RED DOT Jan.

2009
HVAC Maintenance Instructions

Build to Survive

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Visual Inspection - System Off

Build to Survive

1. Observe the System

2. Inspect Parts

3. Check Hoses and Fittings

4. Check for Refrigerant Leaks

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Visual Inspection “Hose Conditions”

Build to Survive

Check Hose Clamps

Check hose surface condition / Fittings

If needed replace damaged component

When replacing Hoses use same type & ID – Use Steel fittings properly crimped.

When hose or fittings are shielded or clamped to prevent vibration damage, be

sure these are in position or secured.

If notice of vibration damage – add clamps or grommets.

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Hose / Connection replacement

Build to Survive

Use proper O-rings (R134a – not damaged - clean)

Mount smoothly (NO FORCE) - use refrigerant mineral oil. (avoid using PAG oil)

Always use 2 wrenches disconnecting or connecting fittings attached to metal lines.

Tube O-ring type fittings require only 24,4 Nm (18 lbf.ft)

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of torque for correct sealing.
RED DOT Jan. 2009
HVAC Maintenance Instructions

Visual Inspection “Compressor & Clutch”

Build to Survive

Visual Inspection

Check if electrical power is reaching the clutch

– Test ground – Test conductance pressure switch - thermostat – relay

Check clutch gap according to supplier’s specifications – Adjust or replace clutch

Check if clutch surface is clean & free from Oil - Replace or clean.

Check

¾ belt condition – eventually replace belt

¾ belt tension – eventually adjust

¾ Mounting bracket / compressor (fastened securely?)

¾ drive belt >< pulley alignment

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Visual Inspection:
“Spot Leaks points”
Build to Survive

Look for signs of refrigerant oil forced out with refrigerant leaks – they can be at any connection

(Condenser – Compressor – evaporator - receiver-dryer)

Feel at the bottom of all connections. Make sure the system is not hot.

Checking with electronic leak detector is the best way

– should be done by HVAC skilled person.

Obvious Spot: Compressor Shaft Seal – Centrifugal force will throw

the oil against the engine, bracket or whatever is close.

Confidential information not to be copied or shared

6 without the express written consent of Red Dot Corporation
RED DOT Jan. 2009
HVAC Maintenance Instructions

Visual Inspection: “Condenser”

Build to Survive

Make sure the condenser is relative clean – DIRT reduces heat dissipation.

Check fins – eventually use fin comb

Check mounting bolts/screws and tighten them if necessary

Confidential information not to be copied or shared
7 without the express written consent of Red Dot Corporation
RED DOT Jan. 2009
HVAC Maintenance Instructions

Build to Survive
Keep the Air filters clean

Follow Suppliers Cleaning / replacing instructions

Check Recirc. Filter in the cab regularly.

Big influence on cooling capacity

Check Fresh Air Filters regularly. Can have

influence on de-fogging.

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RED DOT Jan. 2009
HVAC Maintenance Instructions

System is not properly cooling or heating

Build to Survive

+ Check the Heater system:

The Water valve is properly closed? If not this could work against the evaporator cooling operation.

+ Troubleshooting includes collecting enough information to locate the cause of the problem.

Experienced troubleshooters talk to the operator if they can, then personally verify the symptoms of

the problem whenever possible

- See Trouble Help Check List on next slide.

- Scrolling through Diagnostics gives following info:

Cab Air T: Scroll for “CAB” High Pressure: Scroll for “Hi-P”

Evap. T: Scroll for “EVAP” Syst. Voltage: Scroll for “VOLT”

If possible note the Ambient temperature & Louver OUT T

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Troubleshooting Chart

Build to Survive

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Troubleshooting Chart

Build to Survive

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Advanced Diagnostic Mode

Press PWR Key to Scroll through Diagnostics
Build to Survive
allow reading following Values

CAB Cab Air Temp (°F/°C)

EVAP Evap Core Temp (°F/°C)
HEAT Water Valve Req. (% of Open)
A-C Clutch Request (On/Off)
FAN Blower Fan Speed (% of Max)
DEF Defrost Request (On/Off)
HI-P High Side Pressure (psig)
FRSH Fresh/Recirc Pos (% Fresh)
COND Condenser Fan Req. (On/Off)
PRHT Pre-Heat Signal (On/Off)
VOLT System Voltage (DC Volts)

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RED DOT Jan. 2009
HVAC Maintenance Instructions

Yearly HVAC Check

WARNING

Build to Survive Direct contact with refrigerant can cause frostbite

or blindness

Always use safety glasses and protective gloves.

Avoid moisture and dust entering the system.

Work in clean environment.

Only skilled people are allowed working with

refrigerant.

Contact your official JD service station for a yearly check up of your HVAC system – by preference in the

beginning of the hot season. 13