Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 Rd-5-5741-0 rev For Reference Only. Subject to change without notice Page 1 of 6
Note: Steps 13-16 relate to Fig. 2. 13. Mount receiver drier bracket to the right of 7/8" hole just drilled in the firewall, using [2) #4 sheet metal screws provided. 14. Mount trinary pressure switch to Schrader port on receiver drier. 15. Install receiver drier with trinary pressure switch to mounting bracket. 16. Route water valve control cable through 718" hole drilled in firewall. 17. Install 1 1/4" x 5/8" grommet through original lower heater plumbing hole 18. Install 1/4" x 5/8" grommet in 3/8" hole drilled directly above regulator.
Install R-8720 Unit 1. Place unit on floor in front of firewall. 2. Connect orange and black motor wires to the existing wires left when disconnecting old unit. 3. Install R-8720 unit using original 5/16 mounting nuts. 4. Route drain hose through 1 1/4" x 5/8" grommet in firewall. 5. Remove control panel from dash. a. Remove and discard fresh air door control cable [lower cable on driver's side of panel]. b. Attach fresh air door control cable from R-8720 unit to control panel with clip provided. Note: Adjust cable so that the fresh air door is fully closed when the mode lever is in the "OFF" position. c. Drill 1/2" diameter hole between light dimmer switch and cigarette lighter, and mount A/C switch on dash. d. Connect the yellow wire provided on the unit wire harness, to the bullet connector on the motor blower switch, and the A/C switch just installed. [Per the wiring diagram] e. Connect the white thermostat wire from the unit to the A/C switch. (Per the wiring diagram] f. Reinstall control panel in dash.
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 Rd-5-5741-0 rev For Reference Only. Subject to change without notice Page 2 of 6
6. Reinstall regulator on firewall using the original upper right-hand stud and the new 1/4 stud pro-vided by the R-8720 unit using original nuts.
Note: Steps 7-10 relate to Fig. 3. 7. Attach [2] 90 degree molded heater hoses to heater core plumbing using [2] hose clamps. 8. Attach 90 degree brass elbow to outlet heater hose from unit and to outlet hose from engine using [2] heater hose clamps. Note: Cut additional length off existing heater hose as required. 9. Attach cable operated water valve to inlet heater hose from unit and to inlet hose from engine using [2] heater hose clamps provided. 10. Connect control cable to new water valve. 11. Attach plug button to old heater plumbing outlet hole. C. Install Condenser 1. Remove front grill and frame from truck by removing [7] 8-32 hex head screws from the inside of the hood and [6] 1/4-20 phillips head screws on the outside of the grill. [Discard 1/4-20 screws]. 2. Place condenser inside grill and frame just removed and align the [6] mounting holes, Note: For hose routing purposes, condenser fittings can be located on either side of hood. [Ref. Fig. 4 or 5] 3. Mount the assembly to the outside of the hood, using [6] 1/4-20 x 1 1/2'' long screws and [6] #12 washers provided with condenser. Note: Additional spacing of condenser to the hood might be required if truck is equipped with shutters. See Fig. 4. 4. Re-secure grill on the inside of the hood using [7] existing 8-32 hex head screws. Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 Rd-5-5741-0 rev For Reference Only. Subject to change without notice Page 3 of 6

Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 Rd-5-5741-0 rev For Reference Only. Subject to change without notice Page 4 of 6
Wiring Instructions 1. Attach trinary boot assembly to trinary pressure switch. Note: Coil and tie wrap the orange and yellow wires when truck is not equipped with air clutching fan. a. Route black and black/white wires from boot assembly through 5/8 x grommet in firewall. b. Route the black wire to the compressor relay located on the unit. c. Route black/white wire to the A/C thermostat on the unit. 2. 3. 4. 5. 6. 7. Route black wire from compressor relay on the unit, through the 5/8 x 1/4 grommet in firewall Remove [2] screws securing fuse panel to dash. Route red compressor relay wire from the unit to the fuse panel. Use wire splice provided and connect red wire to black with green stripe accessory wire. Reinstall fuse panel. Wire per wiring schematic. See Fig. 6.
Route Freon Hoses Note: a.Lubricate "O" rings with refrigeration oil before using b.Make certain "O" rings are installed on all freon fittings. c. Do not leave hoses unsupported! The service life of the Heater/Air Conditioner unit or condenser may be greatly reduced as a result of broken fittings, Hose clamps and tie wraps are provided in kit to secure both freon and heater hoses.
1. Route #6 freon hose with 90 degree fitting from the "in-port" of the receiver drier to the bottom #6 fitting on the condenser, Cut hose to length and install 90 degree #6 push-on fitting using self-locating hose clamp or ferrule provided. See Figures 2, 4 or 5, and 7. 2. Route the #6 freon hose with [1] 45 and [1] 90 degree fitting, from the "out-port" of the receiver drier to the #6 side of the expansion valve. See Figures 2 and 3. 3. Route #8 freon hose with 90 degree #6 fitting from the condenser to the "high-pressure" port of the compressor, Cut hose to length, and install 45 degree #8 push-on fitting using self-locating hose clamp or ferrule provided. See Figures 4 or 5, and 7. 4. Route #'10 freon hose from the expansion valve to the "suction-side" of the compressor. Cut to length, and install 45 degree #10 push-on fitting, using self-locating hose clamp or ferrule provided. See Figures 2, 3, and 7 Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 Rd-5-5741-0 rev For Reference Only. Subject to change without notice Page 5 of 6
5. Secure #6 and #8 freon hoses from the condenser fittings, with double hose clamp with 1/4-20 nut to stud provided on condenser. 6. Wrap and tie wrap freon hoses around hood hinging area with protective sleeving provided. See Fig. 4 and 5
Final Assembly and Check 1. Connect clutch wire from Step D-2. 2. Reinstall air cleaner. 3. Evacuate the system, test for leaks and charge with R-12. 4. reconnect batteries. 5. Turn the ignition switch to the "ON" position and place the fan speed on the highest position. 6. Place the Heat/AC switch to the AIC" position and the temperature control lever on the coldest position. a. The clutch should click on and be engaged. If not, see Step b. The evaporator blower should be turning at high speed. 7. Turn the fan switch to medium and Iow positions and check that the evaporator blower slows down. 8. Move the Heat/AC switch to the "HEAT" position and compressor clutch should disengage. 9. Start engine and run at 1500-2000 RPM. Place the Heat/AC switch to the 'A/C" position and the fan speed on high. Check sight glass on receiver drier for bubbles. Add 6 to 8 ounces more R-12 after the sight glass just clears. 10. Make sure clutch cycles on and off as system is operating. 11. if clutch does not engage the system may not have been charged to a high enough pressure to actuate the binary/trinary switch Place a jumper wire across the switch and run system until it is fully charged then remove jumper wire

Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 Rd-5-5741-0 rev For Reference Only. Subject to change without notice Page 6 of 6

R-8725/R-8730 UNDERDASH

FOR FORD L SERIES CONVENTIONALS
Taking advantage of the existing O.E.M. housing and blower system, Red Dot offers evaporator kits for the new Ford L Series vehicles. Included is the installation kit, hose kit, condenser, and evaporator to make an easy complete installation. NOTE: DOES NOT FIT FORD AEROMAX

PAGE U-36

R-8725 SYSTEM ORDERING GUIDE FOR VEHICLES 1991 TO 1996 Note: Not for viscous fan application. For complete kits order one of each item marked:
Year 1991-1996 Models Heater-Air Conditioner Kit R-8725-0 Kit Includes Installation Kit w/Accumulator Hose Kit Condenser Evaporator 134a Charge Fittings Cummins 6 Cyl. L-10 Cummins N Series Full Flow Cooling With Outside Acc. Drive Pulley Open. Will Not Fit 20 Tilt. Engine 3208 CAT with Air or Water Pump Fan V/8 Caterpillar V-636 w/Bracket Mounted Fan Std/Pwr Std/Pwr Steering Vacuum Brake Std/Pwr With Air Brakes R134a Compressor Tecumseh/ CCI See Note A Tecumseh/ CCI See Note A 75R8612 75R8612 Compressor Mount Kit 75R9180

75R9540 75R9670

For complete kits order one Heater-Air Conditioner Kit, Compressor, Compressor Mount Kit Not for viscous applications
NOTE A: TECUMSEH/CCI Compressors Require One Each (R134A 75R5688 & 75R5681); Clutch 75R1202 NOTE B: Condenser Only Fits Hoods Without Shutters
FORD R-8730 DROP IN EVAPORATOR FOR L SERIES 1997-ON WITH AIR CONTROLS
Year 1997Models 9500 (Series) with Air Controls Heater-Air Conditioner Kit R-8730-0P Kit Includes * Installation Kit Hose Kit Condenser Evaporator Engine Cummins M-11 CAT C-10 Steering Air Brakes R134a Compressor 75R8382 Compressor Mount Kit 75R9550 75R9560
* The following items need to be ordered from Ford to complete installation: One F6HZ-19980-A One F6HZ-19B 888-B Air Control to May 2000

PAGE U-37

Drop In Evaporator Model R-8725
1991 AND UP FORD "L" SERIES EVAPORATOR
1. Remove heater/evaporator case cover (4 screws). 2. Remove evaporator slot cover (8 screws). 3. Center-punch or drill a 1/8" pilot hole in the center of the evaporator tube holes located on the passenger side of the firewall. Drill from the outside. 4. From the inside drill two 1" holes using the pilot holes and a holesaw. Drill through the CASE BACK ONLY. 5. Remove shavings and slip evaporator in to the case and remount cover. Check evaporator for orifice before installing. 6. Remove air solenoid attached to the fresh air door on top of blower case. Remount to the front of the blower case. 7. Using strap and OEM screw, secure door closed (door arm should point toward seat). Use the boss closest to the firewall which was used to mount the solenoid. 8. Remove control panel (6 screws). Remove switch blank located between other toggle switches. Mount A/C switch. 9. Attach wire and fuse holder to heater-a/c breaker in fuse box. Route wire behind dash and connect to switch. Route other switch wire through firewall to pressure switch on accumulator. Reinstall heater case cover and control panel.

Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-3-7057-0 REV For Reference Only. Subject to change without notice Page 1 of 3
1991 AND UP FORD "L" SERIES UNDERHOOD
1. Install compressor mount and compressor per instructions. 2. Install condenser per instructions, it is usually better to have the fittings on the passenger side of the track. 3. Mount accumulator and bracket on firewall (location may vary by truck). 4. Route hoses as needed. 5. Install cycling switch on accumulator. 6. If truck is equipped with an air fan clutch, an air solenoid must be installed on the fan hub and a trinary switch on the hose splitter between the condenser and the evaporator. 7. Complete wiring per schematic. 8. Vacuum and charge with x.xx lbs. of refrigerant.
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-3-7057-0 REV For Reference Only. Subject to change without notice Page 2 of 3
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-3-7057-0 REV For Reference Only. Subject to change without notice Page 3 of 3

R-2110 UNDERDASH

Air Conditioner Unit
FOR MACK MS SERIES MID-LINER TRUCKS
The R-2110 is the ultimate in cab cooling for Mack Mid-Liner trucks. It is designed to mount easily under the dash and provides the look and performance of a factory installed unit. It is equipped with easy to operate controls and three multi-directional louvers for even air distribution.
R-2110 SPECIFICATIONS BTUS AIR FLOW WEIGHT MOTOR CURRENT DRAW CONTROLS MODELS Cooling 14,300 BTU/Hr with 36F (kw 4.19 w/ 2.2C) refrigerant temp and 80F (26.7C) wet bulb entering air 210 CFM (356 m3/h) 70 lbs. (32 kg) 12-volt DC permanent magnet type 15 amps @ 13.6 VDC (includes 4 amps for A/C clutch) Three-speed blower motor switch R-2110-21P, R-2110-19P

36.6" 930mm

15.6" 397mm
5.5" 138mm 18.9" 482mm 4.5" 115mm

R-2110 SYSTEM ORDERING GUIDE R-134A COMPATABLE UNIT CONDENSER INSTALLATION KIT COMPRESSOR CLUTCH MOUNT KIT R-2110 Air Conditioner Radiator Mount Included in R-2110 kit package SANDEN SD-508-HD Included in R-2110 kit package. Included with compressor. Included in R-2110 kit package.

Year 1982 - - 9/97*

Model MS200 & MS250 All
Engine 6 Cyl. 335 Turbocharged 6 Cyl. 538 Cu. In. Diesel (Engine Model #060226)
Kit Number R-2110-21P (Engine Model #060212 and #060226) R-2110-19P
* 9/24/97 and on need to order RD-9-1306-0P mount kit to complete installation

PAGE U-14

Red Dot Air Conditioner Model R-2110 Series

ITEM 15

PART NO. RD-2-1539-O RD-5-5928-0 RD-5-3646-O RD-5-3596-0 RD-5-3647.O RD-4340-0 RD-3-4351-0 RD-2-1521-0 RD-2-1501-1 RD-4157-0 RD-2-1510-O RD-4427-24 RD-2-1506-0 RD-2-1533-0 RD-2-1499-1
DESCRIPTION COVER KNOB SWITCH, 3 SPD. (ROTARY) LOUVER (2" DIA) RESISTOR LOUVER (2) GUARD-RESISTOR COVER MOUNT ASSY. DIFF. HOUSING (BOTTOM) EXPANSION VALVE EVAPORATOR THERMOSTAT MOUNTING BRACKET (RH) MOUNTING ASSY (COVER) HOUSING (TOP)
CAT. NO. ITEM 71R72R71R72R24 71R76R71R28 29
PART NO. RD-2-1502-0 RD-5-3653-0 RD-5-5656-0 RD-5-3550120 RD-5-5614-0 RD-5-4097-0 RD-2-1502-1 RD-2-1508-0 RD-5-5658-0 RD-4-4130-0 RD-4-4155-0 RD-4-4154-0 RD-4-4249-0 RD-4-4146-0
DESCRIPTION ENTRY RING (RH) ELBOW - 90 (DRAIN)(2) BLOWER WHEEL (2) HOSE (DRAIN) MOTOR (12V) TEE (DRAIN) ENTRY RING (LH) MOUNTING BRACKET (LH) FAN & MOTOR ASSY CONDENSER ASSY MOUNTING BRACKET ASS'/ MOUNTING BRACKET ASSY ROCK GUARD BRACKET ASSY (2)

CAT. NO

73R7000 78R 0070 73R4062
Red Dot Corporation PO Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5755-0 REV For Reference Only. Subject to change without notice Page 1 of 1
Air Conditioner MACK MS 200 / 250 / 300 Model R-2110
Note: Please read instructions all the way through and review layout of components illustrated in Fig. 1 before beginning work.
PREPARATION OF TRUCK FOR INSTALLATION OF AIR CONDITIONER UNIT. 1. Disconnect batteries. 2. Remove glove compartment and center dash panel. (Save parts and screws). See Figure 2. 3. Disconnect flex hose from right side of heater unit and move it out of the way. 4. Remove tool compartment door by drilling out (4) rivets (discard door). See Figure 2. 5. Remove bracket located on tool compartment floor (1987-on model vehicles). Cut holes in tool compartment floor using template provided. On newer trucks a cut out will already be in the desired locations.

Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 1 of 8
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 2 of 8
Caution: Be careful not to drill into windshield washer reservoir or brake lines located underneath tool compartment. a. Install boot and grommet provided in kit. Note: Set aside dong tie wrap to seal boot after hoses and wires have been installed. 6. Install compressor (per instructions provided with compressor mount kit). 7. Install condenser. a. Place condenser between inter-cooler and front bumper. Note: Condenser fan must be located between the condenser and inter-cooler. b. Use (4) 5/16 bolts and (4) 5/16 flatwashers to attach condenser to bumper mounting brackets. See Figure 3. Note: On 1987 and newer model trucks, attach adapter mounting brackets (included in kit) to condenser assembly, using (4) 5/16 bolts and (4) 5/16 flatwashers, before installing condenser on vehicle. Then attach condenser to bumper mounting brackets using (4) 5/16 bolts, (4) 5/16 spring lockwashers, (4) 5/16 nuts and (4) 5/16 flat washers. c. Drill two 5/16 holes in bumper then secure front support brackets to bumper using (2) 1/4 x 3/4 bolts, (2) 1/4 flatwashers, (2) 1/4 lockwashers and (2) 1/4 nuts. See Figure 3. d. Attach condenser wire harness to condenser fan motor leads and route wire up through boot, into tool compartment. Provide sufficient clearance around sharp edges to prevent damage to insulation. Secure wires with tie wraps provided in kit. 8. Install receiver drier and mounting bracket. See Figure 4. a. Attach receiver drier mounting bracket to frame using bolts provided as shown in Figure 4.
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 3 of 8
Refrigerant hose routing. Note: Lubricate "O rings with refrigeration oil before installing them on all refrigerant hose fittings. Provide sufficient clearance around sharp angles and edges to prevent damage to refrigerant hose assemblies. Caution: Do not leave hoses unsupported! The service life of the air conditioner unit, condenser and hose assemblies may be greatly reduced if hoses are not properly secured. Hose clamps and tie wraps are provided in the general installation kit to secure hose assemblies. a. Attach the #8 and #10 refrigerant hose assemblies to the compressor and route both hoses down between the frame rail and radiator. See Figures 5 and 6. Then route the 90 bent end, of the #10 refrigerant hose assembly up through the boot into the tool compartment. Attach the #8 hose to the condenser. See Figures 4 and 5. b. Attach the (30) #6 refrigerant hose assembly to the #6 refrigerant hose fitting on the condenser, then route and attach it to the "in-port" on the receiver drier. See Figure 4. Note: Use a tie wrap to secure the #6 hose assembly for the front frame support. c. Attach (56'" #6 refrigerant hose assembly to the "out-port" of the receiver drier, then route it up through the boot and into the tool compartment. See Figures 4 and 6. d. Attach trinary wire harness to trinary switch on receiver/drier assembly. Route black wire from the trinary to the compressor clutch. Route trinary and condenser wires up through boot into tool compartment. Provide sufficient clearance around sharp edges to prevent damage to insulation. Secure wires with tie wraps provided in kit. e. Lower truck cab.

Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 4 of 8
AIR CONDITIONER UNIT INSTALLATION. 1. Install unit in tool compartment opening, mark (6) mounting hole locations remove unit. See Figure 7. Note: On newer vehicles threaded holes will be provided from the factory. a. a. Drill (4) 5/16 diameter holes; 2 holes to the right of tool compartment opening and 2 holes to the left of opening. b. Drill (2) 3/16 diameter holes for duct support at the end closest to the driver. 2. Install unit in tool compartment opening and secure using (4) 1/4-20 nuts and screws for unit and (2) #14 sheet metal screws at driver's end of unit duct. Note: if truck has been factory equipped with mounting holes, use metric screws provided in kit. Note: If necessary, loosen mounting brackets where they attach to unit and adjust unit to provide best fit and appearance. Re-tighten all screws
Note: Make sure drain tube remains attached to both sides of the unit and is routed through 7/8" hole in tool compartment floor. 3. Connect #10 and #6 refrigerant hose fittings to expansion valve. Push the hoses as far forward as possible and secure them with a tie wrap. See Figure 6. Note: Support expansion valve with a wrench when tightening refrigerant hose fittings to avoid damage to evaporator. Wrap refrigerant hoses and expansion valve with refrigeration tape to prevent condensation inside the tool compartment area. 4. Locate 5/16" mounting hole in dash support and attach power panel using (1) 1/4-20 x 3/4 screw and nut. See Figure 7.
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 5 of 8
ROUTE AND ATTACH WIRES FROM COMPONENTS AS FOLLOWS. 1. Connect 12 red and black wires from power panel to red and black wires from A/C unit. 2. Connect black and blue wires from power panel to black and blue wires from condenser fan motor. 3. Connect purple wire and black and white wire from A/C unit to orange wire and black and white wire from trinary. 4. Connect yellow wire from power panel to yellow wire from trinary. 5. Connect 4' orange wire from power panel to terminal on back of water temperature gauge. 6. 1989-1/2 and newer vehicles. a. Connect 4' red and black wires to power supply connector on blue striped wire. The power supply wire is located behind center dash panel in or near access boot on drivers side of vehicle similar to boot included in this kit. 7. 1989 and older vehicles. a. Remove plastic connector from terminals on 4' red and black wires. Plug red wire into blue striped wire located behind center dash panel on drivers side of heater. Wrap connection with electrical tape. Cut terminal off black wire and install ring terminal included in kit. Attach to suitable ground. 8. Use long tie wrap to seal boot around hoses and wires.

Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 6 of 8
FINAL ASSEMBLY AND CHECK. 1. Reinstall fresh air-intake hose, glove box and center dash panel. 2. Connect the batteries. 3. Evacuate the system, test for leaks and charge with R-12 refrigerant. (R-134a for R-2110-19) 4. Turn the ignition switch to the "on" position, place the fan speed switch on high. a. The clutch should click on and be engaged. If not, see step #8. b. The evaporator blower should be turning at high speed. 5. Turn the fan speed switch to medium and low positions and check that the evaporator blower slows down. 6. Turn the fan speed switch to the "off" position and check that the compressor clutch disengages. 7. Start engine and run at 1500-2000 RPM. Turn fan speed switch to high. Check sight glass on receiver drier for bubbles. Add 6 to 8 ounces more R-12 after the sight glass clears. Note: Be aware that the sight glass may appear "milky" when charging with R-134a. Be careful not to overcharge the system. 8. Make sure clutch cycles on and off as system is operating. Note: If clutch does not engage, the system may not have been charged to a high enough pressure to actuate the trinary switch. Place a jumper wire across the switch and run system until it is fully charged then remove jumper wire.
9. Fill out service label properly and adhere in prominent location. Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 7 of 8
Red Dot Corporation P.O. Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-5-5673-0 REV B For Reference Only. Subject to change without notice Page 8 of 8

R-2120 UNDERDASH

FOR MACK CS SERIES MID-LINER TRUCKS
The R-2120's outstanding performance cools the cab with ease. Contemporary unit styling blends into the dash with a factory installed look featuring a convenient fan control. Three adjustable louvers and even a coin tray. Mounting on the rear surface of the dog house allows for easy installation and servicing. The R-2120 also features high quality components such as a long life permanent magnet motor, Red Dot Trinary system protection, high capacity receiver drier and internal nylon barrier hose.

R-2120 SPECIFICATIONS BTUS Cooling 20,500 BTU/Hr @ 36F (kw 6.00 w/ 2.2C) refrigerant temp. and 80F (26.7C) wet bulb entering air 260 CFM (442 m3/h) 25 lbs. (11 kg) 12 volt permanent magnet type with long life brushes and heavy duty pre-lubricated sealed ball bearings 9.6 amps @ 13.5 VDC (includes 4 amps for A/C clutch) Three-speed blower motor switch R-2120-9P, R-2120-1P, R-2120-11P
20.7" 526mm 19.0" 481mm

RED DOT CORPORATION

24.3" 617 mm

10.1" 256mm

AIR FLOW WEIGHT MOTOR
CURRENT DRAW CONTROLS MODELS
R-2120 SYSTEM ORDERING GUIDE UNIT CONDENSER INSTALLATION KIT COMPRESSOR SERVICE VALVES CLUTCH COMPRESSOR MOUNT KIT R-2120 Air Conditioner Included Included Included Included Included Included
Model CS200 & CS250 - THRU 1989 #060226 CS200 & CS250 - 1990 to 9/97 * CS300

Engine #060212 #060226

Complete Kit Number R-2120-9P 134a** R-2120-1P R-12
* 9/24/97 and on need to order RD-9-1306-0P mount kit to complete installation ** The following items need to be ordered from Mack: One each: 4103-5010332161 4103-5010332164 4103-5010332652 Three each: 4103-5000717723

PAGE U-15

HEATERS AND AIR CONDITIONERS

R-2120 Air Conditioner

1. Please read instructions all the way through, making sure you have all the parts and tools. 2. While working on or around a vehicle disconnect the battery to prevent accidental startup or electrical shorts. 3. It has been established that R-12 refrigerant does deplete the earth's protective ozone layer. Use care so as not to release this material into the atmosphere. 4. A/C systems operate under high pressure. At 77F the R-12 container will be pressurized to 80 psi. Use caution when working with these materials. Goggles are recommended. 5. To function properly the A/C system must be clean and dry. Keep caps or protective covers on all hoses and fittings until final assembly. A. R-2120 A/C INSTALLATION 1. Disconnect vehicle battery and drain cooling system. 2. Remove left and right rubber "anti-noise flaps," and the air cleaner assembly. B. COMPRESSOR INSTALLATION 1. Install compressor mount and compressor per the instructions in the mount kit. C. CONDENSER INSTALLATION CS 200/250 (FOR CS 300 GO TO STEP D) 1. Loosely attach condenser mount brackets to condenser using (7) 1/4" washer head screws and nuts. See Figure 1. 2. Attach condenser assembly to radiator frame using (6) 1/4" x 3/4" hex head screws, flat washers and nuts. See Figure 1. 3. Tighten all condenser mount screws. Go to Step E. D. CONDENSER INSTALLATION CS 300 1. Loosely attach condenser mount brackets to condenser using (5) 1/4" washer head screws and nuts. See Figure 2. 2. Attach condenser assembly to radiator frame using (5) 1/4" x 3/4" hex head screws, flat washers and nuts. See Figure 2. 3. Tighten all condenser mount screws. E. RECEIVER-DRIER INSTALLATION 1. On the passenger side of radiator locate 2 existing screws attaching the fan shroud to the radiator support channel. Remove the screws and use them to install the receiver - drier bracket to the existing holes in the fan shroud. See Figure 2.

RD-5-6328-0 (REV A)

PAGE 1

R.H.BRACKET CONDENSER

RADIATOR L.H.BRACKET
SOME FASTENERS OMITTED FOR CLARITY FORWARD CS 200/250 FIGURE 1
RADIATOR L.H.BRACKET SOME FASTENERS OMITTED FOR CLARITY

CS 300 FIGURE 2

RD-5-6328-0 (REV A) PAGE 2

FORWARD

R-2120 UNIT INSTALLATION 1. Refer to Figure 3. Layout and drill the 7/8" dia. hole through the engine tunnel cover and insulation underneath it. Remove 4 existing screws from cover as shown. Position the A/C unit into the "dished" area of the tunnel cover, taking care not to kink the drain hose. While holding the unit firmly against the rubber dashboard trim, replace and tighten the 4 screws previously removed from the tunnel cover. 2. Remove the plastic cover from the passenger side fuse box. Refer to Figure 4. Layout and drill a 2" dia. hole, per dimensions shown, through the floor mat and the floor.
HOSE ROUTING 1. Route the short, #6 hose from the condenser outlet up to the inlet port of the receiver drier. Route the #8 hose from the compressor, along the frame rail and over the top of the radiator to the condenser inlet. Route the #10 hose and the #6 hose through the 2" hole in the cab floor (follow the frame rail, to the compressor and receiver - drier respectively). Keep these 2 hoses as far from the turbocharger and exhaust system as possible. 2. Slip the double hose grommet over the #6 and #10 hoses in the cab and push the grommet firmly into the 2" hole, replace floor mat. Install the #6 and #10 hoses into the A/C unit expansion valve. Wrap hoses and hose fittings with refrigeration tape. NOTE: A soap and water solution applied to hoses and grommet will ease installation of grommet.
3. Remove the unit cover by loosening the (10) hand tight 10-32 screws, install the vacuum formed hose cover over the hoses using the (4) sheet metal screws from the kit. NOTE: Install the screws ONLY into the side of the engine tunnel. DO NOT drill into the side of the R-2120 unit.
4. Reinstall the unit cover and tighten the 10-32 screws. 5. After installing the hoses, carefully inspect the routing to make sure they are all clear of sharp edges and hot components. Use the tie wraps and hose clamps from the kit to support hoses and prevent damage to the condenser fittings and other vehicle components.

REMOVE

DRILL 7/8" DIA. FOR DRAIN HOSE

4 1/8"

ENGINE TUNNEL COVER DIAGRAM FIGURE 3 RD-5-6328-0 (REV A) PAGE 3
WIRING 1. Attach power panel behind glove box near defrost duct using 1/4" x 1/2" hex head screw and nut. 2. Tuck the unit wire harness up against the bottom of the dash and route straight forward to, and then behind, the fuse box. Drill a 1/4" dia. hole next to the wire harness approximately 4 to 5 inches back from the upper passenger side corner of the engine tunnel. Secure the harness to the side of the engine tunnel using the "push-in" tie wrap from the kit. Connect the red, and black wires as shown on the wiring diagram, using the terminals supplied with the installation kit. Push the black/white wire through the grommet in the firewall and connect to the binary switch boot as shown in the diagram. Connect the black binary wire to the compressor. 3. Re-connect vehicle battery, refill cooling system, and replace air cleaner and fuse box cover (cover needs to be trimmed to clear A/C unit wire harness). Charge the A/C system with R-12 as required and check the function of the system for proper operation.

ELECTRICAL PANEL COVER

DOG HOUSE SIDE
16.50 (RIGHT ALONG THE SIDE OF DOG HOUSE)

LOOKING DOWN AT FLOOR

2" DIA. FOR GROMMET (DRILL THRU RUBBER MAT & FLOOR; GROMMET GOES INTO SHEET METAL, MAT GOES OVER GROMMET)
1.38 (PARALLEL TO DOG HOUSE)
HOSE GROMMET LOCATION - CS 200-250 FIGURE 4
RED DOT CORPORATION 495 Andover Park East Seattle, WA 98188 (253) 575-3840 DISTRIBUTED BY:

PAGE 4

R-8820 UNDERDASH
FOR ALL MACK R MODEL CABS
The R-8820 heater/air conditioner is without question the best unit available for Mack R Model cabs. It can be installed using existing mounting points in all R, U, DM, RL/RS and RW cabs. Features include high performance, factory installed look and a completely new air control system.
R-8820 SPECIFICATIONS BTUS Heating 27,000 BTU/hr @ 100F (kw 7.91 @ 37.8C) air temperature rise Cooling 20,000 BTU/hr with 36F (kw 5.86 with 2.2C) refrigerant temp and 80F (26.7C) wet bulb entering air 250 CFM (425 m3/h) 34 lbs. (15 kg) Permanent magnet, extended life 14 amps @ 13.6 VDC Three speed blower motor switch, temperature level and mode selection lever R-8820-1P (tan) R-8820-2P (grey)
AIR FLOW WEIGHT MOTOR CURRENT DRAW CONTROLS MODELS

1.0" 26mm

14.1" 358mm

10.0" 254mm

8.5" 216mm

13.9" 363mm

17.9" 455mm

12.1" 303mm

32.5" 826mm

PAGE U-38

R-8820 SYSTEM ORDERING GUIDE
MODEL COLOR REFRIGERANT ENGINE UNIT * INSTALLATION KIT COMPRESSOR CONDENSOR with CMCAC CONDENSOR without CMCAC MOUNT & DRIVE KIT

1 RD-3-3758-0 PANEL ASSY. - TOP 2 RD-3-3760-1 HOUSING ASSY 3 RD-2-1480-1 EVAPORATOR ASSY 4 RD-5-6868-0 EXPANSION VALVE 71RRD-1-0615-1 HEATER CORE ASSY 6 RD-5-5414-4 AIR ACTUATOR ASSY (2) 7 RD-4427-17 THERMOSTAT 71RRD-3-4148-0 COVER ASSY - CORE 9 B RD-3-3812-0P CONTROL PANEL ASSY 10 C RD-3-3812-2P CONTROL PANEL ASSY 11 RD-5-3647-0 RESISTOR 71RRD-3-3805-0 COVER ASSY (GRAY) 13 RD-5-5476-0 LOUVER 14 RD-5-5458-0 DUCT - DEFROST 15 RD-5-5423-0 DUCT - FRESH AIR 16 RD-5-5452-0 DUCT - TRANSITION 17 RD-5-5450-0 DUCT INTAKE 18 D RD-3-3430-0 BLOWER HOUSING ASSY NOTES: A = NOT SHOWN B = R-8050 ONLY C = R-8820 ONLY D = CAN ONLY BE PURCHASED ASSEMBLED AS RD-3-3425-0

AB AC A A A A D

BLOWER WHEEL MOUNT - MOTOR MOTOR - 12V AIR ACTUATOR ASSY WATER VALVE 72R5210 LOUVER (2 1/2") LOUVER - A/C (2) PANEL FRONT PANEL FRONT KNOB (3) MICRO SWITCH SWITCH - FAN 71R0450 CABLE - CONTROL BOOT - TRANSITION COVER ASSY (TAN) PAN AIR CONTROL SERVICE KIT
Red Dot Corporation PO Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-3-3804-0 REV E For Reference Only. Subject to change without notice Page 1 of 2
Red Dot Corporation PO Box 88790, Seattle, WA 98138 (425) 251-6897 Fax (425) 251-3934 RD-3-3804-0 REV E For Reference Only. Subject to change without notice Page 2 of 2
Heater-Air Conditioner Model R-8820/8150

DIMENSIONS

TECHNICAL SALES BULLETIN AND SERVICE PARTS LIST

1 in (2.6 cm)

14.1 in (35.8 cm) 8.5 in (21.6 cm) 13.9 in (35.3 cm) 17.9 in. (45.5 cm)

10 in (25.4 cm)

12.1 in (30.3 cm)

32.5 in. (82.6 cm)

SPECIFICATIONS
BTU's: Heating - 27,000 BTU/Hr @ 100F (6,804 kcal/h @ 37.8C) Air Temp Rise Cooling - 20,000 BTU/Hr @ 36F (5,040 kcal/h @ 2.2C) Refrigerant Temp and 80F (26.7C) Wet Bulb Entering Air 250 CFM (425 m3/h) 34 Lbs (15 Kg) 14 Amps @ 13.6 VDC
Air Flow: Weight: Current Draw:

SCHEMATICS

ELECTRICAL SCHEMATIC
LIGHT WHT MICRO SWITCH WHT/BLK BLK 14 GA. ORG 14 GA. RED FAN SWITCH BLK YEL RESISTOR THERMOSTAT WHT BLK

PLUMBING SCHEMATIC

#8 High Pressure Expansion Valve #10 Suction To Condenser
Compressor From Condenser #6 High Pressure Rec/Drier #6 Liquid

14 GA. RED

BLK WHT

14 GA. ORG

RD-3-8266-0 (REV -)

INTERNATIONAL

R-8230 UNDERDASH
FOR NAVISTAR S, 4000, 7000 AND 8000 SERIES TRUCKS 1983 TO 1994
The R-8230 performance and features go beyond anything offered in-dash for all S Series and new conventional vehicles. With styling that matches the factory dash, the R-8230 includes Max A/C and Defrost Interlock features not offered by any other Navistar conventional S Series or 4000, 7000, and 8000 Series systems. The R-8230 mounts directly to the rewall and mates to existing inlet and outlet ducting.

R-8230 SPECIFICATIONS BTUs: Heating 29,700 BTU/Hr at 100F (kw 8.70 at 37.8C) air temperature rise Cooling 22,400 BTU/Hr with 36F (kw 6.56 with 2.2C) refrigerant temp. and 80F (26.7C) wet bulb entering air 265 CFM (450 m3/h) 48 lbs. (22 kg) Permanent magnet 19.5 amps at 13.6 VDC (includes 4 amps for A/C clutch) R-8230-0 BTUs and air ow in installed conditions Not for viscous fan applications
13.9" 354mm 15.3" 389mm 19.7" 499mm 19.4" 494mm 6.1" 155mm
Air Flow: Weight: Motor: Current Draw: Model: NOTE:
R-8230 SYSTEM ORDERING GUIDE
Heater - Air Conditioner Kit R-8230-0P for Vehicles 19831994 Series 4600 Through 8100 S Series 1600 Through 2600 Engine V/8 International 6.9 Liter, & 7.3 Liter DT Steering Std/Pwr w/wo Vacuum Brakes Compressor Compressor Mount Kit
75R8212 75R9530 75R8612 (134A) 75R7100 75R9100 75R7130 (134A) Tecumseh, see Note A 75R8212 75R9980 75R8612 (134A) 75R8212 75R9980 75R8612 (134A) 75R8212 75R9980 75R8612 (134A) 75R8212 75R9540 75R8612 (134A) 75R9985 75R8612 (134A)
6 Cyl IHC DT466, DTA466, DT360 or DTACyl IHC DT466, DTACyl IHC DT360, DTA 360 Cummins 6 Cyl L-10 S Series 1994-1997 DT408/DT466 (will not work on DT466E)
Std./Pwr Std./Pwr Std./Pwr Pwr
Air Hydraulic Hydraulic Air 75R8212
Kits Include: Heater A/C Unit Heater Hose And Water Valve Refrigerant Hose & Fittings High Capacity Receiver Drier TrinaryTM Protection Switch NOTE A: Wiring Harness Condenser Miscellaneous Installation Hardware And Brackets Tecumseh Compressors require 75R1202 Clutch and one each (Service Valves and Charge Ports) R12: 75R5618 & 75R5611 or R134A: 75R5688 & 75R5681

PAGE U-28

R-8235 UNDERDASH

Drop-In Evaporator Kit

FOR NAVISTAR S, 4000, 7000 AND 8000 SERIES TRUCKS, 1995 to 2002
The R-8235 drop in evaporator kit takes advantage of the OEM housing and motor blower assembly. 134a compatible, this kit meets all OEM specications.
R-8235 SYSTEM ORDERING GUIDE
Heater - Air Conditioner Kit R-8235-0P For Vehicles 1995 to 2002 Series 4600 Through 8100 S Series 1600 Through 2600 Engine V/8 International 6.9 Liter, & 7.3 Liter DT 6 Cyl IHC DT466, DTA466, DT360 or DTACyl IHC DT466, DTACyl IHC DT360, DTA 360 Cummins 6 Cyl L-10 S Series 1995-1997 DT408/DT466 (will not work on DT466E) Steering Std/Pwr w/wo Vacuum Tecumseh, see Note A Std./Pwr Std./Pwr Std./Pwr Pwr Air Hydraulic Hydraulic Air Brakes Compressor 75R8612 (134A) 75R7130 (134A) 75R8612 (134A) 75R8612 (134A) 75R8612 (134A) 75R8612 (134A) 75R8612 (134A) Compressor Mount Kit No. 75R9530 75R9100 75R9980 75R9980 75R9980 75R9540 75R9985

PAGE U-29