899912020 Mercury TAPPET, (3.398)

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Personal injury can result from contact with refrigerant.This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in NEUTRAL or PARK and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen.
Before any service work is performed on the air conditioning system, refer to Air Conditioning and Heating, Testing and Adjusting, "Machine Preparation for Troubleshooting".
Recover the refrigerant from the air conditioning system. Refer to Air Conditioning and Heating, Testing and Adjusting, "Refrigerant Recovery".
Illustration 1 g01048252
Illustration 2 g01048248
Remove hoses (2) from the refrigerant compressor.
Disconnect harness assembly (1).
Disconnect harness assembly (5) from the refrigerant pressure switch of the engine ECM.
Loosen nut (4). Remove the refrigerant compressor.
Attach a suitable lifting device to the refrigerant compressor.
Remove bolt (6) from the bracket.
Remove bolt (7) from the bracket.
Remove nut (3).
Remove the refrigerant compressor from the engine. The weight of the refrigerant compressor is approximately 37 kg (82 lb). Installation Procedure
Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.
Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.
Illustration 3 g01048248
Illustration 4 g01048252
Install the refrigerant compressor. The weight of the refrigerant compressor is approximately 37 kg (82 lb).
Install nut (3).
Install bolt (7) on the bracket.
Install bolt (6) on the bracket.
Remove the suitable lifting device from the refrigerant compressor.
Install the refrigerant compressor belt. Tighten nut (4).
Connect harness assembly (5) to the refrigerant pressure switch of the engine ECM.
Connect harness assembly (1).
Install hoses (2) to the refrigerant compressor.
Use nut (4) to adjust the tension of the refrigerant compressor belt. Use a BT-33-95 belt tension gauge from Borroughs Tool Company or an equivalent part in order to check the tension of the belt. The correct belt tension is 535 22 N m (394.6 16.2 lb ft) for a new belt and 400 44 N m (295.0 32.5 lb ft) for a used belt.
Evacuate the air conditioning system. Refer to Air Conditioning and Heating, Testing and Adjusting, "Refrigerant System - Evacuate".
Charge the air conditioning system. Refer to Air Conditioning and Heating, Testing and Adjusting, "Refrigerant System - Charge".