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Air

Conditioning

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Red Dot

HVAC

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H eavy-Duty
Air Conditioning
And Heater
Service

Heavy Duty Air Conditioning and Heating

Service Training Manual

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Copyright Information

Prepared by
HEATERS AND
AIR CONDITIONERS
®

Red Dot Corporation

Heavy Duty Air Conditioning and Heating
Service Training Manual
Publishedby

HEATERS AND
AIR CONDITIONERS
®

RED DOT CORPORATION 495 Andover Park E. P.O. Box 58270 Seattle WA 98138-1270

RED DOT CORPORATION
Publisher
Red Dot Part No. RD-5-5900-0

Trademarks: The terms CTC™, Binary™, Trinary™, and TWIN TEMP™ are
registered trademarks of Red Dot Corporation. Freon® is a registered trademark of DuPont Corporation. MITYVAC® is a registered trademark of NewardEnterprises Incorporated.
Disclaimer: The technical information and procedures described in this publication have been obtained from the most reliable sources available. The publisher assumes the data is accurate and current at the time of publication and
does not accept any liability for errors, omissions or the correctness of contents
or procedures described herein.
Copyright: No part ofthis work may be reproduced or used in any form or by
any means—graphic, recording, taping, or information storage and retrieval
systems—without written permission of the publisher and copyright holder.

Second Edition
Copyright © 1993 by RED DOT CORPORATION—All rights reserved.

Table of Contents
Table of Contents .........................................................1-3Introduction........................................................... Intro-1
1
Chapter 2
Chapter 3
Chapter 4
Chapter 5
Chapter 6
Chapter 7
Chapter 8
Chapter 9
Chapter 10
Chapter 11
Chapter 12
Chapter

Air Conditioning / Heating Function .......................... 1-1
Overview of System Operation ....................................2-1
Heater Components and Controls...............................3-1
Air Conditioner Components .......................................4-1
System Controls ...........................................................5-1
Service Tools and Their Use ........................................6-1
Inspection and Maintenance–without gauges ............ 7-1
Troubleshooting & Service Procedures ....................... 8-1
Refrigerants.................................................................9-1
Component Repair or Replacement .......................... 10-1
Typical HVAC Systems and Components ................. 11-1
Retrofitting an R-12 System ......................................12-1
Glossary ........................................................................ i-1
Figure Index................................................................ ii-1
Subject Index.............................................................. iii-1

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Introduction
This manual has been designed and written for your use. Take your time
reading it. Study the illustrations, charts and photos. Figure 1 shows a typical
HVAC system (heating, ventilating, air conditioning) installed.
The illustration is cut away so you cansee component locations. All of the
main components are labeled, connected together and positioned approximately as they appear in the vehicle. These components may differ from one
cab to another. There could be other system devices for safety or perhaps
sleeper cab comfort.

Figure 1
The illustration shows a
typical HVAC system with
in-cab components mounted
on the fire wall. The mainsystem components are
noted in this illustration.

DEFROSTER DUCT

BLOWER AND
MOTOR

AC/HEATER
VENTS

EVAPORATOR
COIL

REFRIGERANT
SUCTION LINE
REFRIGERANT
DISCHARGE LINE
COMPRESSOR

HEATER CORE

MAGNETIC
CLUTCH

EXPANSION
VALVE (TXV)
COOLANT
LINE (RETURN)

COOLANT
(WATER) VALVE
COOLANT LINE
SUPPLY
SIGHT GLASS
BINARY™
OR TRINARY™
SWITCH
RECEIVERDRIER...