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

Affected Serial Number Range

TBK00100 to TBK01120

TL943

TBL00100 to TBL01517

TL1055

TBM00100 to TBM001167

TL1255

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

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 72hose 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:
2.5x 15 to front vent
3 x 48 to 2nd vent
3 x 72 to 3rd 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

Notch
in dash

22. Connect suction vent filter to top of tube

using six #6 x 1/2 self-tapping screws.

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
machine for operation.

and

prepare

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