GROUPS 85

AIR-CONDITIONING
 AIR-CONDITIONING
OPERATION AND ADJUSTMENT
85-8-10 EN

06 / 02 / 2003
 INSTRUCTIONS - CONTENTS
1 -MANITOU S.A. AIR CONDITIONING UNIT OPERATING
PRINCIPLE
1.1- GENERAL INFORMATION ON THE MANITOU AIR-CONDITIONING FUNCTION
1.2- THE COMPRESSOR
1.3- THE CONDENSER
1.4- THE DEHYDRATING FILTER
1.5- THE EXPANSION VALVE
1.6- THE EVAPORATOR
1.7- SAFETY PRESSURE SENSITIVE SWITCHES
1.8- THE THERMOSTAT
1.9- THE HOSES

2 -INSTRUCTIONS FOR STARTING UP THE MANITOU

PRODUCTION UNIT
2.1- CHECK BEFORE LOADING
2.2- CHARACTERISTICS OF COOLANT R134a
2.3- SAFETY MEASURES FOR HANDLING COOLANT R134a
2.4- COOLING LOAD
2.5- CHECKING SETTINGS

3- MANITOU DEALER STARTING UP INSTRUCTIONS

3.1- CONTROL BEFORE USE
3.2- REGULATION CONTROL
3.3- FORMATION CLIENT

4- CUSTOMER USE MANUAL

4.1- PRESENTING THE MANITOU AIR CONDITIONER
4.2- FUNCTION OF THE MANITOU AIR CONDITIONER
4.3- DESCRIPTION OF THE CLIMATE CONTROL
4.4- HEATING FUNCTION
4.5- AIR CONDITIONING FUNCTION
4.6- DEMISTING FUNCTION

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 INSTRUCTIONS - CONTENTS
5- CUSTOMER MAINTENANCE MANUAL
5.1- MAINTENANCE
5.2- PRECAUTIONS

6- AFTER SALES SERVICE PRODUCT SHEETS

6.1- THE COMPRESSOR
6.2- THE CONDENSER
6.3- FILTER DRIER
6.4- THE EXPANSION VALVE
6.5- THE EVAPORATOR
6.6- THE PRESSURE SWITCH
6.7- THE THERMOSTAT
6.8- THE HOSES LINE

7- FLOWCHART

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1 -MANITOU S.A. AIR CONDITIONING UNIT OPERATING
PRINCIPLE
1.1- GENERAL INFORMATION ON THE MANITOU AIR-CONDITIONING FUNCTION

1 Compressor
2 Condenser
3 Dehydrating
filter
4 Expansion valve
5 Evaporator
6 Blower system

The MANITOU air-conditioning unit is based on the coolant's ability to absorb heat in considerable
quantities when it is subjected to physical changes on being transformed from a liquid state to a gas.

Operating cycle (see diagram) :

The gas coolant, at low temperature and pressure, is sucked in by the compressor which is driven by the
vehicle engine.

The compressor expulses the coolant, still as a gas, at high pressure and temperature, and it goes into the
condenser in this state.
Inside the condenser, the fluid undergoes a physical transformation from a gas to a liquid state, giving off
heat in the process. The warm air which passes through the condenser is evacuated by a dynamic effect
produced by the engine cooling fans. The liquid coolant leaving the condenser crosses the dehumidifying
filter which removes the humidity and solid impurities, then goes on to the expansion valve.
When the liquid is vaporized in the expansion valve, the pressure falls and lowers the temperature in the
evaporator. During its travel through the evaporator, the coolant is physically transformed from a liquid to
a gaseous state and then sent to the compressor. The air which flows over the cold surfaces of the
evaporator is cooled in turn, lowering the temperature in the cab.

This air, which is circulated by an electric blower system is dehumidified because the vapour in the air, is
condensed following contact with the cold walls of the evaporator. This condensation water is collected in
a drainage trap and evacuated outside the machine.

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Electric skeleton diagram

TC Control panel CONNECTORS

BP Bouton poussoir C1 5-way, black AMP MIC IV-TV - Ref. 144 518-2
L Tongue C2 6.35 x 0.8 mm female connector
S Blower C3 90" 6.35 x 0.8 mm female connector
T Thermostat C4 Deutsch Ref. HD10-6-12P
P1 Low pressure gauge C5 1-way RKG female connector Ref. 920 510
P2 High pressure gauge C6 Deutsch Ref. HD16-6-12S-B010
R Relay C7 2-way female DT - Ref. 552 459
EC Compressor clutch C8 2-way male DT - Ref. 552 457
F1 7.5 A fuse C9 2-way male DT - Ref. 552 457
F2 30 A fuse C10 2-way female DT - Ref. 552 459

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 1.2- THE COMPRESSOR

The compressor's job is to pump the coolant leaving the evaporator, in gas phase, at low temperature and
pressure, and compress it into the condensor at high pressure and temperature.

The compressor mechanisms are lubricated with a special oil which is included in the compressor during
manufacture. Part of this lubricant is circulated through the installation by the coolant.
The compressor is driven by the engine via a belt and activated by engaging an electromagnetic clutch.

10 cm3 extra oil PAG SP20 is added to the original quantity to compensate for the length of
the hoses.

A fluorotracer additive, miscible in the oil lubricant, is used to detect leaks in the system
during after sales service operations and this is in the compressor casing.

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 1.3- THE CONDENSER

The condenser is a heat exchanger which condenses the coolant. This arrives in the form of a gas at high
pressure and temperature, and the condenser liquefies it through the fall in temperature caused by the air
passing throught it. The condenser is fitted with easily identified input and output connections. The fluid
arriving as a gas goes in through the large connection and leaves by the small one in liquid form. The
condenser must be supplied with air by the radiator cooling fan which pulses air through it to condense
the fluid.

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 1.4- THE DEHYDRATING FILTER

The dehydrating filter is the only part of the installation which must be changed periodically, at least
every 2 years.
The dehydrating filter has 6 very important functions. Remember that it is between the condenser and the
expansion valve and is therefore crossed by fluid in liquid form.

1st FUNCTION :
It provides a reserve of fluid in liquid form.

2nd FUNCTION :
Known as the damping function or "buffer" function. Indeed, any compressed and liquefied gas has on
its liquid surface a gaseous cap which ensures the fluid storage pressure. This naturally compressible gas
cap absorbs the shocks generated by the sudden engagement of the compressor, particularly at high
engine speeds, thus protecting the installation, above all the expansion valve.

3rd FUNCTION :
The microfiltering provided by synthetic components designed to stop any solid impurities which could
have got into the installation during assembly or later operations.

4th FUNCTION :
Dehydration. The filter is crossed by coolant in liquid form. The outer humidity or that produced by the
installation penetrates the compressor tubes and ring seal. This humidity can produce hydrochloric and
hydrofluoric acid on contact with the coolant. When the humidity is in contact with oil and metals, it can
promote corrosion which can damage the compressor, condenser and evaporator. Humidity can also
produce so much ice that the expansion valve is blocked, making the installation inefficient. To avoid
these problems, humidity absorbing material has been fitted inside the filter through which the refrigerant
flows, to absorb it to saturation point. These materials are silica gel, activated aluminium and the
molecule trap.

5th FUNCTION :
Decantation. The direction of flow of the fluid is always shown clearly on the filter body because the
inner plunger tube stops 20 mm from the bottom of the filter, creating a decantation zone allowing heavy
foreign bodies (e.g. welding debris) left over from manufacture to be deposited.

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 1.5- THE EXPANSION VALVE

The expansion valve's function is to reduce the pressure of the coolant at the evaporator input to a preset
value, so that on leaving the evaporator, the fluid is in a fully gaseous state before being sucked into the
compressor.
While circulating through the evaporator, the fluid removes heat from the atmosphere which is being
conditioned, i.e. cooled, by passing it over the evaporator louvres.

The expansion valve therefore plays a very important role in the installation because it controls the fluid
flow rate to achieve maximum cooling power from the installation, and it is fitted at the entrance to the
evaporator.
The expansion valve has 3 functions. It acts as a :

1st FUNCTION :
Doser. A calibrated hole inside the body of the expansion valve, by throttling, creates a difference in
pressure between the fluid entering in liquid form and the mixed liquid + gas leaving. This throttling also
promotes vaporization of the fluid.

2nd FUNCTION :
Modulator. Inside the expansion valve a special, thermostatically controlled component, controls the
coolant flow rate between the maximum open and maximum closed positions. In this way, the correct
quantity is guaranteed and evaporation is complete.

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3rd FUNCTION :
Controller. Its modulating function is controlled by a thermostatic expansion valve which must act
rapidly in situations where the value given by the probe changes.

In this expansion valve, there are 2 flows of coolant, one on entering and one on leaving the evaporator.
To set the correct flow rate at the fluid input on the thermostatically controlled expansion valve, a probe
measures the temperature of the fluid leaving the evaporator. At the end of the probe, a diaphragm is in
contact with a volume of highly temperature-sensitive gas.

This volume rises or falls according to the variation in temperature of the coolant leaving the evaporator
and exerts more or less pressure on the diaphragm which is in contact with a modulating component.

For example, when the probe registers an increase in temperature on leaving the evaporator (overheating)
the gas in the probe volume dilates. It exerts a pressure called VP (volume pressure) on the diaphragm,
itself being in contact with the modulator which is held in place by the spring exerting a pressure called
SP (spring pressure).

The balance point, i.e. the point of closure is VP=SP.

SP is set when the expansion valve is manufactured, so as to obtain the desired temperature and only VP
varies with the temperature of the fluid leaving the evaporator ; when VP is greater than SP the valve will
be open and when VP is less than SP the valve will be closed, for a temperature variation of 2 to 3
degrees, depending on the manufacturer.

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 1.6- THE EVAPORATOR

The evaporator is the last of the main components of the MANITOU air-conditioning system. It is a heat
exchanger like the condenser but it changes the state of the fluid in the opposite direction. In the
condenser the fluid is liquefied, in the evaporator, on the other hand it is 100% gasified. The coolant
leaving the expansion valve is a mixture of gas and liquid at low pressure and temperature ; in the
evaporator it absorbs heat from the air, to provide the cooling effect required. The evaporator therefore
cools the air in the cab. The fluid must evaporate completely because the compressor would be
automatically damaged by fluid in liquid form, even in small quantities.
The cooling capacity of the evaporator lead to dehumidification of the air, providing optimal conditions in
the cab. Indeed, unlike the condenser where the hottest fluid is inside, condensation in the evaporator
takes place on the outside. The humidity in the air blown through by the fans is deposited on the louvres
and emerges dry into the cab. The water which runs off the evaporator louvres is collected in a container
and evacuated under the machine cab. A release valve ensures that the unit is sealed against the
penetration of water from the outside.

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 1.7- SAFETY PRESSURE SENSITIVE SWITCHES :

Protection is needed to avoid damaging components in the event of abnormal operation.

The protection systems are controlled by electrical transducers sensitive to pressure values, called
pressure sensitive switches. These will continually monitor the installation operations so that it does not
exceed the authorized pressures, either minimal or maximum.
These pressure sensitive switches act on the power supply to the compressor's electrical clutch. When
given values are exceeded, the clutch power is cut and the air-conditioning system stops running.

LOW PRESSURE SENSITIVE SWITCH :

When there is a considerable lack of coolant in the system or there is a blockage in the circuit, the
normally closed pressure sensitive switch records minimum pressure and opens the compressor power
supply circuit.

HIGH PRESSURE SENSITIVE SWITCH :

Excessive fluid or pressure can cause damage because the pressure is always directly linked to the
temperature of the fluid. To avoid this situation, the high pressure sensitive switch which is normally
closed registers maximum pressure and opens the power circuit to the clutch beyond a pressure threshold
generally set to 24 bars.

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 1.8- THE THERMOSTAT

It is used to switch on and then obtain the desired temperature in the cab (exactly like a domestic
refrigerator), managing the installation operating time. Indeed, when the coolant is circulating, the
temperature in the evaporator is almost constant, so that the temperature in the cab changes according to
the quantity of fresh air blown into it on the one hand and the calories recorded in it on the other. The
thermostat acts on the compressor power circuit.
The thermostat is a control device which is sensitive to the temparature of the evaporator. The system is
the same as that of the expansion valve. A volume of gas enclosed in a small bladder communicating with
a capillary tube acting as a probe and inserted between the evaporator louvres, checks temperature
variations and compares them with required values.
The bladder, which records variations in gas pressure in the probe due to temperature variations in the
evaporator, acts directly on a rocker which opens or closes the compressor clutch power circuit according
to the mechanical resistance of the adjustment spring.
The more compressed the spring, the more "cold" must be produced to keep the bladder traction greater
than that of the spring.
In other words, the more compressed the spring, the longer the compressor clutch is engaged and the
more fresh air is pulsed into the cab.
With its capillary probe, the thermostat is not only a device for switching on and adjusting the system but
also a safety device. It prevents the condensation water deposited on the evaporator louvres from freezing,
which would slow the flow rate of air through the evaporator. The position of the probe in the evaporator
must be carefully checked, particularly the length of probe inserted into the louvres, to ensure a correct
operating range.
The range of settings of the thermostat for the evaporator louvre temperatures is between +2 and +16 °C.

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 1.9- THE HOSES

The hoses connect the air-conditioning system components between compressor and condenser,
dehydrating filter and evaporator expansion valve and evaporator and compressor. The different materials
and textile reinforcements used in the hose composition protects them against external attack and
guarantees that loading is maintained in the system.

SITUATION HOSE INNER EXTERNAL CONNECTION

MODULE DIAMETER DIAMETER THREAD

Between Module 8 10 mm 20.5 mm _

compressor and 16 per inch
condenser
Between Module 6 8 mm 18 mm 5/8
dehydrating filter 18 per inch
and expansion
valve
Between Module 10 13 mm 23.5 mm 7/8
evaporator and 18 per inch
compressor

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2 -INSTRUCTIONS FOR STARTING UP THE MANITOU
PRODUCTION UNIT

2.1- CHECK BEFORE LOADING

Tightening the coolant connections according to the torque table.

CONNECTION MODULE TORQUE Nm

COMPRESSOR DISCHARGE 8 _ ‘’ 15.4 Nm
COMPRESSOR SUCTION 10 7/8 ‘’ 24.4 Nm
CONDENSER INPUT 8 _ ‘’ 15.4 Nm
DEHYDRATOR OUTPUT 6 5/8 ‘’ 15.4 Nm
EVAPORATOR INPUT 6 5/8 ‘’ 15.4 Nm
EVAPORATOR OUTPUT 10 7/8 ‘’ 24.4 Nm

2.2- CHARACTERISTICS OF COOLANT R134a

WARNING : The MANITOU air-conditioning system uses

coolant R134a only (Ref. MANITOU 4500421 – 14.5 Kg bottle)
and PAG SP20 oil code : 430A08 only.

Characteristics of coolant R134a

* Trade name : Fluorocarbon 134a
* Use : Coolant
* Chemical characteristics : Tetrafluoroethane 134a
* Chemical formula : CH2FCF3
* Physical state : Liquefied gas
* Colour : Colourless
* Odour : Slightly of ether
* Boiling point (s/1bar) : -26.5 °C
* Melting point : -101°C
* Density at 25°C : 1.21kg/l
* Critical pressure : 40.56 bar
* Critical temperature : +100.6 °C
* Weight as gas : 5 times heavier than air
* 1 kg in liquid state at 1 bar : 200 l in gaseous state
* Thermal decomposition : from 110°C
* Hazardous decomposition products : hydrogen halides and traces of carbonyl halides
* Dangerous reactions : With alkaline metals and alkaline-earths of
powdered metal salts : Al-Zn-Be...
* Flash point : No flash point
* Self-ignition temperature : Over 750°C
* Limit of explosivity : Below none, above none
* Ozone destruction potential : Zero (none).

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 2.3- SAFETY MEASURES FOR HANDLING COOLANT R134a

Personal protective measures :

For the eyes : complete protective goggles
For the hands : rubber gloves.

Storage :
To be stored hermetically sealed in a dry, cool, well-ventilated place.

Handling :
Only in well-ventilated areas.

Waste disposal :
Can be reused after reconditioning by a collection and recycling centre.

Action to take in the event of accident :

After accidental spillage, overflow, escape of gas, the liquid evaporates.
In the event of fire there is no contraindication with respect to the means of extinction.
Be careful however, the fire may cause hydrogen halide to be given off ; autonomous respiratory
apparatus should be worn.

First aid :
On inhalation, place the victim in the fresh air. Give oxygen or artificial respiration as necessary (do not
give medication) and consult a doctor.
On contact with the eyes, rinse well in running water for at least 15 minutes and consult a doctor .
On contact with the skin, wash immediately in running water and remove contaminated clothing.

2.4- COOLING LOAD

THE QUANTITY OF COOLANT TO LOAD FOR MANITOU AIR-CONDITIONING

EQUIPMENT IS :

FORKLIFT TRUCK QUANTITY OF COOLANT

MLA 628 S2 ------------------------------------------------------ 1000 G ±50G
MT 845/940/1233/1240/1330/1337/1637 LINE 2---------- 950 G ±25G
MT 845/940/1332/1637 H LINE 1--------------------------- 950 G ±25G
MLT 629/633/730 LINE A / MT732/932 LINE A------ 800 G ±25G
MT/MLT 523 LINE A----------------------------------------- 800 G ±25G
MT/MLT 526 LINE A----------------------------------------- 800 G ±25G
MLT 733/740 / MT 1033 HLT--------------------------------- 800 G ±25G
M 26-2 /M 30-2 / M40-4 / M50-4 / ---------------------------- 850 G ±50G
MC 30 / 40 / 50 / 60 / 70
MA 470 ------------------------------------------------------------ 900 G
MSI 20 / 25 / 30 D ----------------------------------------------- 880 G

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 2.5- CHECKING SETTINGS

During this check the machine engine is running.

HEATING CHECK

The controls must be set as follows :

D : Control with light indicator off
E : Set to maximum temperature
F : Set to the left limit of travel
G : Set to 3

After inserting the thermometer in one of the two air diffusers, note the temperature.

OUTSIDE TEMPERATURE AT TIME TO REACH

TEMPERATURE DIFFUSER OUTPUT TEMPERATURE
-10°C +40°C 30 min.
-5°C +40°C 25 min.
0°C +40°C 20 min.
+10°C +40°C 10 min.
+15°C +40°C 15 min.
+20°C +40°C 5 min.
+25°C +45°C 15 min.
+30°C +50°C 10 min.

AIR-CONDITIONING CHECK

The controls must be set as follows :

D : Control with light indicator on
E : Set to the left limit of travel
F : Set to maximum temperature
G : Set to 3

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After inserting the thermometer in one of the two air diffusers, note the temperature.

OUTSIDE TEMPERATURE AT TIME TO REACH

TEMPERATURE DIFFUSER OUTPUT TEMPERATURE
+20°C +7°C 5 min.
+25°C +10°C 10 min.
+30°C +12°C 15 min.

Compressor regulation must be switched off before reading a temperature lower than +1°C .

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3- MANITOU DEALER STARTING UP INSTRUCTIONS
3.1- CONTROL BEFORE USE (GB)

Check that the air inlet are not obturated either by frost, snow or leaves.

Check that at least the cabin air louvers are opened to avoid the evaporator to freeze.

Check the tension of the compressor driving belt :

too high tension : early wearing of the compressor bearings
too low tension : early wearing of the belt

THE MANITOU AIR CONDITIONING SYSTEM WORKS ONLY IF THE VEHICLE IS

RUNNING.
WHILE USING YOUR AIR CONDITIONING SYSTEM, IMPERATIVELY WORK WITH
CLOSED DOORS AND WINDOWS.

3.2- REGULATION CONTROL (GB)

During this control, the machine engine is running.

HEATER CONTROL

Controls must be set as follows :

D : control switch with led turned off

E : on max. temperature
F : on left position
G : on position n°3

After having positioned the thermometer in one of the two air inlet distributors, start collecting
temperatures.

EXTERNAL OUTLET TEMPERATURE TEMPS DE MONTEE EN

TEMPERATURES TEMPERATURE
-10°C +40°C 30 MN
-5°C +40°C 25 MN
0°C +40°C 20 MN
+10°C +40°C 10 MN
+15°C +40°C 15 MN
+20°C +40°C 5 MN
+25°C +45°C 15 MN
+30°C +50°C 10 MN

AIR CONDITIONING CONTROL

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Controls must be set as follows :

D : Control switch with led turned on

E : On left position
F : On max. temperature
G : On position n°3

After having positioned the thermometer in one of the two air inlet distributors, start collecting
temperatures.

EXTERNAL OUTLET DISTRIBUTOR TEMPS DE MONTEE EN

TEMPERATURE TEMPERATURE TEMPERATURE
+20°C +7°C 5 MN
+25°C +10°C 10 MN
+30°C +12°C 15 MN

The compressor regulation must happened before reading a inferior temperature of + 1°C.

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4- CUSTOMER USE MANUAL

4.1- PRESENTING THE MANITOU AIR CONDITIONER (GB)

4.1.1- The Manitou air conditioning system allows the driver to control the temperature in
the cabin without causing extreme temperatures.
It ultimately improves the working conditions in the cabin, reducing tiredness and any
discomfort and increasing the level of concentration even during the hottest hours. It
improves comfort and security behind the wheel.

4.1.2- It dehumidifies the air in the cabin, keeping the windows dry, allowing good
visibility and ultimately reducing any accidents.

4.1.3- The air is filtered by various ways, firstly through the foam. The air is also passed
through the evaporator coil past the moist surfaces on the blades, which destroys any build
up of dust, pollen, etc. Naturally, it's a plus if the driver is allergic.

4.1.4- The difference in pressure levels inside and outside the cabin helps preventing dust
setting inside. This pressure can be increased by increasing the ventilation speed.

4.1.5- The unit can be operated with the doors and windows closed, clearly protecting the
driver from any risk of cold or rheumatism as well as easing noise levels inside the cabin.

4.2- FUNCTION OF THE MANITOU AIR CONDITIONER (GB)

The principle of how the conditioner works is based on physical laws what govern the evaporation and
condensation of a fluid.

Function cycle (see drawing) :

The compressor that is engaged through the drive belt and electromagnetic clutch, raises the refrigerant to
the pressure at which the corresponding temperature is above that outside : therefore the refrigerant in the
condenser condenses and the heat flows out from the radiator fan.

The refrigerant then passes through the receiver drier that maintains any solid impurities and traces of
humidity.
At this point, the expansion valve reduces the fluid pressure to below outside the cabin. In the following
phase of evaporation (from liquid to gas the heat is absorbed in the cabin, blown by the electric fan
through the evaporator.

The air withheld is blown back into the cabin, fresh and deshumidificated. Any humidity in the
evaporator blades is the released into the drain tubes.

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 4.3- DESCRIPTION OF THE CLIMATE CONTROL (GB)

IMPORTANT :
THE MANITOU AIR CONDITIONER ONLY OPERATES WITH THE VEHICLE ENGINE
RUNNING.
ALSO MAKE SURE ALL WINDOWS AND DOORS ARE CLOSED.

D : Control with warning light connects and disconnects the air conditioner and, if control G is in
position 1, 2 or 3
E : Control regulating the temperature of the heater
F : Control regulating the temperature of the air conditioning
G : Airflow adjuster and fan speed control. In position ‘0’ the air conditioning system is off

OBSERVATIONS :

1 It is possible that water loss could occur under the vehicle, from the drain pan. This can happen in
very hot and humid conditions.

2 Please insure that the air intake of the air conditioner MANITOU is free from ice, snow and
leaves.

3 One of the louvers in the cabin must be open when the system is in operation in order to prevent
the evaporator freezing over.

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 4.4- HEATING FUNCTION (GB)

The control described are adjusted as follows :

D : Control with warning light disconnects

E : On the desired temperature
F : All the way to the left
G :On the desired position 1,2 or 3

4.5- AIR CONDITIONING FUNCTION (GB)

The control described are adjusted as follows :

D : Control with warning light connect
E : All the way to the left
F : On the desired temperature
G :On the desired position 1,2 or 3

4.6- DEMISTING FUNCTION (GB)

The control described are adjusted as follows :

D : Control with warning light connect
E : On the desired temperature
F : On the desired temperature
G :On the desired position 1,2 or 3

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5- CUSTOMER MAINTENANCE MANUAL

5.1- MAINTENANCE (GB)

Every 50 hours :
Check the condenser coil (clean it if necessary).
Check the air filter cleanness (clean it if necessary).

In winter :
To ensure maximum efficiency of the air conditioner, allow it to run once a week, even for a short while.
This will lubricate the O rings.

During cold weather :

Allow the vehicle itself to run a few minutes before starting the air conditioner so as to allow the liquid
refrigerant situated in the lower part of the compressor to evaporate under the engine heat. A liquid
refrigerant could damage the compressor.

Every 200 hours :

Check the belt tension
Higher tension : Wears the compressor bearings.
Lower tension : Wears the belt.
Replace the air filter cabin.

Every 2 years : (Manitou dealer’s process)

Clean the condenser and evaporator coils
Clean the drain pan and the check valve.
Refrigerant recovery for replacing the filter drier.
Refrigerant charge and check the thermostatic control and pressure switches

Don't forget to replace de gasket cover, after opening the evaporator unit.

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 5.2- PRECAUTIONS (GB)

5.2.1- Once the A/C system is slowing down, it is losing its efficiency. Contact an
approved MANITOU dealer if this is the case with your air conditioner.

CAUTION : Never repair your air conditioner by yourself. An approved MANITOU dealer will
have the technical know-how, all the necessary tools and the spare parts.

5.2.2- Do not open the A/C system, as it will cause loss of refrigerant.
The refrigerant in the A/C system can carry some risks. The R-134a refrigerant is
colourless, odourless and denser than the air.

5.2.3- Never loosen the compressor-draining plug, as it will cause loss of the refrigerant.
Always check the oil level in the compressor when the A/C system is empty

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6- AFTER SALES SERVICE PRODUCT SHEETS

6.1- THE COMPRESSOR (GB)

ATTENTION : PRIOR USING YOUR COMPRESSOR, PLEASE READ WHAT FOLLOWS

CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME PRECAUTIONS
:

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.1.1- RECEIVER DRIER

The receiver drier has to be replaced each time the compressor is replaced. It must not be let at the open
air in order to protect it from the humidity contamination.

6.1.2- UNSETTING OF THE COMPRESSOR

Remove the refrigerant from the air conditioning system thanks to recuperation, filling, recycling and
flushing station.
The collected oil quantity must be stored (see compressor oil level).
Disconnect the battery ground cabinle and the clutch coil.
Disconnect the compressor pipes
Loosen the holding bolts. Hold the compressor while running this operation. Take the compressor out
being aware not to spill its oil. This compressor oil will later help to determine the required quantity for
the new compressor (see compressor oil level).

6.1.3- CLEANESS OF THE SYSTEM

The compressor breakdowns are mostly due to the refrigerant contamination. This contamination is
provoked by various material introductions such as metallic particles, hydrocarbons sediments, humidity,
acids or decayed dehydrates.

Check the pipes and the expansion valve to see if there are no bits left. Should there be some tracks of
contamination on the parts, in the oil or if the previous compressor is replaced because of an internal
breakdown, take the required measures to protect the new compressor from contamination by cleaning the
air conditioning system and being aware of not introducing new contaminants in the system.

ATTENTION : ALL COMPRESSOR OR SYSTEM THAT WILL HAVE BEEN FLUSHED AND
CLEANED WITH ANOTHER REFRIGERANT THAN THE SYSTEM ONE, WILL NOT BE
CONCERNED BY THE CONTRACTUAL WARRANTY.

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 6.1.4- NEW COMPRESSOR OIL LEVEL
Your compressor is consigned with a load of 200cc. Before setting the new compressor, flush in a
graduated container, the old compressor oil, then flush the new compressor oil in another clean container.
Pour in the new compressor the same collected oil quantity as the one collected in the old compressor.
You must add new oil for each replaced or cleaned component, as explained here below :

NEVER REUSE OLD OIL BUT ONLY NEW OIL OF TYPE SP 20

Evaporator : 30cc Expansion valve : 30cc

Condenser : 30cc Drier : 30cc

After complete flushing of the system, the compressor oil load is of 160cc.

6.1.5- COMPRESSOR SETTING

Set the compressor on its support
Set the hoses by installing new O'ring gaskets. Lubricate the O'ring gaskets with the system oil before
mounting them.
Set clutch belt. Set the belt at the required tension.
Electrically link the clutch
Flush the system during at least 30 minutes
Connect again the battery ground wire
Fill the system in according to the instructions given
Proceed to a leak checking

6.1.6- CHECK IN LIST

To set the compressor and properly maintain and fix the air conditioning system, one has to plan the
following operations :

Refrigerant recovery and recycling

Cleaning of the system
Replacement of the expansion valve
Replacement of the new filter drier
System vacuum during 30 minutes
Setting the new O'ring gaskets
Checking of the system waterproofness
Refrigerant charging
Compressor regulation control.

6.1.7- WARRANTY REGISTRATION

The return of the warranty certificate is COMPULSORY. Its non-return leads to the loss of the warranty.

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 6.2- THE CONDENSER (GB)

ATTENTION : PRIOR USING YOUR CONDENSER, PLEASE READ WHAT FOLLOWS

CAREFULLY : THE REPLACEMENT OF A CONDENSER IMPLIES SOME PRECAUTIONS :

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
CONDENSER. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.2.1- RECEIVER DRIER

The receiver drier has to be replaced each time the compressor is changed. It must not be let at the open
air in order to protect it from the humidity contamination.

6.2.2- PRECAUTIONS

Avoid any risks of contaminants introduction or foreign bodies in the condenser or inside the air
conditioning system.
Prior to any operations implying the circuit opening, the area located around the hoses must be cleaned
carefully with the cleaning spray. All the components that have to be reused or set reinstalled must be
cleaned with this cleaning spray and dried with a fluffyless cloth.

6.2.3- POSITIONING

Therefore the risk of mistake is low, make sure the inlet is higher than the outlet, bearing in mind that the
inlet fitting is always bigger than the outlet fitting. What's more, one needs to respect scrupulously the
mounting dimensions and the distance between the condenser and the radiator.

The installation has been sharply studied so that the condenser setting does not modify the terminal
breaking point of the engine work.

Any "funny" setting would lead to bad condenser turn over and in some cases, to the early destruction of
the machine engine.
After the setting has been carried out, proceed to a system leak checking.

6.2.4- LUBRIFICATION

For parts which have to be lubricated before their installation, such as O'ring's gaskets, use the oil
recommended for the system refrigerant.

Further to the condenser replacement, you must add 30cc of new oil.

NEVER REUSE OLD OIL BUT ONLY NEW OIL OF TYPE SP 20

After complete flushing of the system, the compressor oil load is of 160cc.

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 6.3- FILTER DRIER (GB)

ATTENTION : PRIOR USING YOUR FILTER DRIER, PLEASE READ WHAT FOLLOWS
CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME PRECAUTIONS
:

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.3.1- RECEIVER DRIER

The receiver drier has to be replaced each time the compressor is replaced. It must not be let at the open
air in order to protect it from the humidity contamination.

6.3.2- PRECAUTIONS
The tank drier filter is an important component for the protection of the circuit against corrosion. It must
not be left at the open air for its absorbs humidity quickly. Therefore, it has a very low capacity and it can
lead to the dehydrating agent saturation prior to its use.
That is why it is compulsory to show a new drier during operations implying the air conditioning circuit
opening, such as the replacement of a component.
If the dehydrating agent is saturated, the refrigerant is going to be full of humidity. Apart from the fact the
circuit frigorific capacity will be reduced, this will have two bad consequences for the system :
some acids are going to be chemically created and will slow the liquid circulation by decomposing the
materials,
the humidity contained in the refrigerant can frost around the expansion valve and have the system
know a breakdown, leading to a loss of aspiration pressure or a high evaporation, that can lead to the
compressor breaking because of a lack of lubrication.
The drier must always be upright. It cannot be repaired but has to be replaced.

6.3.3- REPLACEMENT OF A DRIER

Remove the new receiver drier buttons only when you are ready to install it on the machine. Avoid all
risks of contaminants or foreign bodies introduction in the drier or inside the air conditioning
system.Before opening the circuit, the area located around the hoses fittings must be cleaned carefully
with the cleaning spray.
All the components that have to be reused or reinstalled must be cleaned with this cleaning spray and
dried with a fluffyless cloth.
After the setting has been carried out, proceed to a system leak checking.

6.3.4- LUBRICATION
For parts which have to be lubricated before their installation, such as O'rings gaskets, use the oil
recommended for the system refrigerant.
Further to the receiver drier replacement, you must add 30cc of new oil.

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 6.4- THE EXPANSION VALVE (GB)

ATTENTION : PRIOR USING YOUR EXPANSION VALVE, PLEASE READ WHAT

FOLLOWS CAREFULLY : THE REPLACEMENT OF AN EXPANSION VALVE IMPLIES
SOME PRECAUTIONS :

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
EXPANSION VALVE. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL
LEAD THE WARRANTY TO BE VOID.

6.4.1- RECEIVER DRIER

The drier filter has to be replaced each time the expansion valve is replaced. It must not be let at the open
air in order to protect it from the humidity contamination.

6.4.2- EXPANSION VALVE INSTALLATION

Avoid any risks of contaminants or foreign bodies introduction inside the air conditioning system.
Prior to any operations implying the circuit opening, the area located around the hoses must be cleaned
carefully with the cleaning spray. All the components that have to be reused or set reinstalled must be
cleaned with this cleaning spray and dried with a fluffyless cloth.
The expansion valve internal pressure monobloc technology, is specifically calibrated to be used on
MANITOU machines. It can in no other case be replaced by a standard component.
The expansion valve must be installed with the thermostatic head upright. It is thermically isolated to
work with the best turn over possible. Its interchangeability is quite easy and requires no particular tools.

6.4.3- LUBRICATION
For parts such as O'rings gaskets, which have to be lubricated before their installation, use the oil
recommended for the system refrigerant.
Further to the expansion valve replacement, you must add 30cc of new oil.

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 6.5- THE EVAPORATOR (GB)

ATTENTION : PRIOR USING YOUR EVAPORATOR, PLEASE READ WHAT FOLLOWS

CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME PRECAUTIONS
:

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.5.1- RECEIVER DRIER

The drier filter has to be replaced each time the compressor is replaced. It must not be let at the open air
in order to protect it from the humidity contamination.

6.5.2- PRECAUTIONS
Avoid any risks of contaminants introduction or foreign bodies in the evaporator or inside the air
conditioning system.
Prior to any operations implying the circuit opening, the area located around the hoses must be cleaned
carefully with the cleaning spray. All the components that have to be reused or set reinstalled must be
cleaned with this cleaning spray and dried with a fluffyless cloth.

6.5.3- POSITIONING
The evaporator inlet corresponds to the 4 capillary tubes pipes and the outlet to a unique large diameter
pipe. The expansion valve fittings being the same and therefore the risk of mistake is low, make sure the
inlet is not linked to the outlet of the expansion valve, know the large diameter hose corresponds to the
smallest expansion valve pipe and that the biggest corresponds to the outlet fitting.
What's more, one has to scrupulously respect the mounting dimensions and the distance between the
condenser and the radiator.
The installation has been sharply studied so that the condenser setting does not modify the thermical
breaking point of the engine work.
Any "funny" setting would lead to bad condenser turn over and in some cases, to the early destruction of
the machine engine.
After the setting has been carried out, proceed to a system leak checking.

6.5.4- LUBRICATION

For parts which have to be lubricated before their installation, such as O'rings gaskets, use the oil
recommended for the system refrigerant.
Further to the evaporator replacement, you must add 30cc of new oil.

30 / 32
 6.6- THE PRESSURE SWITCH (GB)

ATTENTION : PRIOR USING YOUR PRESSURE SWITCH, PLEASE READ WHAT

FOLLOWS CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME
PRECAUTIONS :

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.6.1- IDENTIFICATION
Pressure switches are security components that when detecting a variation of low or high pressure, allow
to avoid the compressor to seize up or the installation to break.
They cut the electrical installation of the compressor clutch. They reactivate the clutch for values slightly
moved in order to be sure that what caused its start, disappears.

6.6.2- REPLACEMENT
The minimum pressure or low-pressure switch is located on the low-pressure circuit in the evaporator
unit. The maximum pressure or high-pressure switch is placed on the high-pressure gas line of the
receiver drier, after the condenser.
To remove it is easy for they are screwed on a fitting made of a valve allowing their removal without
flushing the system.

Before installation, make sure the pressure switch corresponds to the low or high-pressure circuit. The
low-pressure switch is marked with a white point and the high-pressure switch is market with a red point.
The screw fitting must be cleaned with the cleaning spray. Dry with a fluffyless cloth.

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 6.7- THE THERMOSTAT (GB)

ATTENTION : PRIOR USING YOUR THERMOSTAT, PLEASE READ WHAT FOLLOWS

CAREFULLY : THE REPLACEMENT OF A COMPRESSOR IMPLIES SOME PRECAUTIONS
:

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.7.1- IDENTIFICATION
The thermostat is a component that enables to run the compressor and set temperatures but also assures
the air conditioning system security. It is made to avoid water condensation to frost and to limit the
airflow through the evaporator fins. The thermostat tuning range concerns evaporator outlet temperatures
included between +2°C and +16°C.

6.7.2- REPLACEMENT
The thermostat is located in the evaporator unit. Its removal is easy and does require the refrigerant
flushing.
Scrupulously respect the position of the thermostatic probe in the evaporator and introduce only 50mm,
that shall guaranty a proper use.
Beware not to break the thermostatic probe while moving the thermostat.
Proceed to the cabinle setting so as to guarantee the control handle run.

6.8- THE HOSES LINE (GB)

ATTENTION : PRIOR USING YOUR HOSES LINE, PLEASE READ WHAT FOLLOWS
CAREFULLY : THE REPLACEMENT OF A HOSES LINE IMPLIES SOME PRECAUTIONS :

SHOULD YOU NOT COMPLY WITH THE HERE BELOW INSTRUCTIONS, BE AWARE
THAT YOU TAKE THE RISK TO BOTH INJURE YOURSELF BADLY AND SPOIL THE
COMPRESSOR. THE NON RESPECT OF THE PRESENT USE INSTRUCTIONS WILL LEAD
THE WARRANTY TO BE VOID.

6.8.1- RECEIVER DRIER

The receiver drier has to be replaced each time one of the hoses line is changed. It must not be let at the
open air in order to protect it from the humidity contamination.

6.8.2- REPLACEMENT
The charge connectors of the hoses lines are not similar on purpose, to avoid any installation mistake.
Avoid any risks of contaminants introduction or foreign bodies in the hoses line or inside the air
conditioning system.
Prior to any operations implying the circuit opening, the area located around the hoses fittings must be
cleaned carefully with the cleaning spray. All the components that have to be reused or set reinstalled
must be cleaned with this cleaning spray and dried with a fluffyless cloth.

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 1 VACUUM

Vacuumizing the circuit

Min. time : 20 minutes

Check vacuum seal

Min. pressure : - 800 mbar

Time : 15 minutes

Constant pressure Slight loss of pressure Steep pressure drop

Result : -500 mbar Result: 0 mbar

2 LOAD 2 LOAD 4. CHECK USING NITROGEN

3 CHECK USING ELECTRONIC DETECTOR

 2 LOAD

Verification of the quantity to use

HP loading
Liquid phase

Possible LP complement
Gas phase

HP reading: (Condensation temp.) LP reading: (Evaporation temp.)

Max.: Ext. temp. + 16°c Mini : 0.2 bar

3 CHECK USING ELECTRONIC DETECTOR 3 CHECK USING ELECTRONIC DETECTOR

3 CHECK USING ELECTRONIC DETECTOR

2.CHARGE

Switch on A/C max. Aerosol leak confirmation

CHECK CONNECTIONS Leak detected Leak not detected

REPAIR 6. CHECK USING TRACER

1. VACUUM

2. LOAD
4 CHECK USING NITROGEN

Pressurization using nitrogen

Maxi : 10.5 bar

CHECK CONNECTIONS

Aerosol leak confirmation

Leak detected Leak not detected

REPAIR 3.CHECK USING ELECTRONIC DETECTOR

1. VACUUM

2.LOAD