815951 Mercruiser CAP

Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant R-12 (CCl2F2 Dichlorodifluoromethane) or refrigerant R-134A can cause freezing of human flesh. Do not smoke while working on air conditioning systems. INHALING REFRIGERANT R-12 OR REFRIGERANT R-134A THROUGH ANY SMOKING MATERIAL, ALTHOUGH NOT TOXIC OR FLAMMABLE, CAN GENERATE LETHAL PHOSGENE GAS AND CAUSE VIOLENT ILLNESS OR DEATH. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, Form No. SENR5664, for more information on removal and installation of lines and refrigerant from the system.
1. Evacuate the air conditioning system of refrigerant. 2. Open right hand door assemblies (1) and (2). Remove bolt (4), the washer, and right hand door assembly (3) from the engine enclosure. 3. Remove four bolts (5), the washers, and plate (6) from the engine enclosure tube assembly. Remove step sheet assembly (7). 4. Remove four bolts (8) and the washers from grate assembly (9).5. Remove grate assembly (9) from the engine enclosure. 6. Position a suitable lifting device to right hand door assembly (10) as shown. Secure the lifting device to a hoist.
Top of engine enclosure
Bottom of engine enclosure7. Remove four bolts (11), the washers, and right hand door assembly (10) from rear frame assembly (12). The weight of right hand door assembly (10) is 34 Kg (75 lb). 8. Disconnect two hose assemblies (13) and (18) from air conditioning condenser (17). Cap and plug all connections to avoid system contamination.9. Loosen, but do not remove two bolts (14) on each side of air conditioning condenser (17), that hold brackets (15) to the radiator guard and support.10. Using two people, remove four bolts (16) and the washers from each side of air conditioning condenser (17). Remove air conditioning condenser (17) from the radiator. The following steps are for the installation of the air conditioning condenser.11. Make sure all components of the air conditioning condenser are clean of dirt and foreign material prior to installation.12. Check all O-ring seals and components for wear or damage and replace if necessary. 13. Using two people, put air conditioning condenser (17) in position on the radiator guard and support. Install four bolts (16) and the washers to each side of air conditioning condenser (17).14. Tighten two bolts (14) on each side of air conditioning condenser (17) that hold brackets (15) to the radiator guard and support.15. Connect two hose assemblies (13) and (18), and the O-ring seals to air conditioning condenser (17). 16. Position a suitable lifting device to right hand door assembly (10) as shown. Secure the lifting device to a hoist.
Top of engine enclosure
Bottom of engine enclosure17. Put right hand door assembly (10) in position on rear frame assembly (12). Install four bolts (11), and the washers. The weight of right hand door assembly (10) is 34 Kg (75 lb). 18. Install grate assembly (9), four bolts (8), and the washers to the engine enclosure. 19. Install step sheet assembly (7), plate (6), four bolts (5), and the washers to the engine enclosure tube assembly.20. Repeat Step 19 for the remaining side.21. Charge the air conditioning system. For the correct charging procedures refer to topic "Charging Air Conditioner System" in the 24H Motor Grader Service Manual "Air Conditioning and Heating Systems with R-134a Refrigerant", Module SENR5664. 22. Put right hand door assembly (3) in position on the engine enclosure. Install bolt (4), and the washer.