- Motor Grader:
- 12H NA (S/N: 4XM1-UP; 2WR1-UP; 8MN1-UP)
- 12H ES (S/N: 2LR1-UP; 2GS1-UP)
- 120H NA (S/N: 4MK1-UP; 2AN1-UP; 6YN1-UP)
- 120H ES (S/N: 6NM1-UP; 2YR1-UP)
- 135H NA (S/N: 3YK1-UP)
- 140H NA (S/N: 2ZK1-UP; 9ZN1-UP; 9TN1-UP)
- 140H ES (S/N: 8KN1-UP; 3AS1-UP)
- 160H NA (S/N: 9EJ1-UP; 3GM1-UP)
- 160H ES (S/N: 6WM1-UP; 2HS1-UP)
- 12H ES (S/N: 2LR1-UP; 2GS1-UP)
Introduction
This publication will give instructions for the field installation of an air conditioner assembly.
- The 12H, 140H, and 160H use the 192-1511 Air Conditioner Gp .
- The 120H and 135H use the 192-5372 Air Conditioner Gp .
General Information
All refrigerant lines must be free of sharp bends. Also, do not use a refrigerant line that is kinked. Sharp bends will cause a restriction in the refrigerant flow. Restriction in the lines will reduce the performance and the efficiency of the system.
The radius of bends in the flexible hose must never be less than 10 times the outside diameter of the hose.
Do not allow the flexible hoses to come within the 63.5 mm (2.5 inch) of the exhaust manifold.
The hoses need to be inspected yearly for leaks and for hardness. Do a leak test on all the hoses and all the lines. Refer to the Service Manual, SENR5664, "Refrigerant Leakage - Test" section in Testing and Adjusting. Replace the hose if the hose leaks. Replace the hose if the hose is brittle. Replace hoses with a new hose that is sealed and free of contaminants.
The correct use of wrenches is very important when connections are made. The type of wrench is also important. Use only the wrenches that are made for use with the tube type fittings. When a hose or a metal line is connected or a hose or a metal line is disconnected, use a wrench on the fitting and on the nut. Also use a wrench on the hose connection.
When the components and the refrigerant lines are disconnected, refer to the Testing and Adjusting section of Service Manual, SENR5664, "Refrigerant Recovery".
Install protective plugs or caps on all components and all hoses that are disconnected.
The O-rings and the seals must be in good condition. Small cuts, scratches or particles of dirt will cause a leak in the system. Put new refrigerant oil on all new O-ring seals at time of installation. Do not use any kind of sealant on any of the air conditioner hose connections.
Standard Torques for Air Conditioner Fittings
| Fitting Ends with O-Ring Seals | |
|---|---|
| Thread Size Inch |
Standard Torque |
| 5/8 - 18 | 14 ± 4 N·m (10.3 ± 3.0 lb ft) |
| 3/4 - 16 | 27 ± 4 N·m (19.9 ± 3.0 lb ft) |
| 7/8 - 14 | 40 ± 4 N·m (29.5 ± 3.0 lb ft) |
| 1 -14 | 40 ± 4 N·m (29.5 ± 3.0 lb ft) |
| 1 - 1/16 - 14 | 45 ± 5 N·m (33.2 ± 4.0 lb ft) |
Installation of the 192-1511 Air Conditioner Gp
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
 |
Personal injury can result from contact with refrigerant. 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 precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. 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. Use a certified recovery and recyling cart to properly remove the refrigerant from the air conditioning system. |
 |
|
Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth, level surface. Lower the work tool to the ground and engage the parking brake. Stop the engine and remove the key. Block the wheels and install the steering frame lock. |
|
Note: Put identification marks on all hoses and on all wires for installation purposes. Plug the hoses. This will help keep contaminants from entering the system.
- Install the steering frame lock pin between the front frame and the rear frame. Secure the clevis pin with the locking pin.
Installation of the Evaporator Coil
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 3T-3197 | Grommet |
| 2 | 1 | 9X-7382 | O-Ring Seal |
| 3 | 1 | 3T-3198 | Grommet |
| 4 | 1 | 9X-7381 | O-Ring Seal |
| 5 | 1 | 125-0438 | Gasket |
| 6 | 50 cm | 9X-2126 | Seal |
| 7 | 1 | 9X-9653 | Evaporator Coil As |
| 8 | 1 | 3E-5464 | Thermostat Switch |
| 9 | 2 | 8T-6631 | Screw |
| 10 | 2 | 3B-4501 | Lockwasher |
| 11 | 1 | 8X-7153 | Hose As |
| 12 | 1 | 8X-7152 | Hose As |
| 13 | 1 | 3S-2093 | Cable Strap |
| 14 | 180 cm | 5P-4829 | Tube |
| 15 | 2 | 7T-9793 | Valve |
| 16 | 1 | 8T-4896 | Hard Washer |
| 17 | 1 | 5M-3062 | Bolt |
| 18 | 2 | 8M-2773 | Clip |
| 19 | 1 | 110-6393 | Instruction Plate |
- Remove the seat. Refer to Disassembly and Assembly, "Seat and Seat Belt - Remove and Install".
- Remove setscrews (A) from the side of the knobs for temperature control and for fan speed. Remove knobs (B) from the console. Keep knobs and the setscrews.
 | |
| Illustration 1 | g00755044 |
- Remove four bolts (C) from gate assembly (D) on the transmission control console. Remove gate assembly (D) .
 | |
| Illustration 2 | g00755046 |
- Remove two bolts (E) from cover (F). Remove cover (F).
 | |
| Illustration 3 | g00755071 |
- Loosen the nut on the switch assembly for temperature setting (G). Remove the switch assembly.
 | |
| Illustration 4 | g00755084 |
- Remove shaft (H) from the plate.
 | |
| Illustration 5 | g00755096 |
- Remove two bolts (J) and plate (K) under the console.
 | |
| Illustration 6 | g00755098 |
- Remove two nuts (L) and two washers (M). Keep the nuts and the washers for assembly purposes.
 | |
| Illustration 7 | g00755100 |
- Attach 9X-2126 Seal (6) to evaporator coil (7). Apply the adhesive in two locations on the side of the seal that is toward the evaporator coil.
 | |
| Illustration 8 | g00755103 |
- Insert the 9X-9653 Evaporator Coil As (7) next to the heater coil assembly.
- Insert 3T-3198 Grommet (3) into hole (N) in the floor of the 8C-9787 Cab Heater Gp . Insert 3T-3197 Grommet (1) into hole (P) in the floor of the 8C-9787 Cab Heater Gp .
 | |
| Illustration 9 | g00755118 |
Top view | |
- Install one 9X-7381 O-Ring Seal (4) in 8X-7152 Hose As (12). Connect hose (12) to the evaporator coil.
Note: Apply PAG oil to all O-ring seals prior to installation.
 | |
| Illustration 10 | g00755126 |
- Install one 9X-7382 O-Ring Seal (2) in 8X-7153 Hose As (11). Attach hose (11) to the evaporator coil.
Note: Apply PAG oil to all O-ring seals prior to installation.
- Insert the capillary tube from 3E-5464 Thermostat Switch (8). Insert the capillary tube to a depth of 190 mm (7.5 inch) in evaporator coil (7) .
 | |
| Illustration 11 | g00755129 |
- Locate wire 200-BK (R) and wire 522-WH (S). Connect the wire 200-BK (R) to 3E-5464 Thermostat Switch (8). Connect wire 522-WH (S) to switch (8) .
 | |
| Illustration 12 | g00755131 |
- Secure 3E-5464 Thermostat Switch (8) in position with two 8T-6631 Screws (9) and two 3B-4501 Lockwashers (10). Tighten the screws to a torque of 1.4 ± 4.0 N·m (1.0 ± 3.0 lb ft).
 | |
| Illustration 13 | g00755147 |
- Secure electrical wires to the blower housing. Use 3S-2093 Cable Strap (13) to secure the electrical wires.
 | |
| Illustration 14 | g00756396 |
- Install two nuts (L) and two washers (M). Tighten nuts to a torque of 25 ± 4 N·m (18.4 ± 2.9 lb ft).
| | |
| Illustration 15 | g00755100 |
- Install 125-0438 Gasket (5) to the console.
 | |
| Illustration 16 | g00755177 |
- Install two bolts (J) and plate (K) under the console.
| | |
| Illustration 17 | g00755098 |
- Install 124-9006 Shaft (H) through the plate. Tighten the nut on shaft (H) to a torque of 2.75 ± 0.25 N·m (24.34 ± 2.21 lb in).
| | |
| Illustration 18 | g00755096 |
- Install cover (F). Install two bolts (E) .
| | |
| Illustration 19 | g00755071 |
- Install gate assembly (D) with four bolts (C) .
| | |
| Illustration 20 | g00755046 |
- Install switch (G). Tighten the nut on switch (G) to a torque of 5.2 ± 0.2 N·m (46.02 ± 1.77 lb in).
| | |
| Illustration 21 | g00755084 |
- Install the two knobs (B) and the two setscrews (A) from the console.
| | |
| Illustration 22 | g00755044 |
- Cut two lengths of 5P-4829 Tube (14). Each length should be 865 ± 5 mm (34.0 ± 0.2 inch).
 | |
| Illustration 23 | g00755181 |
(T) 75 ± 3 mm (2.9 ± 0.1 inch) | |
- Insert one 7T-9793 Valve (15) into each length of tube. Insert the valve to a depth of 75 ± 3 mm (2.9 ± 0.1 inch) from the end of 5P-4829 Tube (14) .
- Locate two drains for condensation under the cab. Remove the plugs. Discard the plugs.
- Fit each 5P-4829 Tube (14) to each drain.
- Secure tube (14) to the front left hand frame with the following hardware: one 8T-4896 Hard Washer (16), one 5M-3062 Bolt (17) and one 8M-2773 Clip (18) .
 | |
| Illustration 24 | g00757345 |
- Use one 8M-2773 Clip (18) and the provided hardware to secure tube (14) to the front right hand frame.
 | |
| Illustration 25 | g00757346 |
- Stamp 110-6393 Instruction Plate (19) with 1.6 kg (3.5 lb) for the amount of refrigerant charge. Install 110-6393 Instruction Plate (19) on the front portion of the seat base.
 | |
| Illustration 26 | g00755183 |
Installation of the Refrigerant Compressor
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 3E-1906 | Refrigerant Compressor |
| 2 | 1 | 7E-6460 | Bracket |
| 3 | 2 | 5S-7383 | Bolt |
| 4 | 1 | 8T-9389 | Bolt |
| 5 | 2 | 6V-8188 | Nut |
| 6 | 1 | 7X-0337 | Bolt |
| 7 | 3 | 8T-4223 | Hard Washer |
| 8 | 2 | 106-4127 | Bracket |
| 9 | 6 | 4L-9337 | Bolt |
| 10 | 13 | 8T-4896 | Hard Washer |
| 11 | 6 | 6V-8801 | Nut |
| 12 | 1 | 9F-8885 | Spacer |
| 13 | 1 | 8T-4835 | Bolt |
| 14 | 1 | 7W-4978 | Nut |
| 15 | 1 | 8T-2502 | Bolt |
| 16 | 1 | 7W-4975 | Strap |
| 17 | 1 | 7C-8434 | Bracket |
| 18 | 1 | 4N-7335 | V-Belt |
- Remove four bolts (A) and cover (B). Keep the bolts for assembly purposes.
Note: The refrigerant compressor is mounted on a bracket that is on the right side of the engine.
 | |
| Illustration 27 | g00755187 |
- Install 7E-6460 Bracket (2) to the front face of the cylinder block. Install the bracket with the following components: two 5S-7383 Bolts (3), one 8T-9389 Bolt (4) and one 6V-8188 Nut (5) .
 | |
| Illustration 28 | g00755190 |
- Install two 106-4127 Brackets (8) on 7E-6460 Bracket (2). Install bracket (8) with the following components: one 6V-8188 Nut (5), one 7X-0337 Bolt (6) and two 8T-4223 Hard Washer (7) .
 | |
| Illustration 29 | g00755193 |
- Install 7C-8434 Bracket (17) on 3E-1906 Refrigerant Compressor (1). Install bracket (17) with the following components: two 4L-9337 Bolts (9), four 8T-4896 Hard Washers (10) and two 6V-8801 Nuts (11) .
 | |
| Illustration 30 | g00755196 |
- Install refrigerant compressor (1) on both 106-4127 Brackets (8). Install the refrigerant compressor with the following components: four 4L-9337 Bolts (9), eight 8T-4896 Washers (10) and four 6V-8801 Nuts (11) .
 | |
| Illustration 31 | g00760327 |
Front view | |
 | |
| Illustration 32 | g00755199 |
View A-A | |
- Attach 7W-4975 Strap (16) to the cylinder block. Attach strap (16) with the following items: one 8T-4835 Bolt (13), one 8T-4223 Washer (7) and one 9F-8885 Spacer (12) .
 | |
| Illustration 33 | g00755202 |
- Attach the refrigerant compressor to 7W-4975 Strap (16). Attach strap (16) with the following components: one 8T-4896 Washer (10), one 7W-4978 Nut (14) and one 8T-2502 Bolt (15) .
 | |
| Illustration 34 | g00755205 |
- Install 7N-7335 V-Belt (18) on the compressor pulley. Refer to the Operations and Maintenance Manual, "V-Belts - Inspect/Adjust/Replace" for the procedure.
The initial tension on a new belt should be 534 ± 22 N (120 ± 5 lb). After at least 30 minutes of operation, recheck the V-Belt tension. The tension should be 400 ± 44 N (90 ± 10 lb).
 | |
| Illustration 35 | g00755207 |
- Install four bolts (A) and cover (B) .
| | |
| Illustration 36 | g00755187 |
Installation of Condenser Core
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 4 | 5P-1075 | Hard Washer |
| 2 | 2 | 5S-7383 | Bolt |
| 3 | 1 | 219-0018 | Condenser Coil Assembly |
| 4 | 2 | 7X-0300 | Bolt |
| 5 | 4 | 101-3120 | Spacer |
The condenser is mounted on the side of the radiator that faces the engine.
- Remove the radiator. Refer to the Disassembly and Assembly, "Radiator - Remove" section of the Engine Supplement.
- Remove 15 bolts (A) and 15 washers from lower plate (B) on plate assembly (C).
 | |
| Illustration 37 | g00755209 |
- Remove plate (B) from the radiator shroud.
 | |
| Illustration 38 | g00755211 |
- Remove plate assembly (C) from the radiator shroud.
 | |
| Illustration 39 | g00755212 |
- Put 219-0018 Condenser Coil Assembly (3) in a position that is next to the radiator assembly.
 | |
| Illustration 40 | g00755214 |
- Install two 5P-1075 Hard Washers (1), two 5S-7383 Bolts (2), and two 101-3120 Spacers (5) on the upper corners of condenser coil assembly (3) .
 | |
| Illustration 41 | g00755216 |
- Install two 5P-1075 Hard Washers (1), two 7X-0300 Bolts (4), and two 101-3120 Spacers (5) in the lower corners of condenser coil assembly (3).
 | |
| Illustration 42 | g00755217 |
- Position plate assembly (C) to the bottom inside corner of the radiator shroud.
| | |
| Illustration 43 | g00755212 |
- Position lower plate (B) to the radiator shroud.
| | |
| Illustration 44 | g00755211 |
- Install 15 bolts (A) in lower plate (B). The bolts secure the lower plate to the radiator guard and to plate assembly (C) .
| | |
| Illustration 45 | g00755209 |
- Install the radiator. Refer to the Disassembly and Assembly, "Radiator - Install" section of the Engine Supplement.
Installation of the Air Conditioning Lines and of the Air Conditioner Accumulator
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 197-6218 | Refrigerant Accumulator |
| 2 | 2 | 9X-7383 | O-Ring Seal |
| 3 | 2 | 103-6100 | Quick Coupler |
| 4 | 3 | 9X-7380 | O-Ring Seal |
| 5 | 1 | 3E-3535 | In-Line Refrigerant Dryer |
| 6 | 1 | 8S-6109 | Clip |
| 7 | 1 | 8X-6110 | Block |
| 8 | 1 | 9B-7237 | Bolt |
| 9 | 4 | 5P-1075 | Hard Washer |
| 10 | 1 | 4S-1962 | Clip |
| 11 | 1 | 8X-7151 | Hose As |
| 12 | 4 | 8W-8528 | Sleeve |
| 13 | 2 | 9X-7381 | O-Ring Seal |
| 14 | 1 | 8X-7150 | Hose As |
| 15 | 3 | 8W-8527 | Sleeve |
| 16 | 1 | 114-5334 | Pressure Switch |
| 17 | 1 | 1P-6356 | Plate |
| 18 | 1 | 085-8091 | Bolt |
| 19 | 1 | 128-5924 | Clamp |
| 20 | 1 | 8R-3393 | Strap |
| 21 | 2 | 5M-3062 | Bolt |
| 22 | 1 | 8X-7154 | Hose As |
| 23 | 1 | 9X-7382 | O-Ring Seal |
| 24 | 1 | 3E-4054 | Air Conditioner Fitting |
| 25 | 2 | 9X-7385 | O-Ring Seal |
| 26 | 1 | 3E-4067 | Compressor Fitting |
| 27 | 2 | 9X-7378 | O-Ring Seal |
| 28 | 1 | 106-8704 | Arc Suppressor |
Installation of the Refrigerant Accumulator
Note: Apply PAG oil to all O-ring seals prior to installation.
- Install one 9X-7383 O-Ring Seal (2) in 8X-7153 Hose As (A). Connect hose (A) from the evaporator core to the top of 197-6218 Refrigerant Accumulator (1).
Note: The refrigerant accumulator is located under the cab on the right side of the machine.
 | |
| Illustration 46 | g00755281 |
- Install one 9X-7383 O-Ring Seal (2) in 8X-7154 Hose As (22). Connect hose (22) to accumulator (1).
 | |
| Illustration 47 | g00755298 |
- Install 197-6218 Refrigerant Accumulator (1) by using the following components: one 128-5924 Clamp (19), one 8R-3393 Strap (20), two 5M-3062 Bolt (21) and two 5P-1075 Hard Washer (9) .
 | |
| Illustration 48 | g00755755 |
Installation of the In-Line Refrigerant Dryer
Note: The refrigerant dryer is located under the cab. The refrigerant dryer is located on the right side of the machine.
Note: Apply PAG oil to all O-ring seals prior to installation.
- Install one 9X-7380 O-Ring Seal (4) in 8X-7152 Hose As (B). Connect hose (B) from the evaporator core to the top of 3E-3535 In-Line Refrigerant Dryer (5). Use one 103-6100 Quick Coupler (3) .
 | |
| Illustration 49 | g00755760 |
- Install one 9X-7380 O-Ring Seal (4) in 8X-7151 Hose As (11). Connect hose (11) to 3E-3535 In-Line Refrigerant Dryer (5). Use one 103-6100 Quick Coupler (3) .
 | |
| Illustration 50 | g00755779 |
- Attach 3E-3535 In-Line Refrigerant Dryer (5) to the frame by using the following components: one 8S-6109 Clip (6), one 8S-6110 Clip (7), one 9B-7237 Bolt (8) and one 5P-1075 Hard Washer (9) .
 | |
| Illustration 51 | g00755785 |
Installation of the Air Conditioning Lines
Note: Apply PAG oil to all O-ring seals prior to installation.
- Use one 4S-1962 Clip (10) to secure 8X-7154 Hose As (22) to the frame.
 | |
| Illustration 52 | g00755788 |
- Remove the two bolts from grommet (C) on the front frame. Keep the bolts for future use. Remove the top part of grommet. Place the hoses (11) and (22) in the grommet (C). Reassemble grommet (C) .
 | |
| Illustration 53 | g00755789 |
 | |
| Illustration 54 | g00760355 |
Section A-A | |
- Remove the two bolts from grommet (D) on the rear frame. Keep the bolts for future use. Remove the top part of grommet (D). Place the hoses (11) and (22) in grommet (D). Reassemble grommet (D) .
 | |
| Illustration 55 | g00756719 |
- Install 3E-4054 Air Conditioner Fitting (24) to the suction port of the refrigerant compressor. Install 3E-4067 Compressor Fitting Assembly (26) to the discharge port of the refrigerant compressor. Use two 9X-7385 O-Ring Seal (25), one 1P-6356 Plate (17), one 5P-1075 Hard Washer (9), and one 085-8091 Bolt (18). Tighten the bolt to a torque of 25 ± 7 N·m (18 ± 5 lb ft).
 | |
| Illustration 56 | g00756729 |
- Install one 9X-7382 O-Ring Seal (23) in 8X-7154 Hose As (22). Connect hose (22) to 3E-4064 Compressor Fitting (24) .
 | |
| Illustration 57 | g00756728 |
- Install one 9X-7381 O-Ring Seal (13) to 8X-7150 Hose As (14). Connect hose (14) to 3E-4067 Compressor Fitting (26) .
- Install one 9X-7380 O-Ring Seal (4) in 8X-7151 Hose As (11). Connect hose (11) to the condenser.
 | |
| Illustration 58 | g00756731 |
- Secure 8X-7151 Hose As (11) to the rear frame with four 8W-8528 Sleeve (12) .
 | |
| Illustration 59 | g00756734 |
- Secure 8X-7150 Hose As (14) to the rear frame with three 8X-8527 Sleeves (15) .
 | |
| Illustration 60 | g00756786 |
- Install 114-5334 Pressure Switch (16) and 9X-7378 O-Ring Seal (27) to the compressor. Tighten the nut on the pressure switch to 8.2 ± 1.4 N·m (72.58 ± 12.39 lb in).
 | |
| Illustration 61 | g00756788 |
- Remove the receptacle with wire PU and with wire WH from the wiring harness. Dispose of the receptacle. Connect the plug end of the pressure switch to the wire harness. Secure the receptacle to the clip.
- Remove the plug from receptacle (E). Install electrical 106-8704 Arc Suppressor (28). Use the strap in order to secure the electrical noise suppressor.
 | |
| Illustration 62 | g00756789 |
- Connect the wire BL (F) to the wire OR (G) .
Charge the System
Before you charge the Air Conditioner system, be sure to evacuate the system. The correct charge is 1.6 kg (3.5 lb). Refer to Service Manual, SEN5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure and for the correct tools.
Preparation for Operation
- Install the seat. Refer to Disassembly and Assembly, "Seat and Seat Belt - Install".
- Remove the articulation lock pin.
Installation of the Cab Components for the 192-5372 Air Conditioner Gp
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
|
Personal injury can result from contact with refrigerant. 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 precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. 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. Use a certified recovery and recyling cart to properly remove the refrigerant from the air conditioning system. |
|
|
Sudden movement or accidental starting of the machine can cause personal injury or death to persons on or near the machine. To prevent personal injury or death, perform the following: Park the machine on a smooth, level surface. Lower the work tool to the ground and engage the parking brake. Stop the engine and remove the key. Block the wheels and install the steering frame lock. |
|
Note: This air conditioner group is only for the machines that do NOT have the emission arrangement for the engine.
- Install the articulation lock pin between the front frame and the rear frame. Secure the clevis pin with the locking pin.
Installation of the Evaporator Coil
For the installation of the evaporator coil, refer to the ""Installation of the Evaporator Coil" " for the 192-1511 Air Conditioner Gp .
Installation of Refrigerant Compressor
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 7C-8541 | Bracket |
| 2 | 4 | 8T-4196 | Bolt |
| 3 | 1 | 9Y-1285 | Strap |
| 4 | 7 | 8T-4121 | Hard Washer |
| 5 | 2 | 8T-4136 | Bolt |
| 6 | 1 | 7W-9852 | Plate |
| 7 | 1 | 3E-1906 | Refrigerant Compressor |
| 8 | 2 | 8T-4186 | Bolt |
| 9 | 3 | 8T-4133 | Nut |
| 10 | 1 | 8T-4222 | Plated Washer |
| 11 | 1 | 8T-5436 | Bolt |
| 12 | 1 | 8N-2814 | V-Belt |
The compressor is mounted to a bracket on the front housing cover of the engine on the left side of the machine.
- Install 7C-8541 Bracket (1) to the front housing cover. Use four 8T-4196 Bolts (2) .
 | |
| Illustration 63 | g00755873 |
 | |
| Illustration 64 | g00760385 |
- Install 9Y-1285 Strap (3) to 7C-8541 Bracket (1). Use one 8T-4121 Hard Washer (4) and one 8T-4136 Bolt (5). Loosely tighten bolt (5) .
- Install 7W-9852 Plate (6) to 3E-1906 Refrigerant Compressor (7). Use four 8T-4121 Hard Washers (4), two 8T-4136 Bolts (8) and two 8T-4133 Nuts (9) .
- Install 3E-1906 Refrigerant Compressor (7) to 7C-8541 Bracket (1). Use the following items: one 8T-4133 Nut (9), two 8T-4121 Hard Washers (4) and one 8T-5436 Bolt (11) .
 | |
| Illustration 65 | g00764337 |
- Attach the 7W-9852 Plate (6) to 9Y-1285 Strap (3). Use 8T-4136 Bolt (5) and one 8T-4222 Plated Washer (10) .
- Install 8N-2814 V-Belt (12) to the compressor pulley. Refer to the Operations and Maintenance Manual, "V-Belts - Inspect/Adjust/Replace" for the correct procedure.
The initial tension on a new belt should be 534 ± 22 N (120 ± 5 lb). After at least 30 minutes of operation, recheck the tension in the V-belt (12). The tension should be 400 ± 44 N (90 ± 10 lb).
Installation of Condenser Core
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 219-7493 | Coil |
| 2 | 2 | 5S-7383 | Bolt |
| 3 | 2 | 5P-1075 | Hard Washer |
| 4 | 4 | 101-3120 | Spacer |
| 5 | 2 | 7X-0300 | Bolt |
| 6 | 2 | 138-3776 | Bracket |
The condenser is mounted on the side of the radiator which faces the engine.
- Remove the radiator. Refer to the Engine Supplement Disassembly and Assembly, "Radiator - Remove and Install".
- Remove upper shield (A) from the radiator guard. Keep bolts (B) for later use.
 | |
| Illustration 66 | g00755911 |
- Remove two bolts (E). Discard two bolts (E). Keep all other mounting hardware (F) .
 | |
| Illustration 67 | g00755914 |
- Remove two brackets (C) between the radiator and the upper shield. Discard two brackets (C). Keep all other mounting hardware (D) .
- Use the following hardware to secure the top of 219-7493 Coil (1) to the radiator: two 101-3120 Spacers (4), two 138-3776 Brackets (6), two 7X-0300 Bolts (5) and mounting hardware (F). Use mounting hardware (D) to secure 138-3776 Brackets (6) to the radiator.
 | |
| Illustration 68 | g00755917 |
- Use two 5S-7383 Bolts (2), two 5P-1075 Hard Washers (3), and two 101-3120 Spacers (4) to secure the bottom of 219-7493 Coil (1) to the radiator.
 | |
| Illustration 69 | g00755920 |
- Use bolts (B) to install upper shield (A) to the radiator guard.
| | |
| Illustration 70 | g00755911 |
- Reinstall the radiator. Refer to the Engine Supplement Disassembly and Assembly, "Radiator".
Installation of Air Conditioning Lines
Installation of Refrigerant Accumulator
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 197-618 | Refrigerant Accumulator |
| 2 | 2 | 9X-7383 | O-Ring Seal |
| 3 | 1 | 128-5924 | Clamp |
| 4 | 1 | 8R-3393 | Strap |
| 5 | 2 | 5M-3062 | Bolt |
| 6 | 2 | 5P-1075 | Hard Washer |
Note: Apply PAG oil to all O-ring seals prior to installation.
- Install one 9X-7383 O-Ring Seal (2) in 8X-7153 Hose As (A). Connect hose (A) from the evaporator coil to the top of 197-6218 Refrigerant Accumulator (1) .
 | |
| Illustration 71 | g00755923 |
- Install 197-6218 Refrigerant Accumulator (1). Use the following items: one 128-5924 Clamp (3), one 8R-3393 Strap (4), two 5M-3062 Bolt (5) and two 5P-1075 Hard Washer (6) .
Installation of the In-Line Refrigerant Dryer
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 3E-3535 | In-Line Refrigerant Dryer |
| 2 | 1 | 8S-6109 | Clip |
| 3 | 1 | 8S-6110 | Clip |
| 4 | 1 | 9B-7237 | Bolt |
| 5 | 1 | 5P-1075 | Hard Washer |
| 6 | 2 | 103-6100 | Quick Coupler |
| 7 | 2 | 9X-7380 | O-Ring Seal |
Note: Apply PAG oil to all O-ring seals prior to installation.
- Install one 9X-7380 O-Ring Seal (7) to 8X-7152 Hose As (A). Connect hose (A) from the evaporator coil to the top of 3E-3535 In-Line Refrigerant Dryer (1). Use one 103-6100 Quick Coupler (6) .
 | |
| Illustration 72 | g00755925 |
- Install one 9X-7380 O-Ring Seal (7) in 8X-7151 Hose As (B). Connect hose (B) to dryer (1). Use one 103-6100 Quick Coupler (6) .
- Install 3E-3535 In-Line Refrigerant Dryer (1). Use the following items: one 8S-6109 Clip (2), one 8S-6110 Clip (3), one 9B-7237 Bolt (4) and one 5P-1075 Washer (5) .
Installation of Refrigerant Lines
| Required Parts | |||
| Item | Qty | Part Number | Part Description |
| 1 | 1 | 8X-8009 | Hose As |
| 2 | 1 | 3E-4056 | Air Conditioner Fitting |
| 3 | 1 | 9X-7382 | O-Ring Seal |
| 4 | 2 | 9X-7385 | O-Ring Seal |
| 5 | 1 | 8X-7150 | Hose As |
| 6 | 1 | 3E-4073 | Compressor Fitting |
| 7 | 1 | 7G-3228 | Grommet |
| 8 | 2 | 9X-7381 | O-Ring Seal |
| 9 | 1 | 8X-7151 | Hose As |
| 10 | 1 | 9X-7380 | O-Ring Seal |
| 11 | 1 | 4S-1962 | Clip |
| 12 | 2 | 6D-2667 | Clip |
| 13 | 3 | 8T-4896 | Hard Washer |
| 14 | 1 | 5M-3062 | Bolt |
| 15 | 2 | 4D-7735 | Clip |
| 16 | 2 | 9M-8406 | Clip |
| 17 | 2 | 5S-7379 | Bolt |
| 18 | 1 | 114-5334 | Pressure Switch |
| 19 | 1 | 9X-7378 | O-Ring Seal |
| 20 | 1 | 116-0118 | Clip |
| 21 | 1 | 9G-9150 | Clip |
| 22 | 1 | 7X-2537 | Bolt |
| 23 | 2 | 8T-4224 | Hard Washer |
| 24 | 1 | 5C-7261 | Nut |
| 25 | 1 | 4D-7794 | Clip |
| 26 | 1 | 5P-1075 | Hard Washer |
| 27 | 1 | 1P-6356 | Plate |
| 28 | 1 | 085-8091 | Bolt |
| 29 | 1 | 106-8704 | Arc Suppressor |
Note: Apply PAG oil to all O-ring seals prior to installation.
- Install 3E-4056 Air Conditioner Fitting (2) to the suction port on the compressor. Install 3E-4073 Compressor Fitting Assembly (6) to the discharge port on the compressor. Use two 9X-7385 O-Ring Seal (4), one 1P-6356 Plate (27), one 5P-1075 Hard Washer (26), and one 085-8091 Bolt (28) .
Tighten bolt (28) to a torque of 25 ± 7 N·m (18.4 ± 5.2 lb ft).
 | |
| Illustration 73 | g00756453 |
- Install one 9X-7382 O-Ring Seal (3) in 8X-8009 Hose As (1). Connect hose (1) to 3E-4056 Air Conditioner Fitting (2) .
 | |
| Illustration 74 | g00755927 |
- Install one 9X-7381 O-Ring Seal (8) in 8X-7150 Hose As (5). Connect hose (5) to 3E-4073 Compressor Fitting Assembly (6) .
- Insert one 7G-3228 Grommet (7) into plate (B) .
 | |
| Illustration 75 | g00755929 |
- Install 9X-7381 O-Ring Seal (8) in 8X-7150 Hose As (5). Connect hose (5) to the condenser coil.
 | |
| Illustration 76 | g00755931 |
- Attach 8X-8009 Hose As (1) to the front frame on the right side by using a 4S-1962 Clip (11). Use the bolt and the washer already on the frame.
 | |
| Illustration 77 | g00755933 |
- Remove the two bolts and keep the two bolts from grommet (C) that is located on the front frame on the right side. Remove the top part of grommet. Place hoses (9) and (1) in grommet (C). Reassemble grommet (C) .
- Remove the two bolts and keep the two bolts from grommet (D) located on the rear frame on the left side. Remove the top part of grommet. Place hoses (9) and (1) in grommet (D). Reassemble the grommet (D) .
- Attach 8X-8009 Hose As (1) and the 8X-7151 Hose As (9) to the boss that is located on the left side of the rear frame. Use 6D-2667 Clip (12), one 8T-4896 Hard Washer (13) and one 5M-3062 Bolt (14) .
- Attach 8X-8009 Hose As (1) and 8X-7151 Hose As (9) to the bracket on the rear frame. Use 6D-2667 Clip (12). Use the bolt and the washer already on the frame.
- Place 4D-7735 Clip (15) around 8X-7150 Hose As (5). Place 9M-8406 Clip (16) around 8X-7151 Hose As (9). Attach both clips with the hoses to the back of the fuel tank. Using one 8T-4896 Hard Washer (13) and one 5S-7379 Bolt (17) .
 | |
| Illustration 78 | g00755936 |
- Place 4D-7735 Clip (15) around 8X-7150 Hose As (5). Place 9M-8406 Clip (16) around 8X-7151 Hose As (9). Attach both clips and hose assemblies to the left side of the fuel tank. Use one 8T-4896 Hard Washer (13) and one 5S-7379 Bolt (17) .
 | |
| Illustration 79 | g00755935 |
- Install 114-5334 Pressure Switch (18) and 9X-7378 O-Ring Seal (19) to the compressor. Torque the switch assembly to 8.2 ± 1.4 N·m (6.05 ± 1.03 lb ft).
 | |
| Illustration 80 | g00755939 |
- Install 116-0118 Clip (20) and 9G-9150 Clip (21) to the top of the refrigerant compressor. Use one 7X-2537 Bolt (22), one 8T-4224 Washer (23) and one 5C-7261 Nut (24) .
- Remove the receptacle from the wiring harness with PU and OR wires. Dispose of the receptacle. Connect the plug end of the switch assembly (18) to the wiring harness. Secure the harness to the harness clip.
- Secure the wiring harness with wire OR and wire WH wires with one 4D-7794 Clip (25) .
- Attach 106-8704 Arc Suppressor (29) to the engine wiring harness. Secure the wires with a tie strap.
 | |
| Illustration 81 | g00756510 |
Charge the System
Before you charge the system, evaluate the air conditioner system. The correct charge is 1.6 kg (3.5 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure and for the correct tools.
Preparation for Operation
- Install the seat. Refer to the Operator's Station Disassembly and Assembly, "Seat and Seat Belt - Install".
- Remove the articulation lock pin.