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Curtis 1ACUNIT-G2 Service And Repair Manual

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Service and Repair Manual
Product Specifications
25" x 36" x 7"
Weight: 53 lbs.
Air Flow: 306 CFM
Cooling Capacity: 12,000 BTU / hr
Voltage: 12 VDC
Amp Draw: 62
Refrigerant: R134a, 2.1 lbs. charge
This service manual is intended for use by only properly certified and trained technicians. Refrigeration systems
must only be serviced by individuals meeting all local, state and federal requirements
Air Conditioner
p/n: 1ACUNIT-G2
Approximate Installation Time *
Experienced Dealer Technician – 1 Hour
Average Dealer Technician – 1.5 Hours
Do-It-Yourself – 2 Hours
1 OF 114
Rev. A
p/n: RM-1ACUNIT-G2

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Summary of Contents for Curtis 1ACUNIT-G2

  • Page 1 1 OF 114 Air Conditioner p/n: 1ACUNIT-G2 Service and Repair Manual Product Specifications Approximate Installation Time * 25” x 36” x 7” Experienced Dealer Technician – 1 Hour Weight: 53 lbs. Average Dealer Technician – 1.5 Hours Air Flow: 306 CFM Do-It-Yourself –...

  • Page 2: Table Of Contents

    2 of 114 TABLE OF CONTENTS Section Page HOW TO USE THIS MANUAL…………………………………………..….3 WARNINGS……….………………………………………………….…..4-6 TECHNICIAN REQUIREMENTS…………………………………………...7 TECHNICAL OVERVIEW……………….…………......…..8 SPECIFICATIONS……………...…………………………………..….…..9 FEATURES & OPERATION ………………………………………..…..10 CARE AND MAINTENANCE………..……………………………..….…..10 REFRIGERANT FLOW DIAGRAM…………………………………….….11 BASIC TROUBLESHOOTING…………………...………………………..12 COVER & SEAL…….…………….………………………...……….….13-14 CONDESNER FAN……..……..…………………….………………..15-18 CONDENSER FAN BRACKET…………………......……..19 REFRIGERANT EVACUATION, VACCUM & CHARGE……….…..20-21 CONDENSER…….………………………….……….…………………..22 PRESSURE SWITCH…….……………………..…..……………...…23-24 RECEIVER/DRIER……...…………………...………………………...25-28...

  • Page 3: How To Use This Manual

    3 of 114 1. HOW TO USE THIS MANUAL Included in the first 11 pages of this manual are the operator instructions and service items. Starting on page 12 are technical service and repair procedures. All repair work instructions in this manual are to be done with the A/C unit removed from the vehicle.

  • Page 4: Warnings

    4 of 114 2. WARNINGS Curtis air conditioners feature an assembly of parts designed for your vehicle which require adjustment and alignment of components to accommodate vehicle variations. For accurate installation, proper operation, and years of satisfaction, please read and understand the Service &...
  • Page 5 5 of 114 2. WARNINGS The air conditioner should arrive laying down flat. Do not receive the air conditioner from the shipping company if the air conditioner is standing up on end as Take care to protect the switches and louvers at the bottom of shown.
  • Page 6 6 of 114 2. WARNINGS 30° MAX 30° MAX Do not tip the air conditioner more than 30° in the direction Do not tip the air conditioner more than 30° in the shown above during installation and service. direction shown above during installation and service. Doing so may drain the oil from the compressor.

  • Page 7: Technician Requirements

    7 of 114 3. TECHNICIAN REQUIREMENTS PLEASE FAMILIARIZE YOURSELF WITH THE FOLLOWING TECHNICIAN REQUIRED QUALIFICATION DIAGRAMS AND DESCRIPTIONS. DIAGRAMS ARE LOCATED ON EACH PAGE AT THE TOP LEFT HAND CORNER AS A REFERENCE TO THE SKILL LEVEL AND QUALIFICATION REQUIRED FOR A TECHNICIAN TO SAFELY AND LEGALLY PERFORM THE TASK ON THAT PAGE.

  • Page 8: Technical Overview

    8 of 114 4. TECHNICAL OVERVIEW The Curtis A/C unit (p/n: 1ACUNITG-2) is an all electric driven system that has a 12 volt electric scroll compressor and utilizes R134a refrigerant. The system is assembled from standard automotive grade components, with a Tube and Fin Evaporator and a Bar &...

  • Page 9: Specifications

    9 of 114 5. SPECIFICATIONS WEIGHT: 53LBS (A/C UNIT WITH COVER) HEIGHT ABOVE CAB: 3-5/8” INTRUSION INTO CAB: 2” (OPERATOR AREA); 3” (LOWEST POINT) SYSTEM : 12V DC RUNNING AMPERAGE DRAW: 62 AMP (HIGH BLOWER SPEED) HOUSING: POWDER COATED, CORROSION RESISTANT ALUMINUM ALLOY COVER: POWDER COATED, CORROSION RESISTANT ALUMINUM ALLOY EVAPORATOR CORE: AUTOMOTIVE GRADE, CORROSION RESISTANT ALUMINUM ALLOY, TUBE AND FIN CONDENSER CORE: POWDER COATED, CORROSION RESISTANT ALUMINUM ALLOY, BAR AND PLATE...

  • Page 10: Features & Operation

    10 of 114 6. FEATURES & OPERATION Turn the 4-POSITION FAN CONTROL SWITCH to activate the blower. The air conditioner may be used as a fan in this manner. Toggle the A/C ON-OFF SWITCH to activate the compressor for chilled air. The blower must be turned on before the compressor will activate.

  • Page 11: Refrigerant Flow Diagram

    11 of 114 8. REFRIGERANT FLOW DIAGRAM...

  • Page 12: Basic Troubleshooting

    • If Curtis electric heater will be installed along with an A/C, be aware that when switching quickly between heat and A/C with the rocker switch on the heater mount, it is possible to run both at the same time. It is recommended to shut one accessory off before switching to the other to prevent additional drain on the battery.

  • Page 13: Cover & Seal

    13 of 114 10. COVER & SEAL Tools 3/8” Open/ Box end Wrench or Socket #3 Phillips Head Screwdriver Removal Remove 10 outer cover bolts. Remove center cover screw and sealing washer. Remove cap by lifting directly up. (note sealing cork tape may stick to underside of cap, this is normal and can be overcome with steady pressure taking care not to bend cover) Installation Coat threads of fasteners with anti-seize compound.
  • Page 14 14 of 114 10. COVER & SEAL Tools Metal Shears (Tin Snips) Removal Start at end of seal (per illustration) and peel away from housing. Installation Start new seal installation in location per illustration, pressing seal into place by hand on edge of housing taking care to not damage seal.

  • Page 15: Condesner Fan

    15 of 114 11. CONDENSER FAN Tools #2 Phillips Screwdriver CONDENSER HOSES ARE FLEXIBLE AND DO NOT HAVE TO BE REMOVED TO FACILITATE ACCESS TO THE CONDENSER FAN AND BRACKETS. GENTLY ROTATE THE CONDENSER IN THE DIRECTION DEPICTED, ALLOWING ACCESS TO THE CONDENSER FAN AND BRACKETS Removal Remove 4 plastic condenser-to-fan mounting screws.
  • Page 16 16 of 114 11. CONDENSER FAN Tools Snips CONDENSER HOSES ARE FLEXIBLE AND DO NOT HAVE TO BE REMOVED TO FACILITATE ACCESS TO THE CONDENSER FAN AND BRACKETS. GENTLY ROTATE THE CONDENSER IN THE DIRECTION DEPICTED ALLOWING ACCESS TO THE CONDENSER FAN AND BRACKETS Removal Disconnect blue and black wires at 2-pin connector.
  • Page 17 17 of 114 11. CONDENSER FAN Tools Snips CONDENSER HOSES ARE FLEXIBLE AND DO NOT HAVE TO BE REMOVED TO FACILITATE ACCESS TO THE CONDENSER FAN AND BRACKETS. GENTLY ROTATE THE CONDENSER IN THE DIRECTION DEPICTED AL- LOWING ACCESS TO THE CONDENSER FAN AND BRACKETS Installation Install wires through slot in case and rubber grommet being careful not to damage wires.
  • Page 18 18 of 114 11. CONDENSER-FAN Tools #2 Phillips Screwdriver CONDENSER HOSES ARE FLEXIBLE AND DO NOT HAVE TO BE REMOVED TO FACILITATE ACCESS TO THE CONDENSER FAN AND BRACKETS. GENTLY ROTATE THE CONDENSER IN THE DIRECTION DEPICTED ALLOWING ACCESS TO THE CONDENSER FAN AND BRACKETS Installation Rotate condenser into position being careful not to damage fins.

  • Page 19: Condenser Fan Bracket

    19 of 114 12. CONDENSER FAN BRACKET Tools 3/8” Open/ Box End Wrench RUBBER WASHERS ARE USED TO REDUCE VIBRATION OF FAN AGAINST CASE. THEY ARE LOCATED BE- TWEEN BRACKET AND CASE, NOT UNDER FLANGE BOLTS. Removal Remove bolts retaining bracket(s) to case. Remove bracket(s) from case being certain to remove rubber washers beneath bracket.

  • Page 20: Refrigerant Evacuation, Vaccum & Charge

    20 of 114 13. REFRIGERANT SYSTEM EVACUATION, VACUUM & CHARGE Tools EPA Certified R134a Recovery, Recycle, Recharge refrigerant handling equipment. VERIFY HOSE FITTINGS HAVE BEEN TIGHTENED AT ALL CIRCLED LOCATIONS PRIOR TO CHARGING SYSTEM. HIGH PRESSURE PORT LOW PRESSURE PORT 2 FITTINGS...
  • Page 21 21 of 114 13. REFRIGERANT SYSTEM EVACUATION, VACUUM & CHARGE Tools EPA Certified R134a Recovery, Recycle, Recharge refrigerant handling equipment. System evacuation and charging must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.

  • Page 22: Condenser

    22 of 114 14. CONDENSER Tools 7/8” Open/ Box End Wrench 3/4” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.

  • Page 23: Pressure Switch

    23 of 114 15. PRESSURE SWITCH Tools 1-1/16” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.
  • Page 24 24 of 114 15. PRESSURE SWITCH Tools 1-1/16” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.

  • Page 25: Receiver/Drier

    25 of 114 16. RECEIVER/DRIER Tools 3/8” Open/ Box End Wrench 7/16” Open/ Box End Wrench 5/8” Open/ Box End Wrench 3/4” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant.
  • Page 26 26 of 114 16. RECEIVER-DRIER Tools 3/8” Open/ Box End Wrench 7/16” Open/ Box End Wrench 5/8” Open/ Box End Wrench 3/4” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant.
  • Page 27 27 of 114 16. RECEIVER/DRIER Tools 3/8” Open/ Box End Wrench 7/16” Open/ Box End Wrench 5/8” Open/ Box End Wrench 3/4” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant.
  • Page 28 28 of 114 16. RECEIVER/DRIER Tools 3/8” Open/ Box End Wrench 7/16” Open/ Box End Wrench 5/8” Open/ Box End Wrench 3/4” Open/ Box End Wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant.

  • Page 29: Compressor

    29 of 114 17 COMPRESSOR Tools EPA Certified R134a Recovery, Recycle, Recharge refrigerant handling equipment. System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.
  • Page 30 30 of 114 17 COMPRESSOR STEP 1 Tools Snips Cork tape is extremely tacky, use of gloves when removing is recommended. Removal Remove cork tape from area shown in red. QTY 17 7/8” Part #9SV-9AC-00022 Cork tape...
  • Page 31 31 of 114 17 COMPRESSOR STEP 2 Tools 1/2” Open/Box End Wrench Ensure battery is disconnected if performing this operation with unit on vehicle. Removal Remove compressor power wire from solenoid. POWER WIRE FROM COMPRESSOR SOLENOID POWER WIRE ATTACHMENT LUG 5/16-18”...
  • Page 32 32 of 114 17 COMPRESSOR STEP 3 Tools 5/32” Allen socket/ wrench 7/16” Open/ box end wrench Removal Remove compressor ground wire from ground bolt on case at solenoid mount. GROUND WIRE FROM COMPRESSOR QTY 1 Part # 70-16-0010 1/4-20 x 1” Button head cap screw QTY 1...
  • Page 33 33 of 114 17 COMPRESSOR STEP 4 Removal Disconnect compressor control wires at gray 6-pin connector. GRAY 6-PIN COMPRESSOR CONTROL WIRE CONNECTOR...
  • Page 34 34 of 114 17 COMPRESSOR STEP 5 Tools 1” Open/box end Wrench Cork tape is very tacky, use of gloves when removing is recommended. Removal Remove cork tape from fitting. Remove #10 inlet fitting from compressor adapter at inlet port. #10 COMPRESSOR INLET FITTING...
  • Page 35 35 of 114 17 COMPRESSOR STEP 6 Tools 7/8” Open/ box end wrench Note routing of hoses before removal, routing may be different than picture below. Removal Remove #8 compressor outlet fitting from compressor adapter at outlet port. #8 COMPRESSOR OUTLET FITTING...
  • Page 36 36 of 114 17 COMPRESSOR STEP 7 Tools 3/16” Allen wrench Removal Remove 2 bolts retaining compressor to case and mounting brackets from side of unit. Remove two rubber washers located between compressor mounting lugs and case. Remove Compressor from unit. QTY 2 Part # 71-39-0064 3/8x .813x .093”...
  • Page 37 37 of 114 17 COMPRESSOR STEP 8 Tools 3/16” Allen wrench Removal Remove 2 compressor mounting bracket bolts from underside of case. Remove compressor mounting bracket. Remove two rubber washers located under compressor mounting bracket. QTY 2 Part # 71-39-0064 3/8 X .813 x .093 Rubber washer QTY 1...
  • Page 38 38 of 114 17 COMPRESSOR STEP 9 Tools 4MM Allen wrench Removal Remove #8 outlet port adapter from compressor. QTY 1 Part # 9SV-9AC-00006 Compressor Compressor serial number QTY 1 Part # 9SV-9AC-00024 Compressor outlet port adapter QTY 1 Part # 70-10-0355 M6x1 X 35 Button head cap screw...
  • Page 39 39 of 114 17 COMPRESSOR STEP 10 Tools 4MM Allen wrench Removal Remove #10 inlet port adapter from compressor. Seal compressor fitting and hose ends if system is to be left apart for more than 2 minutes. QTY 1 Part # 9SV-9AC-00025 Low pressure compressor fitting QTY 1...
  • Page 40 40 of 114 17 COMPRESSOR STEP 11 Tools 4MM Allen wrench Install new O-ring. Use caution not to damage O-ring during installation. Installation Ensure fitting and port is clean, install new O-ring on fitting and coat with ZEROL ESTER 68SL oil. Install #10 inlet port adapter on compressor.
  • Page 41 41 of 114 17 COMPRESSOR STEP 12 Tools 4MM Allen wrench Install new O-ring. Use caution not to damage O-ring during installation. Installation Ensure fitting and port are clean, install new O-ring on fitting, and coat with ZEROL ESTER 68SL oil. Install #8 outlet port adapter on compressor.
  • Page 42 42 of 114 17 COMPRESSOR STEP 13 Tools 3/16” Allen wrench Verify that rubber washers are in place between case and compressor mounting bracket. Install Install two rubber washers over bracket mounting holes in case. Ensure alignment using a light amount of grease to hold washers in place.
  • Page 43 43 of 114 17 COMPRESSOR STEP 14 Tools 3/16” Allen wrench Verify that rubber washers are in place between case and compressor mounting lugs. Installation Install compressor into case between compressor mounting bracket and wall of case. Install 2 rubber washers between compressor mounting lugs and case wall. Install 2 bolts thru side of case, compressor mounting lugs, and into threads in compressor mounting brackets from side of unit.
  • Page 44 44 of 114 17 COMPRESSOR Step 15 Tools 3/16” Allen wrench Installation Tighten 2 compressor mounting bracket screws. QTY 2 Part # 70-15-0238 5/16-18 x .3/4” flanged button head screw...
  • Page 45 45 of 114 17 COMPRESSOR Step 16 Tools 3/16” Allen wrench Installation Tighten 2 compressor mounting screws. QTY 2 Part # 70-10-0351 5/16-18x 4-1/2” button head cap screw...
  • Page 46 46 of 114 17 COMPRESSOR Step 17 Tools 7/8” Open/ box end wrench Route hose per position noted in step 6. Installation Ensure fitting and port are clean, install new O-ring on fitting, and coat with ZEROL ESTER 68SL oil. Install #8 compressor outlet fitting onto compressor adapter at outlet port, and tighten.
  • Page 47 47 of 114 17 COMPRESSOR Step 18 Tools 1” Open/box end Wrench Install new O-ring. Installation Ensure fitting and port are clean, install new O-ring on fitting, and coat with ZEROL ESTER 68SL oil. Install #10 inlet fitting onto compressor adapter at inlet port. #10 COMPRESSOR INLET FITTING...
  • Page 48 48 of 114 17 COMPRESSOR Step 19 Note location of connector, route wires away from sharp edges. Installation Connect compressor control wires at gray 6-pin connector. GRAY 6-PIN COMPRESSOR CONTROL WIRE CONNECTOR...
  • Page 49 49 of 114 17 COMPRESSOR Step 20 Tools 5/32” Allen wrench 7/16” Open/ box end wrench Route wires away from sharp edges, ensure wire terminals are routed properly, and only make contact with termination point fastener. Ensure all ground wires are in place with compressor ground wire on ground bolt.
  • Page 50 50 of 114 17 COMPRESSOR Step 21 Tools 1/2” Open/Box End Wrench Route wires away from sharp edges, ensure wire terminals are routed properly, and only make contact with termination point fastener. Installation Install compressor power wire onto solenoid. POWER WIRE FROM COMPRESSOR SOLENOID POWER WIRE ATTACHMENT LUG 5/16-18”...
  • Page 51 51 of 114 17 COMPRESSOR Step 22 Tools Snips Cork tape is very tacky, use of gloves when removing is recommended. Installation Install cork tape over area shown in red, being certain to cover all exposed metal of fitting. QTY 17 7/8” Part #9SV-9AC-00022 Cork tape...
  • Page 52 52 of 114 17 COMPRESSOR Step 23 Tools R134a Recovery machine System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.

  • Page 53: Evaporator Box

    53 of 114 18 EVAPORATOR BOX Tools R134a Recovery machine System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements. Removal System must be evacuated and have condenser removed.
  • Page 54 54 of 114 18 EVAPORATOR BOX Step 1 Tools 3/8” Open/ box end wrench Phillips screw driver Removal Remove 2 controller mounting bolts, nuts, and controller (if installed). QTY 2 Part # 70-31-0101 #8-32 Pan head machine screw QTY 2 Part # 72-04-0100 #8-32 K-locking hex nut...
  • Page 55 55 of 114 18 EVAPORATOR BOX Step 2 Tools 5/16” Allen wrench 7/16” open/ box end wrench Removal Remove 4 button head solenoid mounting bolts. Leave solenoid in place with wires attached. Note location of ground wires being removed with upper longer solenoid mounting bolt. QTY 3 Part # 70-15-0327 1/4-20 X .625”...
  • Page 56 56 of 114 18 EVAPORATOR BOX Step 3 Tools Phillips screw driver Only relays 1 and 4 are required to be removed, other relays shown removed for clarity. Removal Remove relays 1 and 4 from relay bank (see illustration for relay positions). Remove 2 relay mounting screws, allowing relay bank to fall away from case.
  • Page 57 57 of 114 18 EVAPORATOR BOX Step 4 Tools 3/8” Open/ box end wrench Removal Remove 5 hex head bolts, fender washers, and rubber sealing washers from condenser fan tray. SOME PARTS SHOWN TRANSPARENT QTY 5 Part # 70-05-0367 1/4-20 X 3/4” Flange bolt QTY 5 Part # 71-02-0128...
  • Page 58 58 of 114 18 EVAPORATOR BOX Step 5 Tools Phillips screw driver 3/8” Open/ box end wrench Removal Remove 7 upper case half retaining screws and nuts from perimeter of sealed case area. Remove upper case. SHEET METAL SHOWN TRANSPARENT QTY 6 Part # 72-04-0009 #10-32 K-locking...
  • Page 59 59 of 114 18 EVAPORATOR BOX Step 6 Tools Phillips screwdriver 3/8 Open/ box end wrench When removing elbows from drain tubes, care must be taken not to disturb fittings in evaporator case. Do not rotate or pull against these fittings, as damage may very likely occur to plastic threads and/or sealant, resulting in a leak when re-assembled.
  • Page 60 60 of 114 18 EVAPORATOR BOX Step 7 Tools Phillips screw driver Removal Remove 8 Phillips pan head screws attaching vents to case and air ducts. Remove 4 vents from case/ air ducts. Use caution to ensure clip nuts remain in place and are prevented from falling into air ducts.
  • Page 61 61 of 114 18 EVAPORATOR BOX Step 8 Tools 3/16” Allen wrench System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements.
  • Page 62 62 of 114 18 EVAPORATOR BOX Step 9 Tools 3/4” Open/ box end wrench 7/8” Open/ box end wrench Be careful to remove O-rings when removing lines. Oil may be present in lines, prevent oil from draining. Cover all openings if system is to be left disassembled for more that 2 minutes to prevent moisture and contaminants from entering system.
  • Page 63 63 of 114 18 EVAPORATOR BOX Step 10 System evacuation must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements. Removal Remove evaporator and duct assembly from case, being careful not to damage duct at sealing points or drain hose fittings.
  • Page 64 64 of 114 18 EVAPORATOR BOX Step 11 Tools R134a Recovery machine SEE ALL NOTES BELOW Removal If replacing the Evaporator Box Assembly (p/n: 8SV-304-00008), no further disassembly of the box is required. If replacing the Evaporator Core (p/n: 9SV-9AC-00002), it is contained in the Evaporator Box Assembly with the Blower.
  • Page 65 65 of 114 18 EVAPORATOR BOX Step 12 Inspect all joints and fittings to ensure sealant is in place, fittings are not damaged, and are water tight. Be aware that if the drain tube fitting on the long hose side leaks (located beneath the condenser pan when assembled), disassembly of the upper case is required to access.
  • Page 66 66 of 114 18 EVAPORATOR BOX Step 13 Tools 3/4”” Open/ box end wrench 7/8” Open/ box end wrench Confirm Cap/plugs are in place. These prevent water from draining into cabin area of vehicle. Installation Place new O-ring onto lower #6 Evaporator Control Valve to drier line, lubricate and install line. Place new O-ring onto upper Evaporator Control Valve to compressor #10 line, lubricate and install line.
  • Page 67 67 of 114 18 EVAPORATOR BOX Step 14 Tools 3/16” Allen wrench Inspect all joints and fittings to ensure sealant is in place, fittings are not damaged and are water tight. Be aware that If the drain tube fitting on the long hose side leaks (located beneath the condenser pan when assembled), disassembly of the upper case is required to access.
  • Page 68 68 of 114 18 EVAPORATOR BOX Step 15 Tools Phillips screw driver To ease assembly, it is recommended to start all (8) screws prior to tightening them. Caution should be used not to over-tighten screws and damage plastic vents. Installation Place 4 vents into case/ air ducts, confirming clip nuts are in place on air ducts.
  • Page 69 69 of 114 18 EVAPORATOR BOX Step 16 Tools 3/8 Open/ box end wrench Phillips screwdriver When installing elbows into drain tubes care must be taken not to disturb fittings in evaporator case. Do not rotate or pull against these fittings, as damage may very likely occur to plastic threads and/or sealant resulting in a leak when re-assembled.
  • Page 70 70 of 114 18 EVAPEORATOR BOX Step 17 Tools #2 Phillips screw driver 3/8” Open/ box end wrench Installation Position upper case over lower case. Install 7 upper case retaining screws from the outside and nuts on the inside around perimeter of sealed case area.
  • Page 71 71 of 114 18 EVAPORATOR BOX Step 18 Tools 3/8” Open/ box end wrench Install Install 5 hex head bolts, fender washers, and rubber sealing washers onto condenser fan tray thru to lower case and tighten. Tighten 7 upper case screws left loose in previous step. SOME PARTS SHOWN TRANSPARENT QTY 5 Part # 70-05-0367...
  • Page 72 72 of 114 18 EVAPORATOR BOX Step 19 Tools #2 Phillips screw driver Only relays 1 and 4 are required to be removed, other relays shown removed for clarity Installation Install 2 relay mounting screws into relay bank, being careful not to pinch wires. Re-install relays 1 and 4 into relay bank (see illustration for relay positions).
  • Page 73 73 of 114 18 EVAPORATOR BOX Step 20 Tools 3/16” Allen wrench 7/16” open/ box end wrench Be certain all ground terminals are in place against bare metal solenoid mounting base to assure proper grounding installation Position solenoid over mounting holes and install 3 short Allen head solenoid mounting bolts from outside of case with nuts on inside of case.
  • Page 74 74 of 114 18 EVAPORATOR BOX Step 21 Tools #2 Phillips screw driver 5/16” Open/ box end wrench Installation Install 2 controller mounting bolts and nuts (with controller, if applicable). QTY 2 Part # 70-31-0101 #8-32 Pan head machine screw QTY 2 Part # 72-04-0100 #8-32 K-locking...
  • Page 75 75 of 114 18 EVAPORATOR BOX Step 22 System evacuation and charging must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements. Installation If repair is complete, install Condenser and charge system per sections 12 &...

  • Page 76: Evaporator Core

    76 of 114 19 EVAPORATOR CORE System evacuation and charging must only be performed by an EPA Part 609 certified technician, using EPA certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements. Removal The evaporator core is contained in the Evaporator Box which, must be removed from the A/C case prior to disassembly.
  • Page 77 77 of 114 19 EVAPORATOR CORE Step 1 Cork tape is very tacky, use of gloves when removing is recommended Removal With Evaporator Box removed: Remove sealing tape from top and driver’s side of assembly. REMOVE SEALING TAPE...
  • Page 78 78 of 114 19 EVAPORATOR CORE Step 2 Cork tape is very tacky, use of gloves when removing is recommended. Removal Remove sealing tape from passenger side and bottom of assembly. REMOVE SEALING TAPE...
  • Page 79 79 of 114 19 EVAPORATOR CORE Step 3 Cork tape is very tacky, use of gloves when removing is recommended. Removal Remove sealing cork tape from passenger and driver’s side of assembly. REMOVE CORK TAPE...
  • Page 80 80 of 114 19 EVAPORATOR CORE Step 4 Tools #1 Flat blade screw driver #3 Phillips screw driver Cork tape is very tacky, use of gloves when removing is recommended. Removal Remove 1 screw and 3 plastic rivets retaining duct to evaporator box. QTY 3 Part # 73-12-0002 5/16 X .787”...
  • Page 81 81 of 114 19 EVAPORATOR CORE Step 5 Tools #1 flat blade screwdriver needle nose pliers Use screwdriver to gently pry terminal back from pin. Use needle nose pliers to remove, do not pull on wire. Removal Remove 2 thermistor wires from thermostat by pulling push-on connectors from their pins. REMOVE PUSH-ON CONNECTORS...
  • Page 82 82 of 114 19 EVAPORATOR CORE Step 6 Tools #2 Phillips screw driver Care should be taken not to damage fins on core. Bending fins will result in airflow reduction which can cause a reduction in performance of the A/C system. Removal Remove 10 self-tapping screws, separate evaporator box halves, and remove evaporator core from box.
  • Page 83 83 of 114 19 EVAPORATOR CORE Step 7 Tools Two 3/4” Open End Wrenches Care should be taken not to damage fins on core. Bending fins will result in airflow reduction, which can cause a reduction in performance of the AC system. Removal Slide foam sealing ring back to expose fittings (remove cork tape as needed) Remove Evaporator Control Valve being careful not to bend pipes or damage core.
  • Page 84 84 of 114 19 EVAPORATOR CORE Step 8 Tools Hook pick Needle nose pliers Care should be taken not to damage fins on core. Bending fins will result in airflow reduction which can cause a reduction in performance of the AC system. Clips are pushed thru foam, located between core fins and fit over the tubes to retain condensation collection foam to core.
  • Page 85 85 of 114 19 EVAPORATOR CORE Step 9 DO NOT ATTEMPT TO REPAIR EVAPORATOR CORE. ONLY REPLACE WITH THE SAME PART NUMBER CORE AS ORIGIONALY INSTALLED TO ENSURE SAFE AND PROPER SYSTEM PERFOMRANCE. Installation If core is damaged or leaking, replace with a new core part number 9SV-9AC-00002. Remove protective caps &...
  • Page 86 86 of 114 19 EVAPORATOR CORE Step 10 Tools Hook pick Needle nose pliers Care should be taken not to damage fins on core. Bending fins will result in airflow reduction which can cause a reduction in performance of the AC system. Clips are pushed thru foam, located between core fins and fit over the tubes to retain condensation collection foam to core.
  • Page 87 87 of 114 19 EVAPORATOR CORE Step 11 Tools Two 3/4” Open End Wrenches Install new O-rings onto fittings and lubricate with ZEROL ESTER 68SL refrigerant oil prior to assembling. Care should be taken not to damage fins on core. Bending fins will result in airflow reduction which can cause a reduction in performance of the AC system Installation Install new O-rings onto fittings of evaporator core and lubricate with ZEROL ESTER 68SL...
  • Page 88 88 of 114 19 EVAPORATOR CORE Step 12 Tools #2 Phillips screw driver Care should be taken not to damage fins on core. Bending fins will result in airflow reduction which can cause a reduction in performance of the AC system. Installation Install Thermistor and wire assembly into core in same position as noted during disassembly.
  • Page 89 89 of 114 19 EVAPORATOR CORE Step 13 Tools Needle nose pliers Installation Install 2 thermistor wires onto thermostat by pushing connectors onto their respective pins INSTALL PUSH-ON CONNECTOR WITH WHITE WIRE ONTO PIN 3 INSTALL PUSH-ON CONNECTOR WITH BROWN WIRE ONTO PIN 2...
  • Page 90 90 of 114 19 EVAPORATOR CORE Step 14 Ensure plugs are tight in tubes, use sealant if needed to ensure plugs are water tight. Installation Ensure 2 drain tube plugs are in place on unused fittings of evaporator box QTY 2 Part # 9SV-74-12-0008 Sealing plugs...
  • Page 91 91 of 114 19 EVAPORATOR CORE Step 15 Tools #3 Phillips screwdriver Installation Install 1 screw and 3 plastic rivets retaining duct to evaporator box. GREASE SCREW TO SIMPLIFY INSTALLATION QTY 3 Part # 73-12-0002 5/16 X .787” Plastic Tuflok rivet QTY 1 Part # 70-31-0075 M6x1 X 12 Pan head...
  • Page 92 92 of 114 19 EVAPORATOR CORE Step 16 Tools Scissors Cork tape is very tacky, use of gloves when removing is recommended. Installation Install sealing cork tape over gaps at seams between duct and case. QTY 5” Part # 9SV-9AC-00022 Cork tape...
  • Page 93 93 of 114 19 EVAPORATOR CORE Step 17 Tools Scissors Cork tape is very tacky, use of gloves when removing is recommended. installation Install sealing tape over seams. QTY 12” Part # 9TPE-03 sealing tape...
  • Page 94 94 of 114 19 EVAPORATOR CORE Step 18 Tools Scissors Cork tape is very tacky, use of gloves when removing is recommended. Installation Install sealing tape over seams. QTY 5” Part # 9TPE-03 Sealing tape DO NOT COVER HOLE...
  • Page 95 95 of 114 19 EVAPORATOR CORE Step 19 System evacuation and charging must only be performed by an EPA Part 609 certified technician, using EPA Certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements. Installation Re-assemble Evaporator box into unit, per Evaporator Box instructions.

  • Page 96: Thermostat

    96 of 114 20 THERMOSTAT Operation The thermostat is an electronic switching unit that turns off the compressor should the core temperature reach 40 degrees F to prevent freezing of condensation and thus preventing air flow. The thermostat is preset at the factory and requires no adjustments. Should the thermostat fail, only replace with an exact fit component to ensure proper system performance.
  • Page 97 97 of 114 20 THERMOSTAT Tools Needle nose pliers Flat blade screwdriver Use screw driver to gently pry terminal back from pin. Use needle nose pliers to remove, do not pull on wire. Removal Remove 2 thermistor wires from thermostat by pulling connectors from their respective pins. Use screwdriver to pry connectors back, then needle nose pliers to remove.

  • Page 98: Expansion Control Valve

    98 of 114 21 EXPANSION CONTROL VALVE (ECV) Operation The Expansion Control Valve, or ECV, or Expansion Valve, regulates refrigerant flowing into the evaporator core via an orifice and thermostatically controlled needle valve. The ECV is sized to the system’s requirements, and is a very integral part of system refrigerant charge amount and performance.
  • Page 99 99 of 114 21 EXPANSION CONTROL VALVE (ECV) Step 1 Cork tape is very tacky, use of gloves when removing is recommended. Removal Evacuate System per section 13 in this manual. Remove sealing tape from Inlet line (from drier) and outlet line (to compressor) fittings. Remove sealing tape and gasket (if equipped) from fittings attaching ECV valve to core.
  • Page 100 100 of 114 21 EXPANSION CONTROL VALVE (ECV) Step 2 Tools 3/4” Open/ box end wrench 7/8” Open/ box end wrench Remove both the outlet and inlet hose fittings from valve. #6 inlet hose #10 outlet hose...
  • Page 101 101 of 114 21 EXPANSION CONTROL VALVE (ECV) Step 3 Tools 3/4” Open End Wrench 8” Adjustable wrench Install new O-rings onto fittings and lubricate with ZEROL ESTER 68SL refrigerant oil prior to assembling. Care should be taken not to damage fins on core. Bending fins will result in airflow reduction, which can cause a reduction in performance of the AC system.
  • Page 102 102 of 114 21 EXPANSION CONTROL VALVE (ECV) Step 4 Install new O-rings onto fittings and lubricate with ZEROL ESTER 68SL refrigerant oil prior to assembling. Care should be taken not to damage fins on core. Bending fins will result in airflow reduction which can cause a reduction in performance of the AC system.
  • Page 103 103 of 114 21 EXPANSION CONTROL VALVE (ECV) Step 5 Tools 3/4” Open End Wrench 8” Adjustable wrench Install new O-rings onto fittings and lubricate with ZEROL ESTER 68SL refrigerant oil prior to assembling. Care should be taken not to damage fins on core. Bending fins will result in airflow reduction, which can cause a reduction in performance of the A/C system.
  • Page 104 104 of 114 21 EXPANSION CONTROL VALVE (ECV) Step 6 System evacuation and charging must only be performed by an EPA Part 609 certified technician, using EPA Certified refrigerant handling equipment suitable for R134a refrigerant. Both the technician and equipment must meet all State, Local, and Federal requirements. Installation If repair is complete, charge system per section 13 in this manual.

  • Page 105: Wire Harness

    105 of 114 22 WIRING HARNESS QTY 1 Part # 9SV-WH-00106 Wire harness CONFIRM 2 PURPLE HARNESS WIRES ARE CONNECTED TO EACH OTHER...

  • Page 106: Compressor Switch

    106 of 114 23 COMPRESSOR ON/OFF SWITCH Tools #2 Flat blade screwdriver 5/8” Open/ box end wrench Removal Remove connector from back of switch. There is a locking pin in one corner of connector that must be pushed back to release from switch. Depress tangs on side of switch to release from case.
  • Page 107 107 of 114 23 COMPRESSOR ON/OFF SWITCH Installation Install switch into case, being certain of direction for lighted window in relation to decal labeling. QTY 1 Part # 9DL-250 Switch decal Insert with light window toward ON position of decal...

  • Page 108: Blower Switch

    108 of 114 24 BLOWER SWITCH Tools #2 Flat blade screwdriver 5/8” Open/ box end wrench Note flats on switch and knob when installing. Removal Remove connector from back of switch. There is no locking tab on connector. Remove switch from case by pulling knob from stem, then removing retaining nut and washer. Installation Install switch into case, aligning flat side of switch with flat in case cutout.

  • Page 109: Wiring Schematic

    109 of 114 25 ELECTRICAL SCHEMATIC...

  • Page 110: Electrical Circuit Operation

    110 of 114 26 ELECTRICAL CIRCUIT OPERATION The main Power Solenoid located in the Roof Top Unit supplies power to the A/C electrical system. There is a main power cable that goes from the vehicle battery to this solenoid that supplies power at all times the battery is connected.
  • Page 111 111 of 114 26 ELECTRICAL CIRCUIT OPERATION There are two 1 amp diodes contained in the A/C system wiring harness. These prevent power from being back fed to the vehicle when the A/C unit is configured to operate after the vehicle has been turned off for Pedal Start Vehicles.

  • Page 112: Service Parts

    112 of 114 27 1ACUNIT-G2 SERVICE PARTS CONDENSER FAN BRACKET CONDENSER EVAPORATOR ASSEMBLY P/N: 8SV-110-00040 P/N: 8SV-304-00008 P/N: 8SV-304-00006 HIGH PRESSURE LINE DRIER TO EVAPORATOR LINE CONDENSER TO DRIER LINE P/N: 8SV-305-00009 P/N: 8SV-305-00011 P/N: 8SV-305-00013 LOW PRESSURE RETURN LINE...
  • Page 113 113 of 114 27 1ACUNIT-G2 SERVICE PARTS PRESSURE SWITCH, 2-28KG/CM2 EXPANSION VALVE COMPRESSOR, 12 VDC P/N: 9SV-9AC-00005 P/N: 9SV-9AC-00004 P/N: 9SV-9AC-00006 THERMOSTAT HIGH PRESSURE COMPRESSOR AXIAL FAN P/N: 9SV-9AC-00007 P/N: 9SV-9AC-00008 FITTING W/ O-RING P/N: 9SV-9AC-00024 LOW PRESSURE COMPRESSOR REPLACEMENT LOUVER...
  • Page 114 114 of 114 27 1ACUNIT-G2 SERVICE PARTS WIRE HARNESS, A/C ROOF UNIT CAP/PLUG (QTY.: 2) P/N: 9SV-WH-00106 P/N: 9SV-74-12-0008 3/8" PVC HOSE, 5/8" STD BULB, ARCH PSA RUBBER CORK TAPE .20WDX.15TALL 1/16" GRIP BLACK, 1/2" OD (NOT PICTURED) 9SV-AC-00019-15 9SV-PRO2-15...

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