TECHNICAL INFORMATION BULLETIN Reference: TIB 912 June 29, 2009 TITLE: Availability of Air Conditioning System Update Kit APPLICABLE PRODUCTS: This notice affects certain CAT Telehandlers manufactured by JLG Industries, Inc. The affected serial number range is as follows: Model TL642 TL943 TL1055 TL1255 Affected Serial Number Range TBK00100 to TBK01120 TBL00100 to TBL01517 TBM00100 to TBM001167 TBN00100 to TBN00652 DESCRIPTION: An air conditioning update kit is now available for field installation on the referenced TL Series Telehandlers originally equipped with air conditioning. The air conditioning system has recently been redesigned to improve airflow and overall cooling capability. When installed in accordance with the enclosed instructions, this kit will update the internal ductwork of the original system to the current configuration. PARTS NEEDED: The parts needed for this update are as follows: Model Qty. Description Part Number TL642, TL943, TL1055, and TL1255 1 Air Conditioning Update Kit 350-2362 Enclosure: Air Conditioning Update Kit Installation Instructions
Air Conditioning Update Kit Installation (Reference: TIB 912) Parts Required: Air Conditioning Update Kit #350-2362, Qty. 1 IMPORTANT: Use all applicable safety precautions while working on machine. Procedure 1. Prepare machine for servicing. Park the machine on a firm, level surface with boom lowered and fully retracted. Place travel select lever in the (N) NEUTRAL position and engage the parking brake. Shut engine OFF and chock a wheel. 2. Disconnect positive battery cable. Remove steering wheel from column. 3. Remove screws from center instrument panel, right side dash panel, and left side dash panel. Remove knob from auxiliary control lever. Remove key switch, tilt speed control, and fan from dash. Disconnect flex hoses from vents. 7. Remove temperature control from A/C control and drop through hole in right hand console. Remove knob from frame tilt lever, then remove cover panel. Remove front console first; plenum second; and finally rear console. Front console will be re-used, rear will not. 8. Remove all flexible vent hoses and discard. On TL642 and TL943 Models, remove and discard plenum. 4. Remove two bolts on right side of dash; two bolts and plate from the middle of the dash; and one bolt from the lower left corner of the dash. (It will not be necessary to disconnect any wiring from instrument panels. Panels can be angled and passed through holes in dash). 5. Remove dash panel from unit. This part will not be re-used. 6. Remove vent from front panel of seat riser. Remove four nuts holding seat and remove seat. Remove two clamps from rear of seat riser holding rear window washer hose and wiring. Remove four bolts and riser from cab. Seat will be re-used, riser will not. 9. Weld two 3/8-16NC nuts on rear cab tube into the locations specified in Figure 1 (on page 5). Take necessary precautions to prevent weld spatter damage to glass and interior surfaces of cab. DO NOT DRILL TUBE. Page 1 of 6
13. On a TL10 and TL12, route the decompression valve hoses behind a/c unit on floor of cab. Lower rear corner of seat riser is cut out to clear hoses. 10. Remove blower unit mounting bolts to access the mounting screws on bottom of three vent outlet. Remove thermostat switch from vent outlet cover. 11. Remove the three vent outlet covers from blower unit. Replace with four vent outlet cover. Reposition and install thermostat switch to upper rear corner of outlet cover. Seal cover with sealant tape. Short 2.5 outlet goes toward front of cab. 14. Install seat riser vent using four #6x1/2 self tapping screws. Install a/c decal in upper left corner. 15. Install seat riser. Route 48 hose and the 72 hose through oblong hole in side of seat riser. Route the 21 hose through slot in side of seat riser. 12. Install the four new vent hoses as shown below. Secure hoses with hose clamps: 2.5 x 15 to front vent 3 x 48 to 2 nd vent 3 x 72 to 3 rd vent 2.5 x 21 to rear vent After installing vent hoses, install blower unit mounting bolts. 16. Install R.H. Console and A/C control panel. The 48 and 72 hose will lie under the console and be directed toward the dash. The rear (21 ) hose needs directed upwards between the seat riser and console. 17. Connect rear top duct vent tube to rear flexible duct coming from blower unit. Tighten hose clamp to secure. Attach Page 2 of 6
tube to existing riv-nuts in rear cab wall using two 1/4-20x3 bolts, two 1/4 lock washers, and two 1/4 flat washers. Rotator wheels 20. Install sealant tape around rectangular hole at top rear of seat riser as shown below. 18. Assemble upper vent housing to bracket using two 5/16-18 x7/8 long hex head bolts, four flat washers, and two 5/16 nylon lock nuts. Connect upper vent tube to vent housing. Bolt housing and bracket to cab using two 3/8-16x 5/8 hex head bolts, two 3/8 flat washers, and two 3/8 lock washers. 21. Attach suction vent to top of seat riser using four 1/4-20x 5/8 long bolts, four 1/4 flat washers, and four 1/4 lock washers. Attach to cab using riv-nut with a 1/4-20 x 1 bolt, 1/4 flat washer, and a 1/4 lock washer. Route washer line and wiring behind suction vent and attach clamps. 19. Install adjustable louvers in vent housing using two #6x1/2 self-tapping screws in each louver. Keep the rotator wheel to the right side as shown below. Page 3 of 6
22. Connect suction vent filter to top of tube using six #6 x 1/2 self-tapping screws. Notch in dash Arrow point 27. Connect one 2-1/2 x approx. 13 duct hose to each louver. Secure hose to louver with hose clamp. 23. Re-install seat. 24. Install louver into front seat riser panel. Connect front hose to louver, securing with 2-1/2 hose clamp. Attach front panel to seat riser. 25. Install rectangular louvers in top of dash panel. Fasten each with two #6x1/2 self-tapping screws. Rotator wheel should be toward center of dash. 28. Assemble Y connectors to adapters. 26. Install ducts to round louvers and install louvers into front of dash. Align arrow point on louver with notch in dash panel. Page 4 of 6
29. Connect 2-1/2 duct hoses to connector, securing with hose clamps. Perform for each side of dash. Mount tilt speed control plate to dash and drill out center hole for shaft of controller. 30. Install dash panel in place, passing instrument/relay panel out through the opening in the dash panel. DO NOT bolt dash to cab at this time. 31. Connect hoses from A/C unit to Y connectors. Route longest 3 diameter hose to left side under steering column. Slide onto Y-connector and secure with hose clamp. Shorter 3 diameter hose will connect to right side Y-connector. 32. Mount cab fan to left side dash and connect wiring. Install key switch and tilt speed control. Re-install and tighten bolts that hold dash in place. Re-install screws that hold instrument panel and right hand panel to dash. 33. Re-install steering wheel. 34. Re-connect battery and prepare machine for operation. 35. Start engine. Switch A/C to ON position and check all vents for proper air flow. Page 5 of 6
Figure 1 Location of Weld Nuts on Rear Cab Tube Page 6 of 6