HVAC Kit

1. Park the machine on a level surface.

2. Shift the transmission lever to the P (PARK) position.

3. Shut off the engine and remove the key.

4. Wait for the engine to cool completely.

   

   Figure 1

5. Disconnect the negative (-) battery cable from the battery post.

   

   Figure 2

   1. Negative (-) battery cable
   2. Battery post

6. Raise the hood; refer to the machine Operator’s Manual.

7. Drain approximately 2 L (1/2 US gallon) of engine coolant (or until coolant stops flowing out of the rubber hoses) from the cooling system; refer to the Operator’s Manual.

   Note: Retain coolant for reuse after you install the kit.

Parts needed for this procedure:

1. On the dashboard, remove the 4 switch plugs and cut out the material between the switch cutouts (Figure 3).

   

   Figure 3

   Warning

   Using a drill without wearing eye protection may allow debris to enter the eye, causing personal injury.

   When drilling, always wear eye protection.

2. Locate the 2 drill pilot dimples (Figure 4) and drill 2 pilot holes (5 mm or 3/16 inch) directly over the pilot dimples.

   

   Figure 4

   1. Drill pilot dimples

3. Using the HVAC control panel as a template, drill the other 2 holes located on the right side.

4. Install the 2 switches with knobs onto the control panel with 2 switch nuts (7/16 inch) as shown in Figure 5 and Figure 6.

5. Install the A/C rocker switch into the panel (Figure 5 and Figure 6).

6. Install a knob over each switch (Figure 5 and Figure 6).

   

   Figure 5

   

   Figure 6

   1. Switch nut
   2. Decal
   3. Control panel
   4. Rotary switch
   5. Rotary linear switch
   6. Button-head bolt (5/8 inch)
   7. Knob
   8. A/C rocker switch

7. Move the control knobs to the middle position as shown in Figure 7.

   

   Figure 7

   1. Move the knobs to the middle position.

8. Ensure that the heater switch is in the middle position and connect one end of the control cable to the back of the heater switch (Figure 8).

   

   Figure 8

9. Ensure that the water valve is in the middle position and connect it onto the other end of the control cable (Figure 9).

   

   Figure 9

10. Ensure that the heater switch can sweep from low heat to high heat and that the water valve fully opens and closes. Adjust the cable if necessary.

11. For the A/C rocker switch, plug the black-wire spade terminal onto the gold colored switch terminal and labeled number 3.

    Note: Refer to the numbers imprinted in the A/C rocker switch for the correct terminals (Figure 10).

12. Plug the white-wire spade terminal onto the switch terminal labeled number 2.

13. Plug the red-wire spade terminal onto the switch terminal labeled number 1 (Figure 10).

14. Plug the 5-terminal connector on the kit wire-harness into the back of the airflow switch (Figure 10).

15. Route the control cable, water valve, and wire harness through the dashboard and secure the control panel assembly onto the dashboard with 4 button-head bolts (5/8 inch) and 4 locknuts (#10-24); refer to Figure 11. Torque the bolts to 3 N∙m (30 in-lb).

    

    Figure 10

    1. Number 1 terminal for the red wire
    2. Number 2 terminal for the white wire
    3. Number 3 terminal (gold colored) for the black wire
    4. 5-terminal connector
    5. Spade terminal—black wire
    6. Spade terminal—red wire
    7. Spade terminal—white wire
    

    Figure 11

16. Connect the HVAC harness to the vehicle harness (Figure 12 and Figure 18).

    

    Figure 12

    1. HVAC assembly
    2. Torx® screw (#10 x 3/8 inch)
    3. Relay (280 12V 50/30A)
    4. Wire harness (gas engines)
    5. Control connector
    6. Control spade connectors
    7. Spade connectors at the compressor
    8. Ground terminal at the compressor
    9. Connector for vehicle harness
    10. Connector
    11. Condenser connector

17. Route the harness down the right-frame channel. Keep the harness on the interior side of the channel (Figure 13).

    

    Figure 13

    1. Wire harness
    2. Compressor
    3. Condenser

1. Locate the 4 drill pilot dimples on the top of the dashboard (Figure 14) and drill 4 holes (76 mm or 3 inches) directly over the pilot dimples.

   Note: Use a 76 mm (3 inch) hole saw to drill the vent holes.

   

   Figure 14

   1. Drill pilot dimples

2. Locate the 2 drill pilot dimples on the floorboard (Figure 15) and drill 2 holes (76 mm or 3 inches) directly over the pilot dimples.

3. Remove the burrs from the holes.

   

   Figure 15

   1. Drill pilot dimples

Parts needed for this procedure:

Note: Route the long discharge hose and suction hose before installing the HVAC box. This allows for more room to route the hoses.

1. Route the suction hose from the front of the machine to the back near the compressor area (Figure 16 and Figure 17).

   

   Figure 16

   1. Suction hose through slot in the frame

2. Route the discharge hose from the front of the machine to the back near the condenser area (Figure 17 and Figure 18).

   

   Figure 17

   1. Suction hose
   2. Long discharge hose
   3. Short discharge hose
   

   Figure 18

   1. Short discharge hose
   2. Connector
   3. Suction hose
   4. Long discharge hose

Parts needed for this procedure:

1. Connect the 4 vent hoses (55 mm x 68.6 cm or 27 inches) to the adjustable vents and the 2 vent hoses (55 mm x 45.7 cm or 18 inches) to the non-adjustbable vents using 6 large cable ties as shown in Figure 24.

   Note: Ensure that the vents are orientated to blow air toward the operator on the operator’s side of the machine and toward the passenger on the passenger’s side.

2. Route the hoses and install the 4 adjustable vents into the 4 top holes; refer to Figure 23 and Figure 24.

3. Route the hoses and install the 2 non-adjustable vents into the lower 2 holes; refer to Figure 23 and Figure 24.

4. Attach the HVAC box assembly to the HVAC mount bracket with 6 carriage bolts (1/4 x 3/4 inch) and 6 locknuts (1/4 inch); refer to Figure 19. Torque the bolts to 11 N∙m (100 in-lb).

   

   Figure 19

   1. HVAC assembly
   2. Locknut (1/4 inch)
   3. Carriage bolt (1/4 x 3/4 inch)
   4. HVAC mount bracket
   5. Bolt (5/16 x 3/4 inch)
   6. Connector on the main harness

5. Remove the existing cover over the air filter and the 4 bolts on the side of the HVAC assembly. Discard the cover and bolts (Figure 20).

   

   Figure 20

   1. Cover
   2. Bolts

6. Install the foam seal onto the air-intake cover by starting at the corner indicated in Figure 21.

   Note: Keep the foam tight when wrapping around the corners to reduce the wrinkling.

7. Trim the excess foam when you have finished installing the foam.

8. Install the flange adapters into the air-intake cover (Figure 21 and Figure 23).

   

   Figure 21

   1. Start here when installing the foam seal.
   2. Foam seal
   3. Flange adapter
   4. Air-intake cover
   5. Foam seal installed

9. Install the air-intake cover onto the HVAC box with 4 button-socket head screw (M5 x 22 mm); refer to Figure 22 and Figure 23.

   Note: To prevent pushing the rubber swell nuts into the HVAC box, start the screws by hand (Figure 22).

   

   Figure 22

   1. Button-socket head screw (M5 x 22 mm)
   2. Rubber swell nut
   3. Swell-nut insert

10. Install the air-intake cover onto the HVAC box with 4 self-tapping screws (1.46 x 13 mm); refer to Figure 23.

    Note: To prevent stripping the threads in the plastic, hand tighten the self-tapping screws.

    

    Figure 23

    1. Vent hose (55 mm x 68.6 cm or 27 inches)
    2. Adjustable vent
    3. Air-intake housing
    4. Self-tapping screw (1.46 x 13 mm)
    5. Flange adapter (50.1 mm or 2 inches)
    6. Foam seal
    7. HVAC assembly
    8. Non-adjustable vent
    9. Button socket head screw (M5 x 22 mm)
    10. Large cable tie
    

    Figure 24

    1. Vent hose (55 mm x 68.6 cm or 27 inches)
    2. Adjustable vent
    3. Large cable tie
    4. Vent hose (55 mm x 45.7 cm or 18 inches)
    5. HVAC box
    6. Top view of HVAC box

11. Connect the 2 coolant hoses onto the front of the HVAC box with 2 band clamps as shown in Figure 25.

    

    Figure 25

Parts needed for this procedure:

1. Connect the 4 vent hoses (55 mm x 68.6 cm or 27 inches) to the HVAC box and the 2 vent hoses (55 mm x 45.7 cm or 18 inches) to the air-intake cover using 6 large cable ties as shown in Figure 23 and Figure 24.

2. Attach the front of the HVAC box assembly to the frame of the machine with 2 hex bolts (5/16 x 3/4 inch). Torque the bolts to 22.6 N∙m (200 in-lb); refer to Figure 26.

   

   Figure 26

   1. Hex bolt (5/16 x 3/4 inch)
   2. Machine frame
   3. HVAC box assembly

   Important: Do not interfere with the shifter linkage or steering column when installing the hoses.

3. Attach the back of the HVAC box assembly to the dash brackets on the machine with 2 carriage bolts (1/4 x 3/4 inch) and 2 locknuts (1/4 inch); refer to Figure 27.

   

   Figure 27

   1. Locknut (1/4 inch)
   2. Carriage bolt (1/4 x 3/4 inch)

4. Install the relays to the harness and HVAC box assembly (Figure 12).

5. Disconnect the existing coolant hose from the side of the coolant tank (Figure 28) and shorten the hose by 23 cm (9 inches). Retain the band clamp.

   

   Figure 28

   1. Coolant tank
   2. Existing coolant hose

6. Connect the 2 coolant hoses that were previously installed to the heater box to their appropriate ports on the water valve with 2 band clamps (Figure 30).

   Note: If a BOSS snowplow is installed on the machine, route the heater core lower hose (Figure 29) around the plow solenoid.

7. Connect the previously shortened thermostat bypass hose to the water valve with a band clamp (Figure 29 and Figure 30).

8. Connect the remaining hose to the water valve with a band clamp, then connect the other end of the hose to the large port on the upper reservoir with a band clamp (Figure 29 and Figure 30).

   

   Figure 29

   1. To the heater core lower hose
   2. From the thermostat bypass hose
   3. To the upper reservoir large port
   4. To the heater core upper hose
   

   Figure 30

   1. Coolant tank
   2. Coolant hoses (3)
   3. Water valve
   4. Existing coolant hose (previously removed from coolant tank and shortened)

9. Connect the suction hose and the discharge hose to the HVAC box (Figure 31).

   

   Figure 31

   1. Discharge hose
   2. Suction hose

Parts needed for this procedure:

1. Loosen the upper-alternator adjusting bolt and remove the belt.

2. Install the idler pulleys and belt tensioner assembly with 2 bolts (3/8 x 3-1/4 inches) and 2 locknuts (3/8 inch); refer to Figure 32 and Figure 35. Torque the bolts to 40.7 N∙m (360 in-lb).

   

   Figure 32

   1. Bolt (3/8 x 3-1/4 inches)
   2. Idler pulley
   3. Belt tensioner assembly
   4. Locknut (3/8 inch)
   5. Long shoulder towards the belt tensioner assembly

3. Install the compressor to the engine mount with the wire-harness ground ring-terminal, 3 flange bolts (3/8 x 1-1/4 inches) and 3 locknuts (3/8 inch); refer to Figure 35. Torque the bolts to 40.7 N∙m (360 in-lb).

4. Install the compressor fittings on to the compressor by hand; refer to Figure 33 and Figure 34.

   Note: Ensure that the O-rings are seated properly on the fittings to ensure that they are not crushed or cut when you install the fittings.

5. Position the fittings and mark their locations (Figure 33 and Figure 34).

6. Remove the fittings, position the fittings using the marks, and tighten the fittings.

7. Install the compressor fittings on to the compressor and tighten (Figure 33 and Figure 34).

8. Install the fittings, O-rings, and elbows to the compressor as shown in Figure 34.

   

   Figure 33

   1. 90° elbow fitting (O-ring pilot, -8)
   2. Dual-function switch
   3. Short compressor hose
   4. T-fitting (#8, 1/4 inch)
   5. O-ring (-08)
   

   Figure 34

   1. Locknut (3/8 inch)
   2. Dual-function switch
   3. Short compressor hose
   4. T-fitting (#8, 1/4 inch)
   5. O-ring (-08)
   6. 90° elbow fitting (O-ring pilot, -8)
   7. Long compressor hose
   8. 90° elbow fitting (O-ring pilot, -10)
   9. O-ring (-10)
   10. Flange bolt (3/8 x 1-1/4 inches)
   11. Compressor
   12. Locknut (3/8 inch)
   13. Wire-harness ring-terminal
   14. Wire harness
   15. Hand assemble, mark, remove the fittings, tighten the fittings, and assemble onto the compressor.
   

   Figure 35

   1. Belt
   2. Idler pulley
   3. Locknut (3/8 inch)
   4. Compressor hose to condenser
   5. Locknut (3/8 inch)
   6. Dual-function switch—compressor
   7. T-fitting (#8, 1/4 inch)
   8. Bolt (3/8 x 3-1/4 inches)
   9. O-ring (-08)
   10. 90° elbow fitting (O-ring pilot, -8)
   11. Wire harness
   12. Long compressor hose
   13. 90° elbow fitting (O-ring pilot, -10)
   14. O-ring (-10)
   15. Compressor
   16. Flange bolt (3/8 x 1-1/4 inches)
   17. Belt tensioner assembly
   18. Engine mount
   

   Figure 36

   1. Compressor shown installed

9. Install the belt onto the compressor, idler pulleys, engine, and alternator (Figure 35 and Figure 37).

   

   Figure 37

   1. Belt installed

   Note: Adjust the alternator to add tension on the belt.

10. Adjust the alternator until the belt is tensioned. You may use a pry bar to assist in this step.

11. Tighten the upper alternator adjusting bolt.

12. Measure the belt deflection by applying 98 N (22 lbf) of force or 8 to 10 mm (5/16 to 3/8 inch) deflection to the belt between the fan pulley and alternator pulley (Figure 38).

13. If the belt tension is not correct, repeat the steps for tensioning the belt.

    

    Figure 38

    1. Fan pulley
    2. Alternator pulley
    3. Belt
    4. Apply 98 N (22 lbf) of force or 8 to 10 mm (5/16 to 3/8 inch) deflection

Parts needed for this procedure:

1. Loosen the upper-alternator adjusting bolt and remove the belt.

2. Install the fittings, O-rings, and elbows to the compressor as shown in Figure 39.

   Note: Ensure that the O-rings are seated properly on the fittings to ensure that they are not crushed or cut when installing the fittings.

3. Install the compressor hoses to the fittings as shown in Figure 39.

4. Install the compressor to the engine mount with the wire-harness ground ring-terminal, 3 flange bolts (3/8 x 1-1/4 inches) and 2 locknuts (3/8 inch); refer to Figure 39 and Figure 40. Torque the bolts to 40.7 N∙m (360 in-lb).

5. Install the belt onto the compressor, idler pulleys, engine, and alternator (Figure 39).

   Note: Adjust the alternator to add tension on the belt.

   

   Figure 39

   1. Locknut (3/8 inch)
   2. Flange bolt (3/8 x 1-1/4 inches)
   3. O-ring (-08)
   4. T-fitting (#8, 1/4 inch)
   5. Compressor hose to condenser
   6. Dual-function switch
   7. 90° elbow fitting (O-ring pilot, -10)
   8. Suction hose from HVAC box
   9. O-ring (-10)
   10. Spade connectors
   11. Ring terminal—ground
   12. Compressor
   13. Belt
   

   Figure 40

   1. Compressor shown installed
   2. Ring terminal—ground
   3. Spade connectors

   Note: Adjust the alternator to add tension on the belt.

6. Adjust the alternator until the belt is tensioned. You may use a pry bar to assist in this step.

7. Tighten the upper alternator adjusting bolt.

8. Use your finger or ruler to measure the belt deflection by applying 98 N (22 lbf) of force to the belt between the pulleys as shown in Figure 41.

9. If the belt tension is not correct, repeat the steps for tensioning the belt.

   

   Figure 41

   1. Apply 98 N (22 lbf) of force with 9 to 13 mm (5/16 to 1/2 inch) deflection
   2. Apply 98 N (22 lbf) of force with 7 to 10 mm (1/4 to 3/8 inch) deflection
   3. Alternator
   4. Belt

Parts needed for this procedure:

1. Remove the existing side panel from the machine. Remove the existing push-in fasteners from the existing side panel for use in the new side panel. Retain the fasteners.

2. Install the 90° elbow fitting (O-ring pilot, -8) and O-ring (08) to the top of the condenser (Figure 42).

3. Install the 180° fitting and O-ring (06) to the side of the condenser (Figure 42).

4. Slide the R-clamps over the condenser hoses (Figure 42).

5. Install the condenser to the condenser bracket with a bolt (5/16 x 1-1/4 inches) and a flange nut (5/16 inch); refer to (Figure 42). Torque the bolts to 22.6 N∙m (200 in-lb).

6. Install the condenser hose going to the HVAC box (bottom hose) to the condenser using the R-clamp, a bolt (5/16 x 1-1/4 inches), and a flange nut (5/16 inch); refer to Figure 42.

   

   Figure 42

   1. Flange nut (5/16 inch)
   2. Condenser
   3. Condenser bracket
   4. R-clamp
   5. Bolt (5/16 x 1-1/4 inches)
   6. Condenser hose from the compressor (upper hose)
   7. Condenser hose to the HVAC box (bottom hose)
   8. 180° fitting
   9. O-ring (-06)
   10. 90° elbow fitting (O-ring pilot, -08)
   11. O-ring (-08)

7. Route the wire harness to the condenser and install the connector to the condenser.

   

   Figure 43

   1. Wire-harness connector installed
   2. Left rear tire

8. Starting from the rear, install the new side panel to the machine frame with the previously removed push-in connectors (Figure 44).

   Note: The last 2 holes in the side panel use the 2 self-tapping screws (5/16 x 3/4 inches).

9. Install the condenser bracket and new side panel to the machine frame with 2 self-tapping screws (5/16 x 3/4 inches), 2 flat washers (5/16 inch); refer to Figure 44 and Figure 49.

10. Install the condenser hose from the compressor (upper hose) to the condenser using the R-clamp, a bolt (5/16 x 1-1/4 inches), and a flange nut (5/16 inch); refer to Figure 42.

    

    Figure 44

    1. Self-tapping screw (5/16 x 3/4 inches)
    2. Flat washer (5/16 inch)
    3. HVAC side panel
    4. Existing push-in fasteners in new panel

11. From under the machine, install the previously removed plastic screws to the new panel and the gas tank side panel (Figure 45 and Figure 47). Torque the plastic screws to 2.25 N∙m (20 in-lb).

    

    Figure 45

    1. Existing washer
    2. Existing Plastite® screw (2.25 N∙m or 20 in-lb)
    3. New side panel
    4. Condenser

12. For diesel-powered machines, loosen the lower fuel-pump locknut as shown in Figure 48.

    Note: For diesel-powered machines, do not remove the bolt. Loosen the locknut only.

13. For gas-powered machines, install the carriage bolt (1/4 x 3/4 inch) and a locknut (1/4 inch) to the machine using the cutout for the carriage bolt (Figure 46).

    Note: Do not tighten the carriage bolt and nut.

    

    Figure 46

    Gas-powered machine only

    1. Carriage bolt (1/4 x 3/4 inch)
    2. Carriage bolt cutout

14. Slide the condenser bracket between the locknut (1/4 inch) and the lower machine frame (Figure 47 and Figure 48).

15. Tighten the carriage bolt (1/4 x 3/4 inch) and a locknut (1/4 inch); refer to (Figure 47 and Figure 48).

    

    Figure 47

    Gas-powered machine only

    1. Carriage bolt installed with the bracket behind the locknut
    

    Figure 48

    Diesel-powered machine only

    1. Condenser bracket
    2. Carriage bolt installed with the bracket behind the locknut
    

    Figure 49

    1. HVAC side panel
    2. Flat washer (5/16 inch)
    3. Self-tapping screw (5/16 x 3/4 inches)
    4. Carriage bolt (1/4 x 3/4 inch)—gas powered machines only
    5. Locknut (1/4 inch)
    6. Condenser installed
    7. Existing push-in fasteners
    8. Existing washer
    9. Existing plastic screw (2.25 N∙m or 20 in-lb)

Check and ensure that the hose connections are tight.

Secure the harness and hoses away from moving components and any hot surfaces with cable ties (Figure 12, Figure 13 and Figure 50).

Figure 50

1. Short discharge hose
2. Cable tie
3. Connector
4. Suction hose
5. Long discharge hose
6. Heater connector

Connect the negative (-) battery cable to the battery post.

Figure 51

1. Negative (-) battery cable
2. Battery post

Coolant type: 50% ethylene-glycol with organic additive technology (OAT) 50% distiller water

1. Remove the cap from the cooling system reservoir.

2. Fill the cooling system reservoir until coolant reaches the lower line within the reservoir.

3. Rotate the temperature-control knob to full heat.

4. Start and run the engine until the cooling fan cycles.

   When the machine is at operating temperature, the coolant level within the reservoir should be at the upper line.

5. Add coolant as necessary to replace air that has been purged from the cooling system.

6. Install the cooling system reservoir cap.

HVAC system volume: 414 ml (14 ounces)

Refrigerant type: R134a

1. Make sure that all machine air-conditioning components are installed and secure.

2. Have a certified air-conditioning service technician evacuate the air-conditioning system completely, properly recharge the system with R134a refrigerant, and then leak test the system.

The fan has 4 speeds (OFF, LOW, MEDIUM, and HIGH). Rotate the fan-control knob to regulate the speed of the fan.

Rotate the temperature-control knob to regulate the air temperature in the cab.

Turn the air conditioning switch to ON for cooling the cab.

Note: The HVAC air filter is designed to keep the cabin air clean.

1. Remove the air-intake cover from the HVAC box assembly (Figure 52).

   

   Figure 52

   1. Air-intake cover
   2. Filter

2. Gently remove the filter from the HVAC box assembly.

   Note: Do not attempt to clean the filter.

3. Inspect the new filter for damage by looking into the filter while shining a bright light on the outside of the filter.

   Note: Holes in the filter appear as bright spots. Inspect the element for tears, an oily film, or damage to the rubber seal. If the filter is damaged, do not use it.

   Note: Use care when handling the filter to avoid damaging or deforming it.

4. Carefully install the filter.

5. Install the air-intake cover onto the HVAC box assembly with the corresponding hardware.

Important: Do not get the HVAC box or components wet.