Kubota 2482B Engine

⚠ Fuel presents the hazard of explosion or fire which can result in severe personal injury or death.

Tools: tube cutter

1. Remove the plug from the 1/2-inch NPT fitting.
2. Measure the tank depth.
3. Use a tube cutter to shorten the long (fuel supply) tube so it is 2 inches (50.8 mm) shorter than the tank depth.
4. Apply pipe sealer or sealant tape suitable for diesel fuel connections to the NPT threads.
5. Install the pickup tube assembly and tighten the fittings securely to prevent leakage.

⚠ Electrical shock can cause severe personal injury; remove rings, watches and other jewelry.

⚠ Batteries present the hazard of explosion; always disconnect the negative (-) cables first, and connect them last.

Tools: battery cable terminal crimping tool

1. Remove the negative (-) battery cable connection(s) at the battery tray.
2. Route both battery cables to the battery compartment using a path that allows tie points.
3. Cut the battery cables to the correct length, allowing for routing and power unit movement.
4. Install the 3/8-inch ring terminals to the battery cables with a good crimping tool.
5. Connect the positive (+) cable to the battery positive terminal and the negative (-) cable to the negative terminal; tighten securely.
6. Provide adequate support for the battery cables to avoid abrasion.
7. Reconnect the other negative (-) battery cable connection(s) at the battery tray.

⚠ Fuel and electrical systems present the hazard of severe personal injury; check before drilling into the compartment floor to avoid hitting the fuel tank, fuel lines or electrical lines. Do not drill into frame members.

Tools: drill, template

1. Remove the sleeper bunk and other items that interfere with the installation.
2. Trim the template and tape it to the floor of the compartment.
3. Mark each hole location and drill 1/8-inch pilot holes to check for clearance.
4. Drill each of the mounting and routing holes to size.
5. Install the evaporator/heater assembly and secure it to the compartment floor.
6. Direct the blower air outlet into the existing sleeper air outlet or install a new outlet.
7. Install a 7/16-inch I.D. vinyl drain hose on the drain tube if needed.

Tools: drill, template

1. Select a location beneath the sleeper with access for coolant hose routing and fasteners.
2. Hold the solenoid valve assembly with the TE (to engine) connections facing front and AUX connections facing back.
3. Use the reinforcement plate as a template to mark the three mounting holes and drill three 7/16-inch diameter holes.
4. Secure the solenoid valve assembly with the three 3/8-16 x 7/8-inch screws and washers.
5. Connect the wiring harness to the solenoid valve assembly.

⚠ Electric sparks can ignite fuel; run electrical wiring and fuel lines as far apart as possible or separate them by physical barriers.

⚠ Do not over tighten clamps or the hose could be damaged.

Tools: hose cutter

1. Measure the required hose length, allowing for movement of the power unit.
2. Cut both hoses to length and mark one hose supply on each end.
3. Install protective sleeving over both hoses, leaving 3 inches (76 mm) of exposed hose at each end.
4. Secure the protective sleeving every 18 inches (457 mm) with plastic tie wraps.
5. Route and connect the fuel supply hose to the power unit supply fitting and to the pickup supply line.
6. Connect the return hose to the power unit return fitting and to the pickup return line.
7. Secure fuel hoses to the bottom of the sleeper or tractor frame with plastic wire ties.

⚠ Fuel presents the hazard of explosion or fire which can result in severe personal injury or death.

Tools: tube cutter

1. Remove the fuel gauge and save the gasket.
2. Measure the tank depth.
3. Use a tube cutter to shorten the long (fuel supply) tube so it is 2 inches (50.8 mm) shorter than the tank depth.
4. Install the fuel pickup assembly with the gaskets as shown.
5. Tighten each of the mounting screws securely to prevent fuel leakage.

⚠ Dropping the power unit can cause severe personal injury or death.

⚠ Do not drill holes into the tractor rail; drilling will damage it and could cause it to bend or break.

⚠ Over tightening the mounting bracket bolts can damage the angle brackets.

Tools: forklift or floor jack, torque wrench, drill

1. Remove shipping carton staples and carefully lift the carton off the power unit.
2. Leave the power unit skid base on the unit until it has been mounted on the rails.
3. Raise the power unit onto a forklift or floor jack and make sure it is stable.
4. Remove or relocate accessories that interfere with mounting of the power unit.
5. Mark the rail 18 inches (457 mm) apart to indicate the mounting location.
6. Inspect the rail and angle brackets for interference and relocate the unit if found.
7. Maintain 2 inches (50.8 mm) clearance at the air inlet and in front of the radiator.
8. Remove mounting screws from the back of both side panels.
9. Assemble the spacer and then the angle bracket to the side panels.
10. Tighten angle bracket mounting bolts to 32 ft lbs (43 N·m).
11. Secure clamps to the rails with 5/8-inch bolts, flat washers and lock nuts; do not tighten yet.
12. Tighten top mounting bracket bolts to 50 ft lbs (68 N·m), then bottom bolts to 50 ft lbs (68 N·m).
13. Lower the jack, remove the four skid base bolts, remove skid base and reinstall the bolts to 32 ft lbs (43 N·m).
14. Remove the cardboard covering the radiator/condenser outlet and check U-joint alignment.

⚠ Exhaust gas presents the hazard of severe personal injury or death; the tailpipe must terminate away from any vent, window or opening into the cab or sleeper.

⚠ Excessive exhaust back pressure can cause engine damage.

1. Assemble the two exhaust mounting brackets to the bottom of the power unit with 1/4-20 mm bolts.
2. Install the muffler and secure it to the mounting brackets with U-bolts, washers, lock washers and mounting nuts.
3. Secure the muffler inlet pipe to the exhaust manifold outlet with the exhaust clamp.

Tools: hole saw, drill, template

1. Remove the mattress, mattress support and other items that interfere with the installation.
2. Place the template on the sleeper floor next to the evaporator and mark the drain tube and mounting holes.
3. Locate refrigerant lines a minimum of 7 inches (177.8 mm) from the piggyback evaporator expansion valve.
4. Drill a 5/8-inch drain tube hole and two 5/16-inch evaporator mounting holes in the sleeper floor.
5. Drill a 2-inch diameter hole in the sleeper floor for the refrigerant line grommet and install the grommet.
6. Remove the two top cover mounting screws from the evaporator end of the existing evaporator/heater assembly.
7. Bergstrom unit: install the baffle as shown and reinstall the cover.
8. Kenworth unit: disable the built-in control and valve before disconnecting OEM wiring.
9. Install the piggyback evaporator and secure it to the evaporator/heater assembly and compartment floor.
10. Seal the mating surfaces with silicon or other suitable duct sealant.
11. Install a 7/16-inch I.D. vinyl drain hose on the drain tube if moisture could drip on components.

⚠ Do not open the oil fill on the compressor when the system is charged; refrigerant and oil are released under pressure.

Tools: clean syringe

1. Measure the length of the larger #10 refrigerant hose from the power unit to the evaporator.
2. Refer to Table 13-1 to determine the amount of oil to add to the system.
3. Remove the top cover from the power unit and locate the AC compressor.
4. Carefully remove the oil fill cap and use a clean syringe to add the required amount of oil.
5. Securely reinstall the oil fill cap.

⚠ Do not operate the power unit engine. No more than one pound of refrigerant should be added at this time.

⚠ Adding R-134a as a liquid can damage the compressor if not done correctly.

Tools: AC service gauges, weight scale

1. Connect the center service hose from the gauge set to the R-134a container dispensing valve.
2. Purge the hose of any air using R-134a gas pressure from the container.
3. Turn the refrigerant container upside down.
4. Open the R-134a dispensing valve and HP side hand valve on the gauge set to flow liquid R-134a into the system.
5. When approximately one pound of R-134a liquid has been added, close the R-134a supply.

Tools: AC service gauges, vacuum pump

1. Make sure the AC hose fittings are secure at the evaporator and at the power unit.
2. Attach a gauge set to the high pressure (HP) and low pressure (LP) sides at the quick connect access valves.
3. Attach a vacuum pump to the center hose of the gauge set.
4. Open the no load fitting on the pump housing, start the pump, open the manifold hand valves and close the no load fitting.
5. Run the pump for five minutes, then close the hand valves and shut off the pump.
6. Observe the gauge readings for a few minutes; if needles move up there is a leak.
7. Check and tighten fittings, restart the pump and repeat the leak check.
8. Run the vacuum pump for an hour to remove moisture from the system.
9. After one hour, verify LP side reaches minus (-) 29 inches Hg and HP side reads less than zero PSI.
10. Close the hand valves.