Carrier Em1 Manual

							T--311 4-5
Insulated Clamp
Figure 4-- 13 Hose/Harness Clamped to Wall
At this time the evaporator can be mounted. Refer to
Section 2 for the proper procedures for installing a rear
mounted evaporator assembly.
12. You may now make the appropriate connection to
the evaporator.
Proper hose to fitting clamping is critical. Do not attempt
to attach any hose or fitting until you have familiarized
yourself with Carrier Transport Air Conditioning
Quick-Click hose/fitting crimping procedures.
4.3 EVAPORATOR HOSE ROUTING, OUTSIDE
THE BUS WALL
The evaporator has been previously installed. Refer to
Section 2 for the proper procedures for installing a rear
mounted evaporator assembly.
Always keep hose capped until ready to connect to a
system component (See Figure 4-- 1).
1. Determine which side of the vehicle the hoses
should be routed; the drivers side or passenger side.
2. Determine what route the hoses will take. Take into
consideration there are going to be obstacles that
the hoses may have to be routed around, such as
seats, wheelchair lifts, windows, etc.
3. Lay out the hose cover backs in the position that they
eventually will be installed, and mark their position.
Mark the sides and where they stop at the floor and
wall. This will give you an outline where the holes for
the hoses should be placed.
Before drilling holes for the hoses in the wall or through
the floor, make sure there are no electrical harnesses,
braces, etc. in the path of the hose routing and hole saw.
4. Drill a 3/16 inch pilot hole in the center of where you
are going to drill the two 1 1/2 inch holes. This will
show you if you can safely cut the two 1 1/2 inch
holes in the floor.
5. Drill two 1-1/2 inch holes side by side within the hose
cover markings.
6. Saw out any material remaining between the two
holes, leaving an oblong hole to route the hoses
through.
7. Repeat steps 1. through 6. to obtain access to the
wall or floor, depending which one you start with.
8. Remove any sharp edges from around the holes to
prevent hose cutting and/or chaffing.
9. After holes are drilled, sawed and deburred, you are
ready to mount the hose cover backs using a com-
mon fastener such as screws, pop rivets, etc.When drilling into the vehicle wall, always use a drill stop
to help protect against damaging any wiring that might
be located behind the wall.
To help keep hoses, harness, and drain lines secure and
in the center of the hose covers, 3/16 inch holes can be
drilled in the hose cover backs. Insert Tie-Wraps
through the holes before securing the hose cover backs
to the wall (See Figure 4-- 14) .
10. Drill a 3 inch hole in the vehicle wall in order to rout
the hoses and harness to the evaporator area.
11. Remove (deburr) any rough edges from around the
cut-out.
12. Using a small piece of “Trim-Loc” or similar material
around the cut-out will help protect the hoses and
harness from chaffing and/or cutting. See xxxx
13. Route the hoses and harness at this time.
14. Before fastening to the hose cover backs, protect the
hoses and harness wherever they go through the
floor or wall. A piece of scrap drain hose or heater
hose, split down the middle, can be used for protec-
tion.
15. After hoses and harness are protected, secure them
to the hose cover backs with the Tie-Wraps.
At this time the evaporator can be mounted. See
Section 2 for the proper procedures for installing a rear
mounted evaporator assembly.
16. You may now make the appropriate connection to
the evaporator.
Proper hose to fitting clamping is critical. Do not attempt
to attach any hose or fitting until you have familiarized
yourself with Carrier Transport AC’s Quick-Click
hose/fitting crimping procedures.
4.4 EVAPORATOR HOSE ROUTING, SIDE-
MOUNTED
The side-mounted evaporator should be installed in the
desired location. Refer to Section 2 for proper
procedures for installing a side-mounted evaporator
assembly.
1. Always keep hose capped until ready to connect to a
system component.
Side mount hose cover kits are supplied with 45 degree
angle pieces and a transition to aid in routing hoses and
harnesse down the side of the bus/vehicle.
2. Select a window post nearest the evaporator to route
the hoses down. In most cases hoses will need to be
routed around seats, emergency exits, etc. Use the
45 degree angles to obtain the proper clearance.
3. Lay out the hose cover backs in the position they will
eventually be installed.
Take extra precaution when routing hoses to a side
mounted evaporator. You are restricted to a limited
amount of space to route the hose. Make sure the hoses
do not bend to the point of kinking the hose. This would
result in poor system performance and/or failure.
4. Mark where the hose cover back meet the evapora-
tor and the floor. This will give you an outline where
the holes for the hoses should be placed.
Before drilling holes for the hoses in the wall or through
the floor, make sure there are no electrical harnesses,
braces, heater lines, etc. in the path of the hose routing
and hole saw. 
						

							T--3114-6 On many of the larger buses there are heater hose lines
with covers running the length of the bus floor. On most
applications there is enough room inside the heater
hose covers to route the hose, harness, and drain line
behind the heater hose. Extreme care must be taken so
as not to drill into, cut, or kink the heater lines. This type
routing takes a little more time, but makes for a much
neater installation.
5. Drill a 3/16 inch pilot hole in the center of where you
are going to drill the two 1 1/2 inch holes through the
floor. This will show you if you can safely cut the two 1
1/2 inch holes through the floor.
6. Drill the two 1-1/2 inch holes side by side within the
hose cover markings.
7. Saw out any material remaining between the two
holes, leaving an oblong hole to route the hoses
through.
8. Remove any sharp edges from around the holes to
prevent hose cutting and/or chaffing.
9. After holes are drilled, sawed and deburred, you are
ready to mount the hose cover backs using a com-
mon fastener such as screws, pop rivets, etc.
When drilling into the vehicle wall, always use a drill stop
to help protect against damaging any wiring that might
be located behind the wall.
Installation Tip
To help keep hoses, harness, and drain lines
secure and in the center of the hose covers,
3/16 inch holes can be drilled in the hose cover
backs. Insert Tie-Wraps through the holes be-
fore securing the hose cover backs to the wall
(see Figure 4-- 14).
Figure 4-- 14 Hose Cover Backs W/Tie-Wraps10. Remove (deburr) any rough edges from around the
cut-out.
11. Route the hoses and harness at this time.
Before fastening to the hose cover backs, protect the
hoses and harness wherever they go through the bus
floor or heater cover.
A piece of scrap drain hose or heater hose, split down
the middle, can be used for protection.
12. After hoses and harness are protected, secure them
to the hose cover backs with the Tie-Wraps.
13. You may now make the appropriate hose connec-
tions to the evaporator.
Properly clamping a fitting to the refrigerant hose is very
important. Do not attempt to attach any hose or fitting
until you have familiarized yourself with Carrier
Transport Air Conditioning Quick-Click hose/fitting
clamping procedures.
4.5 CHASSIS HOSE ROUTING
Always keep hose capped until ready to connect to a
system component.
Exact routing of hose and harness in the chassis area
cannot possibly be covered in detail due to the various
manufacturers of vehicles and chassis, as well as many
different applications.
Once the hoses are routed from the evaporator area
and through the floor of the vehicle, they will have to be
routed to the condenser and compressor areas.
Before routing the hose, plan the route the hose and
harness will take, avoiding heat sources, sharp or rough
areas, moving parts, etc.
Always protect hose and harness where they cross over
the vehicle frame or any other place where they are
laying on sharp edges (see Figure 4-- 15 & Figure 4-- 17)
or are near any heat source.
Secure the hoses underneath the vehicle with insulated
“P-Clamps”. Clamps should be spaced no more than 24
inches apart. Secure the hoses and harness to the
vehicles floor supports and/or chassis frame (see
Figure 4-- 15 thru Figure 4-- 16). 
						

							T--311 4-7
Figure 4-- 15 Hose Routing (Chassis)
Figure 4-- 16 Hose Routing (Chassis)
Figure 4-- 17 Hose Routing (Chassis)
Figure 4-- 18 Hose Routing (Chassis)
Figure 4-- 19 Hose Routing (Chassis & Condenser)
4.6 CONDENSER HOSE ROUTING
Always keep hose capped until ready to connect to a
system component.When mounting hose in the condenser area, secure the
hose in a manner so that the weight of the hose is not on
the condenser fittings. 
						

							T--3114-8 Always try to leave a service loop in the hose to relieve
stress from the condenser fitting and for ease of
serviceability.
When making condenser connections, always use
caution as you start the fitting onto the condenser.
Lubricate the fitting and “O” Ring with mineral oil before
making the connection.
Secure hoses in the condenser area with insulated
P-Clamps (see Figure 4-- 19).
Properly clamping a fitting to the refrigerant hose is very
important. Do not attempt to attach any hose or fitting
until you have familiarized yourself with Carrier
Transport Air Conditioning Quick-Click hose/fitting
clamping procedures.
4.7VEHICLE COMPRESSOR HOSE ROUTING
Always keep hose capped until ready to connect to a
system component.
When routing hoses in the engine area, you must use
extreme caution, due to the many heat sources, sharp
edges, and engine movement (See Figure 4-- 20).Hoses must be protected with a heat resistant insulation
when routed close to the manifold, turbo pipes, or any
other hot area of the vehicle engine.
Low Side Access
High Side Access
Figure 4--20 Engine Routing (With High & Low
In-Line Access Fittings)
Heat Shielding
Clamps
Low Side AccessHigh Side Access
Figure 4--21 Hose Routing - OEM (To & From Engine)
Caution
Never substitute fittings or hose. Follow the
piping diagram provided with the system.
Follow any special instructions on hose routing that may
have been supplied with the vehicle compressor mount
kit.
Always leave a service a loop in the hoses when
connecting to the compressor on the vehicles engine.
This will allow the hoses to flex with engine movement,
taking stress off of the compressor fittings. Failure to
relieve stress may result in fittings backing off, leaks,
and/or fitting failure.
Secure hoses with insulated P-Clamps whenever
possible (See Figure 4-- 21).
CAUTION
Tie-Wraps may be used to bundle hoses
and harnesses, but should never be used to
secure hoses to the vehicle.
When making compressor connections, always use
caution as you start the fitting onto the compressor.
Lubricate the fitting and “O” Ring with mineral oil before
making the connection.
Apply Mineral Oil to all Flare and O-Ring surfaces prior
to connecting.CAUTION
No matter what type of lubricant (oil) used
in the system, always use mineral oil to lu-
bricate the O-Rings, and fittings. PAG oils
will absorb moisture and become very acid-
ic and corrosive. Mineral oil will not absorb
moisture and thus prevent corrosion.
CAUTION
Always use existing holes in the chassis
frame. Never drill holes in the chassis
frame.
CAUTION
Never secure hoses or harnesses to any
part of the vehicle fuel system.
Install all hoses and fittings in a manner that will not
adversely affect the fitting torque.
4.8 TORQUE SPECIFICATIONS - REFRIGERANT
FITTINGS
All refrigerant hose fitting connections must be torqued
to the specifications listed in Table 4-1. Fittings threads
and O-Rings must be lubricated with mineral oil, not
PAG or POE oils. 
						

							T--311 4-9 Table 4-1 STANDARD TORQUE REQUIREMENTS
SIZETUBE O.D. *FLAREO-RINGTHREAD **
STEEL TUBINGALUM. TUBING
41/4 inch (.250)11-13 ft./lbs.30-35 ft./lbs.5-7 ft./lbs.7/16
53/8 inch (.375)15-17 ft./lbs.30-35 ft./lbs.8-10 ft./lbs9/16
63/8 inch (.375)18-20 ft./lbs.30-35 ft./lbs.11-13 ft./lbs5/8
81/2 inch (.500)36-39 ft./lbs.30-35 ft./lbs.15-20 ft./lbs3/4
105/8 inch (.625)52-57 ft./lbs.30-35 ft./lbs.21-27 ft./lbs7/8
123/4 inch (.750)71-79 ft./lbs.30-35 ft./lbs.28-33 ft./lbs1-1/16
*The tube O.D. is measured at the point it passes through the nut.**Thread pitch may vary.
4.9 ROOFTOP CONDENSER HOSE ROUTING
(CM-7 & CM-11)
Always keep hose capped until ready to connect to a
system component.
Hoses should be routed as close to the evaporator as
possible. This will ease the routing through the roof and
to the condenser.
When making condenser connections, always use
caution as you start the fitting onto the condenser.
Lubricate the fitting and “O” Ring with mineral oil before
making the connection.
Properly clamping a fitting to the refrigerant hose is very
important. Do not attempt to attach any hose or fitting
until you have familiarized yourself with Carrier
Transport Air Conditioning Quick-Click hose/fitting
clamping procedures.
4.10AUXILIARY HEATER HOSE ROUTING
(GENERIC)
Carrier Transport Air Conditioning does not supply
heater hose for connecting to a Carrier Transport Air
Conditioning supplied heater coil.
The following general guidelines have been established
to aid in connecting an auxiliary heater coil to the
vehicles heating system.Use only approved OEM type heater hose or its
equivalent.
Use only worm-gear drive type hose clamps on heater
hose.
Never secure heater hose to the transmission dip stick
tube or on to any fuel system component.
Do not route heater hoses near sharp edges, utilize
edge guards to protect against cutting and/or chaffing.
Secure heater hoses with insulated P-clamps.
CAUTION
Tie-Wraps may be used to bundle hoses
and harnesses, but should never be used to
secure hoses to the vehicle.
The hot water supply hose should be connected to the
lowest part of the heater core.
Minimize air pockets in the system by adding an air
bleed-off device at the systems high point.
The use of a positive shut-off valve in the auxiliary hot
water supply hose is highly recommended. Any leakage
of hot water into the heater core during the air
conditioning season will adversely effect the cooling
efficiency of the air conditioning system.
4.11 PIPING DIAGRAMS
While all piping diagrams could not be included in this
manual, some of the more common installations have.Always refer to the detailed piping diagrams furnished
with the system you are installing. If your specific piping
diagram is not included with your system installation kit,
contact Carrier Transport Air Conditioning Technical
Support Hot Line at 800-450-2211. 
						

							4--10 T--311
Figure 4-22 Rear Evaporator, OEM Tie-in
FILTER DRIER 
						

							4--11 T--311
Figure 4-23 Evaporator, Skirt Monuted Condenser and Compressor
FILTER DRIER 
						

							4--12 T--311
Figure 4-24 Evaporator, Skirt Monuted Condenser and Compressor (AC-- 322, -- 332, -- 442)
FILTER DRIER 
						

							4--13 T--311
Figure 4-25 Evaporator, Skirt Monuted Condenser Compressor and Aftermarket InDash (AC-- 4431)
FILTER
DRIER 
						

							4--14 T--311
Figure 4-26 EM--3 Evaporator, (2) Skirt Monuted Condensers and TM -- 31 Compressor (AC-- 882, -- 883)
FILTER
DRIER
FILTER
DRIER