply. Open the front grille. Drain the A/C system and save the refrigerant (See REFRIGERANT CIRCUIT). Remove the serews from the scoop. Partially drain the engine cooling system (see engine service manual MV5-101), Remove the screws from the flange holding the expansion valve. Remove the refrigerant pipes. Take off the O-rings. Page 22ies) REMOVAL/INSTALLATION Blank off the expansion valve ports. INSIDE OF THE CAB: i M i ring the ib Blank ofthe refgerant pipes wih appropriate sn (1) them ae the harnulto mave it out Plugs. ‘of the way, Install hose clamps on the heating hoses. Remove the trim (2). Dien te meouny noes) Remove the screws from the lower trim. Use spring clamp pliers, Withdraw the lower trim. Remove the screws. Page 23> REMOVAL/INSTALLATION Remove the screws from the framing strip. Withdraw the framing strip. Remove the dashboard. Page 24& REMOVAL/INSTALLATION Remove the storage box. panel. Ly ZU 106 ete Withdraw the appearance panel, using a screwdriver. Remove the screws and withdraw the central ‘rim. Page 25> REMOVAL/INSTALLATION Withdraw the cable clamps and unplug the connectors. Disengage the wiring harness. Slightly separate the air ducts, Remove the screws from the front mounting plate. 72500 Remove the upper attaching screws. Remove the heating block. 702500 Page 25 TO INSTALL Before engaging the heating block, check the positioning of the air ducts. Install the heating block. mi | Lightly screw in the heating biock upper attaching screws. Install the front mounting plate screws and tighten at the recommended torque. Tighten the heating block upper attaching screws at the recommended torque. 70290Diss) Assemble the air ducts to the heating block. Connect up the wiring harness and the connectors. install the cable clamps. fin 8 We 2} 7 We Z Mt srce080 Install the central trim. Install the screws, Tighten at the recommended torque. ae Se fit Md 0IF Wb Util ttl 4It VG emare REMOVAL/INSTALLATION ‘Assemble the appearance panel to the heating control panel board. Fasten the assemibly to the front face. Install the storage box. Install the screws and tighten at the recommended torque. Page 27is) REMOVAL/INSTALLATION Position the dashboard. Position the framing strip. Install the screws and tighten at the recommended torque. Refasten the lower trim and the grab handle. Install the screws and tighten at the recommended torque. OUTSIDE THE VEHICLE Install the screws and tighten at the recommended torque. Withdraw the blanking plugs from the expansion valve and from the refrigerant pipes. {nstall new O-rings on the pipes. Oil all the seals with refrigerant oil Fit the flange to the expansion valve and tighten the holding screw at the recommended torque (8 Nem). Install the screws holding the refrigerant pipe and. tighten to torque. Page 28a Connect the hoses. Be sure to correctly position them. REMOVAL/INSTALLATION Install the clamps. Remove hose clamp. Position the scoop and tighten the screws at the recommended torque (8 N-m). Fill the engine cooling system with coolant to correct level (see engine service manual MV5-101). Fill the AIC system with refrigerant and the correct quantity of refrigerant oll (see REFRIGERANT CIRCUIT). Page 29as REMOVAL/INSTALLATION Motor-Driven Fan Unit Unplug the resistor connector. ‘THERMAL RESISTOR Unscrew the screws. To remove Open the master switch to cut off the electrical power supply. Remove the lower screw securing the grab handle (1), then rotate the handle to move it out of the way. Remove the trim (2). Remove the screws from the lower trim. Withdraw the lower trim, Remove the thermal resistor. Disconnect the wires. Page 90a REMOVAL/INSTALLATION To install Connect the wires to the thermal resistor. Install the thermal resistor and tighten the screws at the recommended torque (1.0-1.3 N-m). Plug in the connector. Position the lower trim and the grab handle. Install the screws. Tighten at the recommended torque. BLOWER AND THERMOSTAT To remove Open the master switch to cut off the electrical power supply. Remove the lower screw securing the grab handle (1), then rotate the handle to move it out of the way. Remove the trim (2). Remove the screws from the lower trim. Withdraw the lower trim. Page 31a> REMOVAL/INSTALLATION Remove the screws from the framing strip. Withdraw the framing strip. 7020 Remove the dashboard. roasea Page 32Dies) Remove the storage box. Withdraw the heating control panel appearance panel. REMOVAL/INSTALLATION Remove the screws and withdraw the central trim. Withdraw the cable clamps and the connectors. Disengage the wiring hamess. i Nee 410 Ub TW i ——— rr Remove the screws. Remove the hood. 10038 eriaeta> Disconnect the wires from the thermostat and from the thermal resistor. REMOVAL/INSTALLATION Remove the screws attaching the thermostat, Remove the thermostat and unclip the capillary tube from the evaporator. 6102288 To install Position and clip the capillary tube on the evaporator. Fasten the thermostat with the screws and tighten at the recommended torque (2.3-3.3 Nem). Engage the blower in the block. Install the screws and tighten at the recommended torque (1,8-2.2 N-m). Connect the wires to the thermostat and to the thermal resistor. Position the hood. Install the screws and tighten at the recommended torque (1.2—1.6 Nem). Connect the wiring hamess and plug in the connectors. Install the cable clamps, Install the central trim. Install the screws and tighten at the recommended torque. ‘Assemble the appearance panel to the heating control panel. Page 34> Fasten the assembly to the front face. Plug the connectors into the waming light cluster board. Fasten the screen, install the screws and tighten at the recommended torque. Position the dashboard. Position the framing stip, install the screws and tighten at the recommended torque. Fasten the lower trim, Install the screws and tighten at the recommended torque. Expansion Valve To remove Open the master switch to cut aff the electrical power supply. Open the front grille. Drain the A/C system and save the refrigerant {see REFRIGERANT CIRCUIT). Remove the screws from the scoop. REMOVAL/JINSTALLATION Remove the screws holding the refrigerant pipes. Remove the screw from the flange holding the expansion valve. Withdraw the pipes. Take off the O-rings. Blank off the refrigerant pipes. Page 35a REMOVAL/INSTALLATION Remove the screws from the expansion valve, Remove the expansion valve. Take off the O-rings. Biank off the HP and LP pipes. Page 95, To install Withdraw the blanking plugs from the expansion valve and from the refrigerant pipes. Replace all seals without fail. Install the O-rings. Oil ail the seals with refrigerant oi Position the expansion valves. Install the screws. Tighten at the recommended torque (8 N-m). Install new O-rings on the pipes. Install the flange to the expansion valves and tighten the holding screw at the recommended. torque (8 Nem). Install the screws holding the refrigerant pipe and tighten to torque. Position the scoop and tighten the screws at the recommended torque (8 N-m). Fill the A/C system with refrigerant and the correct quantity of refrigerant oil (see REFRIGERANT CIRCUIT).a> REMOVAL/INSTALLATION Heating Tap Valve Remove the screws and save the plate holding the tap valve. ‘To remove Pull the tap valve slightly. pen the master switch to cut off the electrical power supply. Open the front grille. Partially drain the engine cooling system (see engine service manual MV5-101). Install hose clamps on the heating hoses. Disconnect the heating hoses. Use spring clamp pliers. Remove the aiip from the tap valve sheath stop. Uncouple the cable from the tap valve. ‘Tako off the O-rings. Page 37ds REMOVAL/INSTALLATION To install Replace all seals without fail. Install the O-rings. Connect the cable to the tap valve. Apply a bead of silicone between the cable sheath and the heating block. Move the temperature control knob to the “Hot” position, Install the clip on the sheath stop. Position the tap vaive on the heating block. Insert the holding plate on the tap valve. Page 38 Install the screws. Tighten at the recommended torque (2.9-3.3 Nm). Connect the hoses. Install the clamps. Remove hose clamp. Fill tho engine cooling system with coolant to level (see ongine service manual MV5-101)..ai» HEATING BLOCK HEATING BLOCK Page 99a> HEATING BLOCK SERVICE PROCEDURES To Disassemble the Radiator Remove the screws. Remove the hood. HEATING BLOCK Remove the screws holding the blower. sreceta Disconnect the wires from the thermostat and from the thermal resistor. Page 40 era Remove the screws attaching the thermostat. Remove the thermostat and unelip the capillary tube from the evaporator. ssaas HEATING BLOCK Remove the screws and save the plate holding the tap valve. Pull the tap valve slightly. Remove the screws from the base. Remove the clip from the tap valve sheath stop. Uncouple the cable from the tap valve. Take off the O-rings. Remove the tubes. Take off the O-rings. sst63 Page 41ay Remove the heater core. ‘700800 HEATING BLOCK Remove the screws, To Disassemble the Evaporator Remove the sheath stop clip from the air inlet flap. Pivot the cable stop, using pliers. Uncouple the cable from the flap. Remove the clips from the sheath stops. Remove the cables. 7easia Page 42iy Pull the main housing vertically to separate it from the base. HEATING BLOCK Remove the guard. 70540 Uncouple the control rod, using a screwdriver. Remove the two flaps. ‘Take out the pin. 70958 Remove the evaporator. Remove blanking plugs. rasa Page 43> HEATING BLOCK Remove the screws. Remove the expansion valve. Take off the O-rings. To Assemble Replace all seals without fail. Install the O-rings. Oil all the seals with reftigerant ol. Position the expansion valve. Page 44 Install the screws. Tighten at the recommended torque (21 Nem). Blank off the expansion valve ports. Position the evaporator on the base. Install the guard. Position the pin,> _ HEATING BLOCK Assemble the flap on the pin. Correctly position the flaps. Install the screws. Tighten at the recommended torque (1.0-1.3 N-m). ‘Assemble the main housing to the base. Install the radiator, Install the screws. Tighten at the recommended torque (1.0-1.3 Nem). All seals must be replaced with new seals. Install the O-rings. Install the tubes. Page 45> HEATING BLOCK Install the screws. Tighten at the recommended torque (2.8-3.2 Nem). Connect the cable to the tap valve. Place the tap valve in the “wide open' position. Install the clip to the sheath stop. Position the tap valve on the heating block. Install the screws to the base. Tighten at the recommended torque (1.01.3 N-m). Install the O-rings. 10344 rosa Page a6ei Install the screws. Tighten at the recommended, torque (2.3-3.3 N-m). Position and clip the capillary tube on the ‘evaporator. Fasten the thermostat with the screws and tighten at the recommended torque (2.3-3.3 Nem). HEATING BLOCK Engage the blower in the block, s7eazta Install the screws. Tighten at the recommended torque (1.8-2.2 N-m). Connect the wires to the thermostat and to the thermal resistor. Page 47a> HEATING BLOCK Install the hood. Check the condition of the gasket. Replace, if necessary. Insiall the screws. Tighten at the recommended torque (1.21.6 N-m). eroxta Heating Control Panel Board ‘TO DISASSEMBLE “Turn the ventilation control knob to the "STOP" Unplug the connectors. position, Hook the cable to the air inlet flap. Remove the clips. Install the clip to the sheath stop. Mark, then remove the cables. TO ASSEMBLE Install the cables to the panel board. Air flow control: 1 — Footwell and side window air flaps. Ventilation control: 2—Recyeling air flaps emoasoe | 3 — External air flap Page 48a» HEATING BLOCK Heating control: Install the clips to the heating block sheath stops. 4—Tap valve Operate the controls to check for correct operation of the air flaps. To ADJUST Place the sheaths on the heating control panel ‘board in the “abutment position, Install the clips to the sheaths. Tum the controls: — _Airdistribution knob to the "Windshield defrosting” position, — Temperature control knob to the “Hot” position. — Ventilation knob to the “STOP” position, 703600 Page 43,> NOTES Page 50CONDENSER CONDENSER Page 51> CONDENSER CONDENSER SERVICE PROCEDURES To Remove Open the master switch to cut off the electrical power supply. Drain the A/C system and save the refrigerant (see REFRIGERANT CIRCUIT). Disconnect the flexible pipes (1). Take off the O-rings. Remove the screws. Remove condenser (2). Page 52 To Install Install condenser (2). Install the screws and tighten at the recommended torque. All seals must be replaced with new seals. Install the unions (see “To Assemble Unions” on page 62). Connect the flexible pipes (1). Tighten at the recommended torque. Fill the A/C system with refrigerant and the correct quantity of refrigerant oil (see REFRIGERANT CIRCUIT).icc RECEIVER/DRYER RECEIVER/DRYER Page 53a> RECEIVER/DRYER RECEIVER/DRYER SERVICE PROCEDURES To Remove Open the master switch to cut off the electrical power supply. Drain the A/C system and save the refrigerant (see REFRIGERANT CIRCUIT). Unplug the connector from the pressure controller. Disconnect the refrigerant pipes. Remove the pressure switch. Remove the O-rings. Remove the receiver/dryer (1). To Install Instal the receiver/dryer. Tighten the clamp. All seals must be replaced with new seals. Union assembly: see “To Assemble Unions” on page 62. Connect the pipe. Tighten to torque, Install and connect pressure switch, Fill the A/C system with refrigerant and the correct quantity of refrigerant oil (see REFRIGERANT CIRCUIT), Page 54Picch COMPRESSOR COMPRESSOR Page 55ir] COMPRESSOR COMPRESSOR SERVICE PROCEDURES To Remove pen the master switch to cut off the electrical power supply. Drain the A/C system and save the refrigerant (see REFRIGERANT CIRCUIT). Remove the engine soundproofing screens. Cut the plastic clamp. Unplug the connector and disconnect the ground braid. Loosen the nuts and bolts (1-2-3-4~5). Remove the drive belt. Remove screw (7) and the flange holding the pipes. Withdraw the pipes. Take off the O-rings. Blank off the pipes and the compressor ports. Loosen the nuts and bolts (1 -2~3). Remove the belt tension adjuster. Remove the compressor shatt (6). Remove the compressor. Remove the mountings. To Install The compressor is supplied with the correct quantity of oil. Asa safety precaution, check the oil level (see "Checking the Oil Level’ on page 57). Install the mountings. Install the compressor, complete with mountings, Install the compressor shatt (6). Install the belt tensioner. Install the nuts and bolts (1-2-3). Install the drive belt. Tension the drive belt. Turn screw (4) to adjust. Tighten the nuts and bolts (1- 2-3-4 —5) at the recommended torque. Install the pipes. All seals must be replaced with new seals. Install the holding flange. Install screw (7). Tighten at the recommended torque (60 N-m). Page 56ai» COMPRESSOR Plug in the connector and connect the ground, braid. Install the clamp. Fill the AIC system with refrigerant and the correct quantity of refrigerant oil (see REFRIGERANT CIRCUIT). Install the engine soundproofing screens. Checking the Oil Level ACAUTION Its essential to drain the oll from the compressor if the A/C system suffers heavy leakage. Determine the angle of assembly of the ‘compressor. Use an angle gauge. When the compressor is inclined towards the left, rotate the shaft until internal part (a) appears. When the compressor is inclined towards the right, rotate the shaft until internal part (b) appears. Insert dipstick No. 6108 (see “A/C SYSTEM TOOLS" on page 78) into the port, with the bend ‘opposing the angle of inclination of the compressor and parallel to the compressor. ‘Withdraw the dipstick and count the graduations in order to determine the oil level according to the ‘able below: ‘Angle of inclination in® | Number of graduations 0 a5 70 oy a) 20 7 30 Cy 1 30 8 50 310 | 0 on 1043 ereasra Page 57a> COMPRESSOR Page 58a> COMPRESSOR Clutch Use suitable puller. TO DISASSEMBLE Remove clamp (11). ee Withdraw wire (10) Use some means of protection (A). Wie ing ring (8). Remove nut (1). Remove coll (9). Withdraw retaining ring (7). Use a press. Extract bearing (6). resena Remove disc (2). Use suitable puller. Save shims (3). Withdraw retaining ring (4). Remove pulley (5). Page 59De) COMPRESSOR TO ASSEMBLE Install bearing (6). Use a press. \nstall retaining ring (7). Install coil (9). Maintain the direction of orientation. Install retaining ring (8). Install wire (10). Install clamp (11). Assemble pulley (5). Install retaining ring (4). iG 0 Ss I TO ADJUST Measure dimension (B). Measure dimensions (C/D). Determine the thickness E of shims (3). (0.6 + B) - (C- D) (Available parts size: 1 - 0.5 - 0.12 mm) Insert shims (3). Replace key (12), if necessary. Install disc (2). Install nut (1). Tighten to the recommended torque (30 N-m). Inspect the clearance (J). Page 60ae HOSES AND UNIONS HOSES AND UNIONS Page 61Pris HOSES AND UNIONS HOSES AND UNIONS SERVICE iriessto on account ol probleme cf rstited i PROCEDURES access, lock the nuts by 1/6th to 1/Srd of a tun maximum, using two spanners, so as not to kink To Change a Damaged Hoses the pipes. 8 pa ‘Always replace a hose with one of the same length, with identical cross-section and conforming to intemational standards SAE J 51B or NFR 18.701, Overtightening will cause irreparable damage to the seal with risk of leakage. In all cases, the leak will occur at point (3) at the base of the union. Before removing a damaged hose, mark its Each time after changing a hose, test for leaks. routing and its fastenings. ‘After replacing a hose, fll the A/C system with rigerant and the correct quantity of refrigerant {see REFRIGERANT CIRCUIT). To Assemble Unions Degrease the union screw-thread (1) and smear with F112 type lube oil 5GS (or mineral oil). Install a new O-ting (2). Assemble the union by hand until both parts eee make contact and tighten to the recommended torque (see table below). Tightening torque (Nm) Module ‘Steel-Aluminum Steel-Steel 6 10-14 74-20 8 18-22 40 10 22-26 w-a3 7% 24-28 40-46 Page 62> REFRIGERANT CIRCUIT REFRIGERANT CIRCUIT Page 63REFRIGERANT CIRCUIT REFRIGERANT CIRCUIT SERVICE PROCEDURES: Environmental Protection Destruction of the ozone layer by chlorofluorocarbons ("CFCs"), which are the active ingredient of refrigerants, has led the public authorities to sign an international agreement (Montreal Protocol and Decree No. 92-1271 dated 07/12/92) in order to limit the use and production of certain CFCs and forbid their discharge into the atmosphere. AA fluid which has been in operation in a system has been fouled by oil, overheating and impurities {such as: carbon deposits, iron filings, etc.). Such a fluid cannot be re-used in such a state and must be treated. ‘Autornatic units have been specially designed for recovery or recovery/recycling of “CFCs” from air conditioners, Such units serve to either package the fluids in special packs made available by chilling fluid distributors, or recycle the fluids and re-Inject them into systems. Refrigerant Oil Whatever the type of recovery/recycle systems used, the oil necessary for lubricating the compressor is recovered. This especially applies if the system was in operation just before drainage of the ol A CAUTION Re-inject the same quantity of fresh oil as that which was recovered from the circuit at the time of transfer. A higher quaniity of oll will lead to a fall in efficiency of some 10 to 20%. A lower quantity will lead to damage to the compressor. Exclusively use SP20 oil. When replacing a single circuit component, add the following extra amounts of oil — Receiver/dryer = 10 ml (0.35 02)* — Piping = 10 mi (0.35 02)* — Condenser = 20 ml (0.67 0z)* — Evaporator = 20 ml (0.67 oz)* — Compressor = 165 ml (5.57 0z)* “These are average figures and may vary. Keep in mind that total system capacity is 165 ml. NOTE ‘Anew compressor is filled with 165 ml of oil by the manufacturer. This amount is distributed throughout the system during operation. Periodically Checking the Charge Each AVC circuit of the vehicle must be checked out approximately once a month during the in- service period and especially just before the annual utilization period. The circuit must also be checked out in the event of irregularity in operation of the system. ‘Connect up two pressure gauges or a charging station. Bleed the pressure gauge pipes or the charging station pipes. Start the engine and run at a speed of 1000 to 1500 rpm. Start up the A/C system, turn the control knob to the “maximum cold” position. Operation is correct when the pressures lie within the curves on the graphs hereatter, which depend on the ambient exterior temperature, If the pressures are insulfticient, itis possible to proceed with partial charging of the system in gaseous phase or regenerate the refrigerant and charge as required. Page 64REFRIGERANT CIRCUIT Charging the System in Liquid Phase This charging method applies to: — empty systems, — exhausted vacuums, With the compressor shut down, the system is, filled through the HP charging take-off (red). Weigh the charging cylinder. pen the charging valve. — - As soonas the pressure in the circuit is the same as the pressure in the charging cylinder, close the charging valve. — Start the engine and bring the compressor into operation. — When the pressure gauges display a value equal to that of atmospheric pressure, stop the compressor and the engine. — Continue the charging operation (as above) to fill the system with the correct ‘amount of refrigerant (see TECHNICAL DATA). Check the HP and LP pressures on the pressure gauges (refer to the graphs below) and check the system pressures and temperatures. Charging the System in Gaseous Phase This charging method applies whenever systems are topped up. With the compressor running, the system is filled through the LP charging take-off (blue). Open the charging valve slighily so as to cause expansion of the gas, read off on the pressure gauges, 10 avoid damaging the compressor, Check the HP and LP pressures on the pressure gauges (refer to the graphs below) and check the system pressures and temperatures. High pressure curve bw ot 2 bos oe we Low pressure curve 254 1s os. ol, 2 Be bo eo Page 65ds REFRIGERANT CIRCUIT s7oceea Page 66a REFRIGERANT CIRCUIT Pressure take-oft: 2 1, High pressure take-off 3. 2. Low pressure take-off. 4. 5. 6 7. 8. 9. 10. nt. 12. 13. OPERATIONS: 1 Connect the charging station. A Remove the blanking plugs. B. Red union on the HP take-off. C Blue union on the LP take-off. D. Connect the red and blue flexible pipes. Open the valves. Bleed the flexible pipes. Recover the refrigerant. Repair the component in question. Exhaust the vacuum (30 minutes). Hold the vacuum (5 minutes). Partially charge the system (300 grams). Test for leaks. Recover the refrigerant (the 300 grams). Replace the receiver/dryer. Exhaust the vacuum (45 minutes). Top up with refrigerant oil. Charge the system with refrigerant. Disconnect the charging station. * Close the valves. * Remove the flexible pipes. © Tighten the blanking plugs For operation and maintenance of the appliance, consult the manufacturer's manual. PIPES: High pressure — gaseous state High pressure — liquid state Low pressure — liquid state Low pressure — gaseous state Page 67a> NOTES Page 68ds TROUBLESHOOTING TROUBLESHOOTING Page 69TROUBLESHOOTING TROUBLESHOOTING DIAGNOSTICS AND TESTING Preliminaries: Before commencing any work, it is necessary to check out: — refrigerant circuit (oil leak, friction... Install the two pressure gauges and refer to the electrical diagram. Compressor = small diameter pipe = hot = delivery = High pressure, old = Low Evaporator = large diameter pip pressure = compressor = suction. — evaporator (icing up, foreign matter, state). — condenser, mechanical components and NOTE When you work on AC systems, always bear in drive belts. mind that your most important enemy is circuit moisture. Symptom Diagnostics DEFECT NOTED PROBABLE CAUSE REMEDY 7 Fuse detective Replace fuse. ‘The system does not coo Electrical installation defective Test line. Clutch defective Change defective clutch components. ‘Compressor partially or completely seized | Change compressor. Expansion valve detective ‘Change expansion valve. Receiver dryer obstructed No refrigerant in system Air fiter obstructed (Change receiver/dryer. ‘Change defective component and recharge system. Clean or change filter. ‘The system cool intermittently. Evaporator iced up Excessive cicult moisture Temperature control set at maximum 2 ‘ir flow Incorrect ‘Check out motor-driven fan uni. ‘The system does not coo! Drive belt slack Tension drive bet ee CClutch slipping ‘Change defective clutch components. Condenser obstructed Clean condenser. Rocoiveridryor partially obstructed Change receiver/dryer. Excessive circuit humiity Drain system, save fluid, change recelver/ ‘dryer, recharge system. Insutficient refrigerant “Top up with rfrigarant. Expansion valve sensor malfunction ‘Change expansion valve. Air fiter partially obstructed Glean or change fier. 3 Electrical installation or control defective — | Test line. Roplace thermostat Drain systom, save fluid, change recelver/ ‘dryer, recharge system. Lower control setting. a The system is noisy. Motordiven fan unit impeler Excossive circuit moisture ‘Change motor-driven fan unit Drain system, save fluid, change receiver! dryer, recharge systom. Page 70TROUBLESHOOTING Excossive refrigerant Entry of air into circuit DEFECT NOTED PROBABLE GAUSE REMEDY 3 Drive bott wom or slack ‘Tension or change drive belt ‘The compressor is noisy. Clutch detective Change defective clutch components. il level too low Drain systom, save fluid, change receiver! dryer, recharge system. ‘Compressor seized ‘Change compressor ‘Check charge. Drain system, save fuid, change recoiver! dyer, recharge system. 6 ‘Abnormal circuit overheating, Engine ventilation defective Condenser obstructed Entry of alr into circuit, Excessive circuit moisture Gheck ventilation. Clean condenser. Drain system, save fluid, change receiver/ dyer, recharge system. 7 Insufficient high pressure, Insufficient refrigerant Refrigerant leak Expansion valve seized (open) Compressor defective ‘Top up with refrigerant. Detect leak, drain system, save fluid, change receiveridryer, recharge system, Change expansion valve. Change compressor. ® Excessive high pressure ‘Condenser obstructed Excossive refrigerant Expansion valve seized (open) lean condenser. Check fing charge. ‘Change expansion valve. Low pressure circuit leak Excessive circuit moisture Evaporator fouled Expansion valve seized (closed) Entry of air into circuit Drain system, save fluid, change receiver! dryer, recharge system. Receiveraryer obstructed Change receiverdryer. 8 Roceiver/dryer obstructed (Change recoiveridryer. Insufficient ow pressure \neuticiont ciccuit charge Recharge system. Find leak, drain system, save fluid, change recelveridryer, recharge system. Drain system, save fluid, change receiver? ‘dryer, recharge system. (Clean evaporator. Change expansion valve. 0 Excossive low pressure Excessive circuit humidity Expansion valve seized (open) Drain sysiem, save fluid, change receiver? ‘yer, recharge system, Change expansion valve. 1 ‘Temperature diffused by air consitioner not corresponding to desired temperature when temperature control in blue zone ‘it distribution control in “Delrosting” position Air conditioner control (AC) not actuated Heating valve partly open Move air distibution control ‘Actuate air conditioner control Check and adjust control cable. R ‘Temperature diffused by air conaitioner not corresponding to sired temperature when temperature control in red zone ‘ir distbution control in “Delrosting® position Ternperature control in Wve air distibation contra, Move temperature control Page 71TROUBLESHOOTING conditioner not corresponding to ‘desired temperature when temperature control in red zone Air conditioner radiator scaled DEFECT NOTED PROBABLE CAUSE REMEDY 3 T Engine not yet at normal operating Tot engine run. temperature ‘Temperature diffused by air Incorrect coolant circulation (Cheek coolant system, Clean radiator 4 Air distribution diftusod not Corresponding to desirod air sistrbution when control i in Motor, wiring hamess, cables Air distribution laps jammed Replace defective parts. Visually check air flaps. ‘corresponding to desired air NOTES Page 76TOOLS TOOLS Page 77as TOOLS A/C SYSTEM TOOLS Locally manufactured tool Page 78AIR CONDITIONING SYSTEM SERVICE MANUAL FREEDOM™ MEDIUM DUTY TRUCKS (MACK TRUCKS, ING. 2001