Air Conditioner Service

AIR CONDITIONER
SERVICE

WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,

READ AND FOLLOW ALL SAFETY MATERIALS IN THE OPERATORS
MANUAL AND AT THE BEGINNING OF THIS SERVICE MANUAL.
The information in this section will help the Service Technician to troubleshoot and repair the Air Conditioning
System.

AIR CONDITIONER SERVICE

TABLE OF CONTENTS
REFRIGERANT & LUBRICANT CAPACITY ........................16-2
AIR CONDITIONING SAFETY ............................................16-3
PRESSURE & TEMPERATURE
RELATIONSHIP CHART ..............................................16-5
FLOW DIAGRAM .................................................................16-6
INSTALLATION DIAGRAM...................................................16-7
INSPECTION & MAINTENANCE ........................................16-8
TROUBLESHOOTING PROCEDURES.............................16-10
TROUBLESHOOTING CHARTS .......................................16-12
PREVENTIVE MAINTENANCE SCHEDULE ....................16-17
REFRIGERANT RECOVERING / RECYCLING ................16-19
EVACUATING & CHARGING the A/C SYSTEM ................16-21

2005, BLOUNT INC. Information on vended components reprinted by permission. This Manual has been compiled from materials available at the time of approval for reproduction. BLOUNT reserves the right to improve its
products without giving prior notice or incurring obligation.

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REFRIGERANT & LUBRICANT CAPACITY

REFRIGERANT USED in Timberking TK 456/458 FORWARDERS

Refrigerant-------------------------------------------------------------------- R134A
Refrigerant Capacity, TK 456/458 ------------------------------------1 lb, 4 oz
System Lubricant ----------------------------- Sanden SP-20 Refrigerant Oil
Lubrication Capacity -------------------------------------------------- 2.0 ounces

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Air Conditioner Service

WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,

READ ALL SAFETY MATERIALS IN THE OPERATOR'S MANUAL
AND AT THE BEGINNING OF THIS SERVICE GUIDE.

AIR CONDITIONING SAFETY

Serious personal injury may occur if the following safety precautions are not observed while servicing any air conditioning system.
1. Servicing any air conditioning system should be performed only by a trained and qualified service technician.
2. Always wear safety glasses, goggles or face shield to protect the eyes from refrigerant.
3. Never apply discharge pressures to refrigerant container. Discharge pressure could
cause container to explode causing severe personal injury.
4. Do not use a torch, electricity or engine heat to raise the temperature of any refrigerant
container. If it becomes necessary to heat a container in order to remove the last of its
contents, apply heat by placing it in a pan of water heated to NO MORE THAN 130F
(54C) while the container is connected to the air conditioning system.
DO NOT EXCEED 130F (54C) OR DANGER OF EXPLOSION WILL EXIST.
5. Refrigerant storage area should never exceed 130F (54C) or danger of explosion will
exist.
6. Never allow refrigerant gas or liquid to come into contact with skin or eyes. When refrigerant is released into the air, its temperature drops INSTANTLY to 26F
(32.2C). If it touches your skin or your eyes, you should flood the area with cool water and GET MEDICAL ATTENTION IMMEDIATELY.
7. Do not allow refrigerant gas or liquid to come into contact with any open flame. The
open flame will break down the refrigerant, releasing phosgene gas. Phosgene gas is
poisonous, colorless and has an unpleasant odor. Phosgene gas causes severe respiratory irritation.
8. Work ONLY in a well-ventilated area.
9. The air conditioning system contains fluid under high pressure. NEVER loosen or
remove hoses UNLESS the system has been evacuated (depressurized) first. Serious
personal injury can occur from the release of high pressure refrigerant gas or liquid.

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Blank Page

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Air Conditioner Service

PRESSURE AND TEMPERATURE RELATIONSHIP CHART

AMERICAN STANDARD
AMBIENT AIR TEMP (F)

70

80

90

100

150

150190

170220

190250

220300

270370

Average Compressor
Suction Pressure PSI

1426

1426

1426

1426

1426

Average Evaporator
Discharge Air Temp (C)

3845

3947

4050

4255

4560

Average Compressor
Head Pressure PSI

NOTE: Pressure and outlet temperatures shown in

this chart are approximate. Pressures and
temperatures will vary according to ambient
humidity and condition of filter elements.

METRIC STANDARD
Ambient Air Temp (C)

21

27

32

38

65

Average Compressor
Head Pressure bar

10.3513

11.7315.18

13.1117.25

15.1820

18.6325.53

Average Compressor
Suction Pressure bar

9661.794

.9661.794

.9661.794

.9661.794

.9661.794

Average Evaporator
Discharge Air Temp (C)

37

48

4.410

5.512.6

715.6

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AIR CONDITIONING FLOW DIAGRAM

c

b
b

AC flow diag.tif

Fig. 1: Air Conditioner flow diagram. Circled Letters refer to the Key Letters chart in Fig. 2 (inset).

AIR CONDITIONER COMPONENTS REQUIRING FREQUENT MAINTENANCE

BELTS

COMPRESSOR CLUTCH

CONDENSER

ADD REFRIGERANT

REFRIGERANT LINES

VALVES

Service Note: Refer to Section 3, Scheduled Maintenance for recommended maintenance intervals.
Actual operating conditions for the machine being serviced will determine or influence
maintenance frequency and requirements.
The material on the following pages reprinted by BLOUNT, Inc., with permission.
TK 456/458

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INSTALLATION DIAGRAM
KEY LETTERS
Key Description

LINE SCHEMATIC
c
d

a = Compressor to Condenser

(high pressure gas)

b = Condenser to Receiver-Drier

(liquid)

c = Receiver-Drier to Evaporator

(liquid)
d = Evaporator to Compressor
(low pressure gas)

EVAPORATOR
Connect hoses to compressor
before mounting

COMPRESSOR

CONDENSER

c
a

b
BINARY
SWITCH

RECEIVER-DRIER
Right Side Of Engine
Arrow on Drier must align with direction of flow

AC kit~1&2.eps

Fig. 2: Air Conditioner installation diagram to show components and line connection points.
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Air Conditioner Service

#1. INSPECTION AND MAINTENANCE

There are three important reasons to perform regular
inspections and maintenance on your machine.
The first is that it will save money. Checking your
system regularly will help you to detect problems in
their early stages, when they could be less costly to
repair and do not require as much down time.
The second is that it improves operator comfort
and safety. Studies have shown that an operator
will be more alert in machine whose climate control system is working properly.

The third is the knowledge and the efficiency you

will obtain as you familiarize yourself with your
vehicle. Surveys of A/C system owners show
that over 30% of the systems are serviced every
6 months or less, and another 62% are serviced
at least once a year. The following chart shows
which A/C components require frequent maintenance. Keep in mind that the failure of any one
of these components could result in failure of the
system.

THE FOLLOWING INSPECTION PROCEDURES SHOULD TAKE APPROXIMATELY 15 TO 20 MINUTES,

DEPENDING ON THE AMOUNT OF CORRECTIVE ACTION NECESSARY.
VISUAL INSPECTION - SYSTEM OFF
Observe the System

maximum. Repeat action of this procedure will

give the experience needed, so the gauge will
no longer be necessary. Replace belts that look
frayed or worn. If the clutch pulley/belt alignment
is obviously off, loosen the compressor and/or
mounting bracket and use an alignment bar to
line up the clutch pulley with the drive pulley.
Tighten the compressor mounting bolts first, then
the bolts on the mounting bracket. Then, adjust
the belt tension.

Be able to answer the following questions:

Has the vehicle just been in operation?
Has the Heater/AC system been in use?
Has a prior operator, or the work order,
explained or described any problems
with the system?
Has the system been worked on recently?
INSPECT THE PARTS
Inspect the system and look for anything that might
come loose, leak, wear out or become dirty and not
function up to par. Visually inspect the following
components for the conditions listed.
Condenser: The condenser should be clean and
free of leaves, bugs, bird feathers, mud and other
debris. If necessary, a condenser fin comb, air
hose and nozzle, or soap and water may be used
to remove the debris. Make sure that the condenser mounting bolts or screws are tight, and
that the hoses are securely clamped.
Evaporator: Remove recirculation air filter and
grill. The evaporator should be clean and free
of debris. If not, remove the roof and evaporator
housing lid and clean the evaporator using a mild
soap and water solution.
Air filters: Both the fresh and recirculation filters
should be clean and sealing properly. If not,
clean or replace as needed.
Components under the hood: The compressor
mounting bracket, compressor clutch assembly,
drive belt and pulley alignment should all be fastened securely, with the clutch groove in line with
the drive pulley.
Drive Belt and Compressor Clutch: The drive
belt should be tight and in good condition. Use
a belt tension gauge to check tension (120 psi
TK 456/458

Refrigerant Metering Valves: Valves should be

free of any obstruction. If the valve is clogged
with sludge or other obstruction, the result is a
valve problem, but the cause is contamination in
the system. Valves can get stuck in the open or
closed position (although, most often they stick
closed), which makes the valve defective. Defective valves need to be replaced.
Check Hoses and Fittings
All hose connections are potential wear points.
Tighten, re-fasten, add, or replace hoses and/or
clamps as indicated by your inspection.
Check for Refrigerant Leaks
Leaks can occur anywhere throughout the system,
but some places are more common and obvious.
The compressor shaft seal, which is hidden behind
the clutch assembly, is a common location for refrigerant leaks. A soap and water solution works well
for detecting leaks. When checking the evaporator,
feel around drain hole. If there is an oily residue, a
leak is possible.
Service Note: Pressure is different in a system at
rest, so small leaks may be hard to detect.
You may want to use a leak detector to check for
leaks in the system when the air conditioner is
operating.
Continued

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#1. INSPECTION AND MAINTENANCE (Contd)

ELECTRICAL SYSTEM INSPECTION
Inspect Electrical Connections
Inspect visually and by feel. Look for corrosion on
leads or connectors, and clean them when necessary. Make sure all leads and wires are properly
supported and securely connected.
Check Electrical Current Flow and Device Functions
Follow the steps below:
1. Turn on ignition (must be ON to check current
flow)
2. Turn A/C system on. This powers the thermostat
and clutch
NOTE: If the system fails to engage, use the A/C
mode switch to check leads.
3. Check fuses (In-cab and In-line)
4. Check clutch engagement: Drive plate should be
against pulley (and not slightly spaced from it) if
clutch is engaged.
5. Test blower speed operation for air flow and
blower sound (speed) changes.
Service Note: The on and off cycling of the thermostat cannot be checked until performance
inspection is done.
PERFORMANCE INSPECTION - ENGINE RUNNING
Inspect System Component Cycling and Cab
Temperature Levels
Turn on the engine and A/C system and inspect
system for compressor cycling and cab temperature
levels. This can be accomplished more rapidly if the
doors and windows of that cab are closed.
Check Thermometer Readings
In the cab, use thermometer to measure air temperature at the vents. In evaporator (if accessible),
use probe to measure evaporator temperature.
When the A/C unit is on, the evaporator temperature
will be approximately 32. It will rise 6-10, and then
move back down again. This is called a temperature swing, and it indicates that the clutch is cycling
and the thermostat is working correctly.
Please note that readings at the vents will be higher,
and the temperature swing slower and less obvious.
Swing temperatures vary depending on outside
conditions.
Check Clutch Cycling Under Load
This is to be done outside the cab while waiting for
the system to stabilize. Follow the steps below:

TK 456/458

1. Open the engine compartment and observe the

clutch cycling under load.
2. Touch the suction and discharge lines. The
discharge line should be getting hotter, while the
suction line gets cooler.
Check Sight Glass
The receiver-drier sight glass should be clear when
system is stabilized.
NOTE: The sight glass will be clear under low load
conditions. However, it will become cloudy
as the load increases. This is normal for
systems using R-134a refrigerant. The
cloudy condition is caused by the refrigerant
oil separating from the refrigerant.
HEATER SYSTEM INSPECTION
The heater system inspection is a combination
engine cooling system and heater inspection. All
heater/cooling system rubber parts deteriorate due
to outside conditions (air, heat, coolant and oils).
Therefore, they need to be replaced at regular
intervals to prevent breakdown. Metal parts and
gaskets are subject to malfunction or breakdown due
to fatigue and corrosion.
In addition, coolant has a limited life and needs to be
replaced regularly. When dirty, it should be drained,
and the system should be flushed or back flushed
(using special equipment) before refilling with a 5050 mix of clean water and antifreeze.
Coolant must be hot when using a hydrometer to
check protection (freeze-up level).
Check Heater Control Valve Function
Follow the steps below:
1. Cool engine - Start with the engine cool, set
temperature to cool and leave the fan off. As the
engine gets warmer, feel the heater return hose.
If it is warm or hot, there is an internal leak in the
heater control valve, which can seriously reduce
the performance level of the air conditioner system.
2. Warm engine - Next, let the engine warm up to
normal operating temperature and set both fan
and temperature on high. Feel both heater supply and return hoses. If there is a noticeable difference in their temperature, a low flow of coolant
is going through the heater core. This could be
the result of a partially closed or blocked heater
control valve, which (if not corrected) could cause
poor heating performance during cold weather.

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#2. TROUBLESHOOTING
TROUBLESHOOTING OVERVIEW
Troubleshooting includes collecting enough information to locate the cause of the problem, then correcting the problem and its cause by replacement,
adjustment, and/or repairing. You begin by gathering
information from the most to the least important
sources.
Starting with the most important:
1. Your personal knowledge and experience with
AC systems.
2. The vehicle operators knowledge and experience
- question him or her.
3. The work order.
4. Good testing equipment and the Heater/AC system.
The routine you follow when troubleshooting should
proceed from the most to least productive way to
locating the problem and fixing the cause.
Experienced troubleshooters talk to the operator if
they can, then personally verify the symptoms of
the problem whenever possible. They attempt quick
fixes on the basis of their knowledge of common system problems and causes when appropriate. They
know where components are located, and make
repairs when they have a good idea of what the
problem is. They fix the cause or causes as well as
the immediate problem.
INITIAL INSPECTION
Before you begin to trouble shoot with the manifold
gauge set, follow the procedures as shown in Topic
#1, INSPECTION AND MAINTENANCE. This
chapter outlines the required inspections below:
1. Visual Inspection
2. Electrical System Inspection
3. Performance Inspection
4. Heater System Inspection.
As stated in Topic #1, conducting this preliminary
evaluation can help eliminate potential problems.
TROUBLESHOOTING USING MANIFOLD GAUGE SET
Manifold Gauge Set Installation
REFRIGERANT ESCAPING UNDER PRESSURE CAN CAUSE SEVERE PERSONAL INJURY.
Never hook up the gauge set when the engine and
air conditioner are running. Be sure all the valves on
the manifold are closed all the way (turn them clockwise). Check the hose connections on the manifold
for tightness.

TK 456/458

A) Locate the low and high side system service

fittings and remove their protective caps.
Position or hang the manifold gauge set in a
convenient location.
B) Connect the high/low pressure hoses from
the manifold gauge set to the service ports
located on the compressor fittings.
C) Follow the steps listed below during and after
installing the manifold gauge set:
Purging Air From Gauge Set Hoses.
Environmental regulations require that all
service hoses have a shut-off valve within 12
inches of the service end. These valves are
required to ensure that only a minimal amount
of refrigerant is lost to the atmosphere.
The R-134a compatible gauge sets have a
combination quick disconnect and shut-off
valve on the high and low sides. The utility
(center) hose also requires a valve.
Attach the utility (center) hose to a vacuum pump.
Activate vacuum pump and draw the gauge set down
into the vacuum. Turn pump off, connect the gauge
fittings to access ports. This process removes air
from the hose assemblies.
Service Note: Initial purging is best accomplished
when connected to recovery or recycle equipment.
Preparing to add Refrigerant to the System
Now that the gauges are connected, you may need
to add some refrigerant to the AC system before an
effective performance inspection can be completed.
However, if leaks are obvious, they should be repaired prior to adding refrigerant.
Service Note: Loss of some refrigerant is not
unusual over an extended period of time. Adding
refrigerant is a typical procedure when the AC
system is maintained on a regular basis.
When adding refrigerant to the system, connect the
utility (center) hose from the manifold gauge set to
the refrigerant dispensing valve on the container.
Before adding refrigerant to the system, study the sight
glass while the engine is running and the air conditioner
is on. Even if a leak was found during the system inspection, it is impossible to know just how much refrigerant has leaked. Bubbles in the sight glass indicate a
low amount of refrigerant in the system.
Next, check the gauges for unusually high or low
readings, or a lack of pressure. Following this procedure, and using your knowledge and experience,
decide if it is safe and necessary to add refrigerant.

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#2. TROUBLESHOOTING (Contd)

Adding Refrigerant to the System
You are now ready to add the refrigerant. For your
safety and to prevent system damage, use the following procedure:
Service Note: To add refrigerant using a charge/
recovery unit, see Operator Manual provided by
the recovery unit manufacturer.
Add refrigerant using manifold gauge set, refrigerant
canister, and weight scale.
1. Turn on the engine and set the idle at 1200 to
1500 RPM and then turn on the air conditioner.
OVER-PRESSURIZING
THE REFRIGERANT CONTAINER CAN CAUSE
AN EXPLOSION, RESULTING IN SEVERE PERSONAL INJURY OR DEATH.
Do not open the high pressure hand valve on
the manifold gauge set. The compressor could
pump refrigerant into the container and cause it
to BURST.
NOTE: Be sure to keep the refrigerant container
upright to prevent liquid refrigerant from
entering the compressor.

REFRIGERANT ESCAPING UNDER PRESSURE CAN CAUSE SEVERE PERSONAL INJURY.

If the gauges show any abnormally high or low pressures as you are adding refrigerant, stop and investigate for probable cause. Never add more than one
Pound of refrigerant. If the system is low enough
on refrigerant to require more than that amount, you
should stop and check again for leaks. Then recover
all of the refrigerant. Repair, evacuate and recharge
the air conditioning system.
4. When the gauges show normal, close the hand
valve on the manifold, the hose end shut-off
valve, and the valve on the refrigerant container.
You can now proceed with the performance
inspection.
Stabilizing the A/C System
For reliable gauge readings as an aid in troubleshooting, the A/C system must be stabilized.

REFRIGERANT ESCAPING UNDER PRESSURE CAN CAUSE SEVERE PERSONAL INJURY.

2. Open the refrigerant dispensing valve on the container and then the low pressure hand valve on
the manifold. This allows refrigerant to enter the
system as a gas on the low pressure or suction
side of the compressor. The compressor will pull
refrigerant into the system.
3. Add refrigerant in 1/4-lb increments, checking
gauges and sight glass until the gauges read in
the normal range and the sight glass appears
clear. The sight glass may not be clear for a moment just before or after the clutch cycles on and
off but should generally be clear. Gauge readings will fluctuate as the compressor cycles on
and off.

TK 456/458

Service Note: Pressure within the air conditioning

system will vary with ambient temperature. A
normal pressure range is defined as follows:
Low side 15-30 PSIg
High side
150-250 PSIg

TOOLS AND EQUIPMENT PLACED NEXT TO DRIVE BELTS CAN

SLING OUT AND CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
Be sure your tools and test equipment are clear of all
moving parts of the engine and air conditioner.
Start the engine and set to a fast idle of 1200 to
1500 RPM. Turn on the air conditioner. After a quick
in-cab performance test of control function, blower
speeds and air flow, set the A/C system controls to
maximum cooling and blower speed on high. All
windows must be closed. If cab temperature is high,
open the windows for a minute or so to let the hot air
out. Run the engine and air conditioner about five
minutes for the system to stabilize.

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WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,

READ ALL SAFETY MATERIALS IN THE OPERATOR'S MANUAL
AND AT THE BEGINNING OF THIS SERVICE GUIDE.

#2. TROUBLESHOOTING the A/C SYSTEM

PROBLEM

PROBABLE CAUSE

SOLUTION

Blower fans, condenser fans

and clutch do not operate.

Blown fuse
Faulty blower fan switch
Faulty wiring

Replace fuse.
Replace switch.
Replace or repair wiring.

Condenser fans and magnetic clutch do not operate

Faulty blower fan switch

Faulty thermostat switch
Faulty solenoid
Faulty wiring

Replace fuse.
Replace switch.
Replace solenoid.
Replace or repair wiring.

Blower fan does not operate

Faulty blower fan switch

Faulty wiring between fan switch
and blower motor
Faulty blower motor

Replace switch.
Replace or repair wiring.

Condenser fans do not operate

Faulty thermostat switch

Faulty solenoid
Faulty wiring
Faulty condenser fan motor

Replace thermostat switch.

Replace solenoid.
Replace or repair wiring.
Replace condenser fan motor.

Magnetic clutch does not

operate

Faulty binary switch

Faulty wiring
Faulty magnetic clutch coil

Replace switch.
Replace or repair wiring.
Replace clutch coil.

Compressor not turning

Loose or broken drive belt

Slipping compressor clutch
Faulty compressor

Tighten or replace belt.

Clean or replace clutch.
Repair or replace compressor. Discharge and flush system, replace
receiver-dryer, evacuate system and
recharge.

Plugged evaporator core

Plugged condenser core
Evaporator core iced up

Clean
Clean
Faulty thermostat switch or expansion
valve. Replace or repair as needed.

Obstructed air flow through

evaporator or condenser

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Replace or repair motor.

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Air Conditioner Service

WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,

READ ALL SAFETY MATERIALS IN THE OPERATOR'S MANUAL
AND AT THE BEGINNING OF THIS SERVICE GUIDE.

#2. TROUBLESHOOTING the A/C SYSTEM

PROBLEM

PROBABLE CAUSE

SOLUTION

Unit shuts off too soon

Faulty thermostat switch

Faulty binary switch
System overcharged

Replace switch.
Replace switch.
Discharge unit and recharge to proper
level.

Suction pressure too high

Expansion valve not closing

properly.
Faulty compressor

Replace expansion valve.

Low refrigerant charge

Install gauges and add refrigerant.

Evaporator icing up

Check thermostat switch and expansion valve.

Suction pressure too low

Discharge pressure too low

Repair/replace compressor.
Evacuate system, replace receiverdryer, flush system and recharge.

Moisture in system

Install gauges, discharge and flush system. Replace receiver-dryer, evacuate

system and recharge.

Low refrigerant charge

Install gauges and add refrigerant.

Compressor belt slipping

Adjust/replace belt.

Compressor clutch slipping

Clean/replace clutch.

Faulty compressor

Repair/replace compressor.
Evacuate system, replace receiverdryer, flush system and recharge.

Discharge pressure too high

Condenser fins dirty

Clean condenser

Condenser fan inoperative

Repair fan/motor

Air or excessive oil in condenser

or system overcharged

Install gauges, discharge and flush system. Replace receiver-dryer, evacuate

system and recharge.
Discharge system, remove restriction
and flush system. Replace receiverdryer, evacuate system and recharge.

High pressure side restriction

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#2. TROUBLESHOOTING (Contd)

TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
SUMMARY OF TROUBLESHOOTING DIAGNOSES
PROBLEM

PROBABLE CAUSE

1. Excessive Pressure - High Side

1. Air in system.
2. Overcharge of R-134a.
3. Engine overheating.
4. Fan belt slipping.
5. Clogged condenser.
6. Excessive oil in system.
7. Restricted lines.
8. Expansion valve superheat setting too low.
9. Filters or screens plugged.
10. Expansion valve stuck closed.
11. Defective thermostatic switch.

2. Excessive Pressure - Low Side

1.
2.
3.
4.
5.
6.
7.

3. Insufficient Pressure - High Side

1. Low charge.
2 Compressor malfunction.

4. Insufficient Pressure - Low Side

1.
2.
3.
4.
5.
6.
7.
8.

5. Insufficient Cooling of Air Flow

1. Defective thermostatic switch.

2. Slipping compressor belt.
3. Compressor defective.
4. Compressor clutch malfunction.
5. Expansion valve malfunction.
6. Low charge.
7. Oil overcharge.
8. Plugged condenser.
9. Overcharge of R-134a.
10. Moisture in system.
11. Air in system.
12. Clogged evaporator.
13. Restricted lines.
14. Engine overheating.
15. Plugged evaporator drain.
16. Evaporator icing

TK 456/458

Defective expansion valve (stuck open).

Moisture in system.
Insufficient oil in system
Slipping compressor drive belt.
Compressor valves defective.
Condenser malfunction.
Excessive air in system.

Low charge.
Evaporator blower malfunction.
Defective expansion valve (closed).
Restricted liquid line.
Restricted suction line.
Thermostatic switch inoperative.
Compressor clutch will not release.
Water present - frozen in expansion valve.

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#2. TROUBLESHOOTING (Contd)

TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS (Contd)
SUMMARY OF TROUBLESHOOTING DIAGNOSES
PROBLEM

PROBABLE CAUSE

6. System Noisy

1. Excessive oil
2. Blower blades not clearing housing.
3. Loose compressor mounts.
4. Loose compressor belt.
5. Loose air ducts.
6. Lines vibrating.
7. Blower motor defective.
8. Obstructed air flow.
9. Defective compressor.
10. Defective expansion valve.

7. Insufficient Air Flow

1. Defective blower.
2. Defective wiring.
3. Defective battery/low voltage.
4. Defective vehicle charging system (voltage).
5. Clogged ducts.
6. Evaporator icing.
7. Loose duct connections.
8. Dirty evaporator.
9. Closed or blocked air outlet louvers.
10. Plugged filters.

8. No Air Flow

1.
2.
3.
4.
5.
6.

Blower motor not operating

Blown fuse
Broken wiring or bad connection
Fan motor malfunction.
Broken resistor.
Fan motor switch malfunction.

9. Sight Glass Bubbles

1.
2.
3.
4.

Restricted condenser air flow.

Low charge.
Moisture in system (tiny bubbles)
Air in system.

10. Intermittent Cooling

1. Frozen moisture in expansion valve.

11. Short & Rapid Cycling of Compressor

1. Defective thermostatic switch.

2. Low air flow across the evaporator.

12. Engine Overheating

1. Condenser plugged.

13. Compressor Not Turning

1.
2.
3.
4.
5.
6.
7.

TK 456/458

Compressor mechanical malfunction.

Overcharged.
Belt loose.
Inadequate voltage at clutch.
Condenser inoperative.
Faulty clutch coil.
Improper gap between clutch faces.

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#3. PREVENTIVE MAINTENANCE SCHEDULE

NOTE: A larger version of this chart, suitable for copying, is provided on Pg 16-17
**

When inspecting the compressor, run the system for at least five (5) minutes
(40F minimum outside temperature), to circulate oil and lubricant components.
*** To guard against the damaging effects of moisture in your air conditioning
system, check the moisture indicator on the receiver-drier once monthly, as
specified on the Preventive Maintenance Schedule above. Dependent on the
degree of contamination, a color change will be evident in the drier sight glass.
COLOR

MOISTURE CONTENT

ACTION REQUIRED

Blue
Pink

Dry
Wet

None
Replace Drier

**** Fresh and recirculation filters should be inspected and cleaned daily, depending upon operating conditions.

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#3. PREVENTIVE MAINTENANCE SCHEDULE FORM

THIS FORM PROVIDED FOR MAKING COPIES

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Air Conditioner Service

#4. REFRIGERANT - RECOVERING / RECYCLING

DESCRIPTION AND PROPERTIES OF
REFRIGERANTS
Refrigerants are contained in the closed system
of an air conditioner and circulate under pressure,
moving heat energy from the cab to the outside air.
Different refrigerants require different operating pressures, causing the refrigerant to undergo a change
of state.

Reclaim - You reclaim a refrigerant when you send it

to an outside facility which can restore it to a new
product specification. This reprocessing usually
includes both a chemical analysis and distillation
of the recycled refrigerant.
Refer to the section below RECLAIMING THE
REFRIGERANT for a complete description of
the reclaiming process.

CHANGES IN SERVICE PROCEDURES

Since the beginning of 1992, the EPA has required that any refrigerant removed from an A/C
system be recovered and recycled before reuse,
Unlike the purging process which releases ozonedepleting refrigerant into the atmosphere, the
recovery processes allow service personnel to use
the same refrigerant over and over.

Recharging an A/C system requires the following

procedure:
Flush - You flush certain A/C system components
and hoses to remove contaminants within them.
Flushing prepares the A/C system for the new
refrigerant.
Refer to the section below FLUSHING THE A/C
SYSTEM.
Evacuate - You evacuate the A/C system to
remove moisture and air. Refer to the section
below EVACUATING AND CHARGING THE
A/C SYSTEM.
Charge - You charge the A/C system by adding new
refrigerant to the system.

A major difference between purge and recover/

recycle procedures is the refrigerant is contained
in an externally sealed container when undergoing
recovery/recycle procedures in order to ensure environmentally safe processing.
In order to reuse a refrigerant in an A/C system, the
following steps are required:
1. Prepare the station for the recovery process.
2. Recover refrigerant from the A/C system.
3. Recycle the recovered refrigerant.
4. Perform the maintenance or repair the system.
5. Flush the A/C system when necessary.
6. Evacuate the A/C system.
7. Charge the A/C system with recycled refrigerant.
Recycling the refrigerant involves the following
procedure:
Recovery - You recover a refrigerant when you
remove it from an A/C system (in order to repair
or replace a component) and then store, transport, recycle, or reclaim it. This is a closed loop
process. The recovered refrigerant may vary in
quality.
Refer to the section below RECOVERING AND
RECYCLING THE REFRIGERANT for a complete description of the recovery process.
Recycle - You recycle a refrigerant when you remove
contaminants such as moisture, acidity, or particulate matter. Many refrigerants are reusable at
this stage.
Refer to the section below RECOVERING AND
RECYCLING THE REFRIGERANT for a complete description of the recycling process.

RECOVERING AND RECYCLING THE

REFRIGERANT
Recovery / Recycle Station
When troubleshooting indicates that a component
in a closed A/C system be replaced or removed for
service, refrigerant must be removed from the system. A handy, dual purpose station performs both
recovery and recycle procedures allowing service
personnel to follow the new guidelines for handling
used refrigerant. The recovered refrigerant can then
be recycled to reduce contaminants and reused.
Equipment is also available to just remove or extract
the refrigerant. Extraction equipment does not clean
the refrigerant. It is used to recover the refrigerant
from an A/C system prior to servicing.
To accomplish this, the recovery/recycle station
separates the oil from the refrigerant and filters the
refrigerant multiple times to reduce moisture, acidity,
particulate matter found in a used refrigerant.
Mixing refrigerant types
damages equipment. Dedicate a separate recovery /
recycle station to each type of refrigerant processing
to avoid equipment damage.

Convtinued
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#4. REFRIGERANT - RECOVERING / RECYCLING (Contd)

Recycle equipment must meet certain standards as
published by the Society of Automotive Engineers
and carry a UL approved label. The basic principles of operation remain the same for all machines,
even if the details of operation differ somewhat.
Service Note: Keep the collection cylinder in an
upright position for the duration of the recovery/
recycle process to ensure that no liquid is drawn
back into the system.
Draining the Oil From the Previous
Recovery Cycle
In preparation for recovery, do the following:
1. Place the power switch and the controller on the
recovery unit in the OFF position.
2. Plug in the recovery station to the correct power
source.
3. Drain the recovered oil through valve marked OIL
DRAIN on the front of the machine.
4. Place the controller knob in the ON position. The
low pressure gauge will show a rise.
5. Immediately switch to the OFF position and allow
the pressure to stabilize. If the pressure does not
rise to between 5 PSIg and 10 PSIg, switch the
controller ON and OFF again. With practice, this
procedure should become easier.
6. When the pressure reaches 5 to 10 PSIg, open
the OIL DRAIN valve, collect oil in an appropriate
container, and dispose of container as indicated
by local, state, or Federal Regulation. THE OIL
IS NOT REUSABLE DUE TO CONTAMINANTS
ABSORBED DURING ITS PREVIOUS USE.

8. If an abnormal amount of time elapses after

the system reaches 0 PSIg and does not drop
steadily into the vacuum range, close the manifold valves and check the system pressure. If it
rises to 0 PSIg and stops, there is a major leak.
Refer to Topic #2, TROUBLESHOOTING for
troubleshooting leak procedures.
9. Check the system pressure after the recovery
equipment stops. After five minutes, system
pressure should not rise above 0 gauge pressure. If the pressure continues to rise, restart
and begin the recovery sequence again. This
cycle should continue until the system is void of
refrigerant.
10. Check the sight glass oil level to determine the
amount of oil that needs to be replaced.
11. Mark the cylinder with a RECOVERED (red)
magnetic label to reduce the chance of charging
a system with contaminated refrigerant. If possible, keep a record of the amount of refrigerant
recovered.
NOTE: Check the sight glass oil level to determine
the amount lost during recovery. You must
add this amount of oil back into the system.
Performing the Recycling Procedure
The recovered refrigerant contained in the cylinder
must undergo the recycle procedure before it can be
reused. The recycle or clean mode is a continuous
loop design and cleans the refrigerant rapidly. Follow equipment manufacturers instructions for this
procedure.

Performing the Recovery Cycle

You are now ready to recover. Follow these steps:
1. Be sure the equipment you are using is designated for the refrigerant you intend to recover.

Purging Non-Condensable Gases (Air)

During purging and refrigerant recovery, air can be
entrapped in the refrigerant container. Air must not
be put into an A/C system. The result is higher operating pressures and possible system damage.

2. Record the sight glass oil level. Because it has

been drained, it should be zero.
3. Check the cylinder refrigerant level before beginning recovery to make sure you have enough
capacity.
4. Confirm that all shut-off valves are closed before
connecting to the A/C system.
5. Attach the appropriate hoses to the system being
recovered.
6. Start the recovery process by operating the equipment in accordance with the equipment manufacturers instructions.
7. Continue extraction until a vacuum exists in the
A/C system.

A simple check can be performed as follows:

1. Store the recovered refrigerant at constant temperatures above 65 F (18.7 C). The container
should include a pressure gauge reading to 1 psi
increments. The container should not be in direct
sunlight or near a heat source.
2. Use a calibrated thermometer to establish temperature within 4 inches of the container.
3. Compare the pressures for like temperatures in
the table below. If the container pressure is equal
to or less than the pressure shown in the table,
excess air is not present.
4. If container pressure is greater than shown in
the table, connect the container to recovery or

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#4. REFRIGERANT - RECOVERING / RECYCLING (Contd)

Purging Non-Condensable Gases (Air), Contd
recycle equipment with the pressure gauge in
place.
5. Bleed a small amount of vapor from the container
until the pressure is below that shown on the
table, then close the valve.
6. Tank temperature may change during the bleed
off process. Mild shaking will assist in temperature stabilizing, but it is a good idea to let it set
for several hours before again checking pressure
against the table.
7. If the pressure remains above that shown on
the table, excess air or another contaminant (for
example, another refrigerant) is still present. This
material must be recycled or reclaimed.
8. If the pressure is equal to or below that shown on
the table, identify the cylinder as recycled.

FLUSHING THE A/C SYSTEM

Flushing has long been recommended as a means
of removing contaminants or other debris from certain system components.
Using compressed air is not a good method of flushing. Air should never be used in an R-134a system.
Closed loop flushing kits are now available, although
they may not remove all foreign material.
The primary use of a flushing kit is to remove contaminants from the A/C system hoses, evaporator
and condenser. Any other component of an A/C
system should be bench checked or replaced, since
flushing may be ineffective or may damage a component. Flushing is usually performed after the recovery process. We recommend it before you replace
the compressor, or when you find contamination in
other components (receiver-drier, expansion valve,
or connections). Some recover/recycle machines
have optional flush kits. The only proper way to
flush system components is to use refrigerant in a
closed-loop system.

#5. EVACUATING AND CHARGING THE A/C SYSTEM

Evacuate the system once the air conditioner
components are repaired or replacement parts
are secured, and the A/C system is reassembled.
Evacuation removes air and moisture from the system. Then, the A/C system is ready for the charging
process, which adds new refrigerant to the system.
Evacuating the System
Follow this procedure:
1. Tighten all connections and attach a vacuum
pump to the center hose of the gauge set.
2. Start the vacuum pump and open both the hand
valves on the manifold all the way. Run the pump
for five minutes, then close the hand valves and
shut off the pump.
3. Check the gauge readings for five minutes. If
the gauge needles move up, the system is not
sealed. There is a leak. Air and moisture are being sucked into the system by the vacuum.
4. Tighten any loose connections. Restart the
pump, and open the hand valves on the gauges
again. Repeat the vacuum test.
5. Run the vacuum pump for at least an hour to
remove the moisture from the system.
The moisture must turn to gas before the pump can
pull it out. The moisture takes time to boil away, so
that it can be drawn out of the system.

Your vacuum pump can draw most of the air out

pretty quickly. But, a deep vacuum requires more
time; the deeper the vacuum, the longer it takes to
get there. To ensure the least possible amount of
air and moisture in the system, buy a good quality
vacuum pump, take care of it, and use it for at least
an hour.
Lubricants removed during
the recovery process must be replaced with new
lubricants.
Charging the A/C System
NOTE: Use a charging station whenever possible.
When adding a full charge of refrigerant, you can put
it in as a gas or as a liquid. Adding refrigerant as a
liquid is faster, but can damage the compressor if not
done correctly. The procedure you use, and where
you add the refrigerant in the A/C system, makes a
difference. When using refrigerant as a liquid, never
add more than two thirds of system requirements
as a liquid. Finish charging the system using gas.
Always keep the refrigerant containers in an upright
position so that no liquid is drawn into the system,

Continued
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#5. EVACUATING AND CHARGING THE A/C SYSTEM (Contd)

Refer to the CHARGING WITH REFRIGERANT
GAS section below for the procedure for gas
charging. Refer to the CHARGING THE SYSTEM
WITH LIQUID REFRIGERANT section for liquid
charging.
Charging with Refrigerant Gas (On the Low Side)
Perform this procedure to charge with
refrigerant gas:
1. Use a charging meter or station to select the
exact amount of refrigerant required. Never
add more than the amount of refrigerant recommended by the manufacturer (in pounds and
ounces). To measure, use a container and scale,
or charging station.
2. Connect the center service hose from the gauge
set to the refrigerant container dispensing valve.
Purge the hose of any air using refrigerant gas
pressure from the container.
3. Run the engine at 1200 to 1500 RPM, with the
A/C unit on maximum cool.
4, Open the dispensing valve, then the low side
hand valve on the manifold,
Service Note: If there are no manufacturers charging specifications, you can watch the sight glass
first for bubbles, then clearing.
In certain conditions, using R-134a refrigerant,
the sight glass will be cloudy.
5. Check the sight glass when you have added
nearly the specified amount of refrigerant. Keep
adding refrigerant until the sight glass clears or
you have added the specified refrigerant charge.
Use an oil injector to replace oil drained from
the system. Remember, a large leak may have
resulted in nearly all the lubricant being lost.
6. Close the valve on the refrigerant container.
Close the hand valve on the gauge set and check
the gauge readings. The gauges should read in
the normal range.
7. Turn off the engine and A/C system. Check for
leaks. If the system checks out OK, back seat
the service valves. Remove the manifold gauge
set hose fittings from the compressor.

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If Schrader valves are in use, be sure to remove

the manifold hose fitting quickly and carefully,
using a glove or shop towel to protect your hand.
Replace the protective caps on the compressor
service valves.
Charging the System with Liquid Refrigerant
This process is used as a time-saver, but requires
much more care to avoid compressor damage.
Make sure that the A/C
system and the vehicle engine is turned OFF.
1. Check the amount of refrigerant recovered, and
add approximately two thirds of that amount, and
no more than recommended by the manufacturer
(in pounds and ounces).
2. Connect the center service hose from the gauge
set to the refrigerant container dispensing valve.
3. Add refrigerant liquid through the compressor
discharge service valve (high side of the system).
If an accumulator is used, add the liquid refrigerant (and gas during final charging) via a Schrader
valve.
4. Open the refrigerant dispensing valves and hand
valves on the hose and gauge set. Liquid refrigerant flows in the system.
5. When you have added two thirds of the recorded,
actual recovered amount of refrigerant, shut off
the refrigerant supply. If you added liquid refrigerant at the compressor high side service fitting,
there may be liquid in the compressor.
6. Finish charging the system with refrigerant gas
by starting the engine and A/C system, Follow
the procedure for charging with gas as shown in
figure.
RECLAIMING REFRIGERANT
Reclaiming refrigerant reprocesses the material to
virgin purity. For sources of reclaimed refrigerant
or to send refrigerant for reclamation, contact the
EPA, the independent industry organizations, or your
states Department of Ecology.

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