- Wheel Loader:
- 938G (PIN: 4YS1-UP; 9HS1-UP; 6WS1-UP; 8RS1-UP)
- Integrated Toolcarrier:
- IT38G (PIN: 7BS1-UP; 6JK1-UP)
Introduction
This publication includes the general instructions for the field installation of an air conditioner. This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine.
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 hardness. Do a leak test on all the hoses and lines. Refer to the Service Manual, SENR5664, "Air Conditioning and Heating with R-134A", "Refrigerant Leakage - Test" section in Testing and Adjusting. Replace hoses if leaks or hardness are in the hoses. 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 wrenches that are made for use with 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 components and refrigerant lines are disconnected or removed refer to the Service Manual, SENR5664, "Air Conditioning and Heating with 134-A", "Refrigerant Recovery".
Install protective plugs or caps on all components and on all hoses that are disconnected or removed.
O-ring seals and seats 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 air conditioner hose connection.
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 192-1513 Air Conditioner Conversion Ar for 938G Wheel Loader and for IT38G Integrated Toolcarrier
| 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. |
Note: Put identification marks on all hoses and on all wires for installation purposes. Plug the hoses. This will help to prevent fluid loss. This will also help to keep contaminants from entering the system.
 |
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. |
 |
Machine Preparation
- Connect the steering frame lock. Refer to the Disassembly and Assembly, "Steering Frame Lock - Seperate and Connect".
|
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. |
|
Installation of the Air Conditioner Group
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 156-4449 | Cable |
| 2 | 1 | 180-9873 | Air Conditioner Gp |
| 3 | 1 | 118-7259 | Gasket |
| 4 | 1 | 5P-0892 | Seal |
| 5 | 1 | 107-6070 | Switch |
| 6 | 2 | 9X-8117 | Tube As |
- Remove the seat. Refer to the appropriate Disassembly and Assembly, "Seat - Remove and Install".
- Remove the bolts (A). Discard eleven bolts (A) and the eleven washers (B) from the top of heater. Remove the cover.
 | |
| Illustration 1 | g00754566 |
- Disconnect the cable assembly from the temperature control knob on the console (C) .
 | |
| Illustration 2 | g00754570 |
- Lift the back of the unit in order to gain access to the hose connections to the heater. Disconnect the heater hoses.
- Remove 180-9874 Cab Heater Gp (D) and the seal. Remove the gasket. Discard 180-9874 Cab Heater Gp , the seal and the gasket.
 | |
| Illustration 3 | g00754573 |
- Connect the output end of 156-4449 Cable (1) to the lever of the water valve on 180-9873 Air Conditioner Gp (2). Position the loop outward from the water valve for the proper alignment. Leave the clamp loose until you are ready for final adjustment.
 | |
| Illustration 4 | g00754578 |
- Attach 118-7259 Gasket (3) to the front of 180-9873 Air Conditioner Gp (2) .
 | |
| Illustration 5 | g00754582 |
- Set into place 180-9873 Air Conditioner Gp (2) and one 5P-0892 Seal (4) .
 | |
| Illustration 6 | g00754587 |
- Connect the input end of 156-4449 Cable (1) to the temperature control knob on the console.
 | |
| Illustration 7 | g00754615 |
- Close water valve (E) (part of 180-9873 Air Conditioner Gp (2) ). Move cable (1) in the opposite direction in order to remove free play.
 | |
| Illustration 8 | g00754616 |
- Tighten the clamp on the output end of cable (1) .
- Install 107-6070 Switch (5) in the console. Connect wire 567-WH to switch (5) .
 | |
| Illustration 9 | g00754618 |
- Connect wire 515-GY to the 6-pin connector on harness (F) .
 | |
| Illustration 10 | g00754621 |
- From the underside of the cab, install two 9X-8117 Tube As (6) to 180-9873 Air Conditioner Gp (2) .
 | |
| Illustration 11 | g00754623 |
Installation of the Refrigerant Compressor
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 153-0689 | Bracket |
| 2 | 2 | 6V-5196 | Bolt |
| 3 | 4 | 9M-1974 | Hard Washer |
| 4 | 4 | 8T-4196 | Bolt |
| 5 | 1 | 7E-7302 | Bracket |
| 6 | 1 | 106-5122 | Refrigerant Compressor |
| 7 | 1 | 3E-8028 | Bolt |
| 8 | 7 | 8T-4121 | Hard Washer |
| 9 | 2 | 8T-4133 | Nut |
| 10 | 1 | 1W-9693 | V-Belt |
| 11 | 1 | 9Y-1285 | Strap |
| 12 | 3 | 8T-4195 | Bolt |
| 13 | 1 | 7C-3941 | Plate |
| 14 | 1 | 126-2277 | Guard As |
| 15 | 2 | 8T-4186 | Bolt |
| 16 | 1 | 8T-4222 | Plated Washer |
The compressor is mounted on a bracket off the intake manifold on the right side of the engine.
- Use two 6V-5196 Bolts (2) and four 9M-1974 Hard Washers (3) to mount 153-0689 Bracket (1) to the intake manifold. Remove the existing hardware.
 | |
| Illustration 12 | g00754668 |
- Use four 8T-4196 Bolts (4) to mount 7E-7302 Bracket (5) to the engine front housing.
 | |
| Illustration 13 | g00754673 |
- When you mount 106-5122 Refrigerant Compressor (6) on the machine, position the ports on the back of the refrigerant compressor, as shown.
 | |
| Illustration 14 | g00754683 |
- Use the following hardware in order to mount the refrigerant compressor (6) to bracket (5) : one 3E-8028 Bolt (7), two 8T-4121 Washers (8) and one 8T-4133 Nut (9) .
 | |
| Illustration 15 | g00754686 |
- Use one 8T-4121 Washer (8) and one 8T-4195 Bolt (12) in order to mount 9Y-1285 Strap (11) to bracket (5) .
Note: Hand tighten the hardware.
 | |
| Illustration 16 | g00754689 |
- Use the following hardware in order to install 7C-3941 Plate (13) and 126-2277 Guard As (14) to the compressor: one 8T-4186 Bolt (15), two 8T-4121 Hard Washers (8) and one 8T-4195 Bolt (12)
 | |
| Illustration 17 | g00754692 |
- Install the following hardware in order to secure strap (11) to the plate (13) :
 | |
| Illustration 18 | g00754694 |
- Tighten all hardware once guard (14) is secure on compressor (6) and on plate (13) .
- Install 1W-9693 V-Belt (10) onto the compressor and onto the crankshaft pulley by using 144-0235 Belt Tension Gauge .
Note: Initial belt tension for a new belt is 534 ± 22 N (120 ± 5 lb). Belt tension for a used belt is 400 ± 44 N (90 ± 10 lb). A used belt is a belt that has a minimum of thirty minutes of operation.
Installation of the Condenser Core
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 6 | 8T-4121 | Hard Washer |
| 2 | 4 | 8T-4137 | Bolt |
| 3 | 1 | 125-8777 | Hinge |
| 4 | 1 | 146-4312 | Plate As |
| 5 | 2 | 8T-4136 | Bolt |
| 6 | 1 | 125-8776 | Plate |
| 7 | 1 | 125-2873 | Condenser Core |
| 8 | 7 | 6N-8744 | Mount |
| 9 | 14 | 8T-4222 | Plated Washer |
| 10 | 7 | 8T-4196 | Bolt |
The condenser is mounted on the side of the radiator which is facing the engine.
- Use two 8T-4121 Hard Washers (1) and two 8T-4137 Bolts (2) to install 125-8777 Hinge (3) to the left side of the radiator.
 | |
| Illustration 19 | g00754719 |
 | |
| Illustration 20 | g00754721 |
- Align the mounting holes on the condenser with the holes on the hinge. Tighten the hardware on the hinge.
- Use two 8T-4121 Hard Washers (1) and two 8T-4136 Bolts (5) to install 146-4312 Plate As (4) on the right side of the radiator.
 | |
| Illustration 21 | g00754731 |
- Use two 8T-4121 Hard Washers (1) and two 8T-4137 Bolts (2) to install 125-8776 Plate (6) to 146-4312 Plate As (4) on the right side of the radiator.
 | |
| Illustration 22 | g00754741 |
- Use the following hardware to install 125-2873 Condenser Core (7) to the plates that are secured to the radiator: seven 6N-8744 Mounts (8), fourteen 8T-4222 Plated Washers (9) and seven 8T-4196 Bolts (10)
 | |
| Illustration 23 | g00754744 |
Installation of the Refrigerant Accumulator
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 9X-7383 | O-Ring Seal |
| 2 | 1 | 159-4589 | Hose As |
| 3 | 1 | 152-2823 | Refrigerant Accumulator |
| 4 | 1 | 173-0272 | Hose As |
| 5 | 1 | 172-0154 | Plate As |
| 6 | 3 | 8T-4139 | Bolt |
| 7 | 3 | 8T-4223 | Hard Washer |
| 8 | 1 | 6V-4356 | Clip |
| 9 | 1 | 6V-4357 | Clip |
| 10 | 1 | 9X-7382 | O-Ring Seal |
The refrigerant accumulator is located under the hood support. Connect the two hoses to the refrigerant accumulator before mounting.
Note: Apply PAG oil to all O-ring seals prior to installation.
- Install one 9X-7383 O-Ring Seal (1) into the male end of 159-4589 Hose As (2). Connect hose (2) to the top port of 152-2823 Refrigerant Accumulator (3) .
 | |
| Illustration 24 | g00754793 |
- Install one 9X-7382 O-Ring Seal (10) on the male end of 173-0272 Hose As (4). Connect hose (4) to the lower port of 152-2823 Refrigerant Accumulator (3) .
- Use the following hardware to mount the refrigerant accumulator (3) to the hood support.
Installation of the Air Conditioning Lines
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 3E-4053 | Air Conditioner Fitting |
| 2 | 1 | 3E-4056 | Air Conditioner Fitting |
| 3 | 1 | 1P-6356 | Plate |
| 4 | 1 | 8T-6466 | Bolt |
| 5 | 1 | 8T-2561 | Hard Washer |
| 6 | 1 | 3H-2900 | Grommet |
| 7 | 1 | 9X-7382 | O-Ring Seal |
| 8 | 1 | 9X-7383 | O-Ring Seal |
| 9 | 3 | 9X-7381 | O-Ring Seal |
| 10 | 1 | 159-4590 | Hose As |
| 11 | 1 | 8S-0948 | Clip |
| 12 | 2 | 8M-2773 | Clip |
| 13 | 2 | 1S-6420 | Clip |
| 14 | 1 | 137-7260 | Hose As |
| 15 | 1 | 9X-7380 | O-Ring Seal |
| 16 | 1 | 5K-8451 | Clip |
| 17 | 5 | 7K-1181 | Cable Strap |
| 18 | 11 | 8T-4908 | Bolt |
| 19 | 11 | 7X-0579 | Hard Washer |
| 20 | 1 | 106-8704 | Arc Suppressor |
| 21 | 3 | 3S-2093 | Cable Strap |
| 22 | 3 | 9U-2277 | Clip As |
| 23 | 1 | 5P-4116 | Hard Washer |
| 24 | 1 | 8T-4189 | Bolt |
| 25 | 1 | 9X-7378 | O-Ring Seal |
| 26 | 1 | 114-5333 | Pressure Switch |
| 27 | 1 | 130-5890 | Air Conditioner Harness As |
| 28 | 2 | 4P-7581 | Clip |
| 29 | 4 | 8T-4121 | Hard Washer |
| 30 | 2 | 8T-4133 | Nut |
| 31 | 2 | 8T-4186 | Bolt |
| 32 | 1 | 5P-9085 | Clip |
Note: Apply PAG oil to all O-ring seals prior to installation.
- Remove the rear cover plate from the compressor. Install 3E-4053 Air Conditioner Fitting (1) into the port marked "D". Install 3E-4056 Air Conditioner Fitting (2) into the port marked "S". Use one 1P-6356 Plate (3), one 8T-6466 Bolt (4), and one 8T-2561 Hard Washer (5) to secure the fittings to the compressor.
Note: The protective caps must stay on the fittings until the hoses are connected to the fittings.
 | |
| Illustration 25 | g00754770 |
- Install one 3H-2900 Grommet (6) into the engine enclosure.
 | |
| Illustration 26 | g00754754 |
- Route one end of 159-4589 Hose As (A) through grommet (6). Install one 9X-7382 O-Ring Seal (7) to the opposite end of the 159-4589 Hose As (A). Connect hose (A) to the large fitting on the back of the air conditioner group.
- Install one 9X-7383 O-Ring Seal (8) on the end of 173-0272 Hose Assembly (B). Connect hose (B) to 3E-4056 Air Conditioner Fitting (2) on the rear of the compressor.
- Install one 9X-7381 O-Ring Seal (9) on one end of 159-4590 Hose As (10). Connect hose (10) to 3E-4053 Air Conditioner Fitting (1) on the rear of the compressor.
- Install one 9X-7381 O-Ring Seal (9) on the other end of 159-4590 Hose As (10). Connect hose (10) to the upper port of the condenser.
- Secure hose assembly (10) to the engine with the following hardware: one 8S-0948 Clip (11), two 8M-2773 Clips (12) and two 1S-6420 Clips (13) .
 | |
| Illustration 27 | g00754756 |
- Install one 9X-7381 O-Ring Seal (9) on 137-7260 Hose As (14). Connect hose (14) to the small fitting on the back of the air conditioner.
 | |
| Illustration 28 | g00754764 |
- Install one 9X-7380 O-Ring Seal (15) to 137-7260 Hose As (14). Connect hose (14) to the bottom port on the condenser.
- Install eleven 7X-0579 Hard Washers (19) and eleven 8T-4908 Bolts (18) to the top of the air conditioner group inside the cab.
 | |
| Illustration 29 | g00754590 |
- Use the following hardware to connect 106-8704 Arc Suppressor (20) to the compressor.
 | |
| Illustration 30 | g00754776 |
- Use one 9X-7378 O-Ring Seal (25) in order to connect the 114-5333 Pressure Switch (26) to the compressor. Tighten the pressure switch to a torque of 8 ± 1.5 N·m (70 ± 13 lb in).
- Secure the wire from pressure switch (26) with one 7K-1181 Cable Strap (17) .
- Connect 130-5890 Air Conditioner Harness As (27) to the compressor with the following hardware:
 | |
| Illustration 31 | g00754784 |
 | |
| Illustration 32 | g00754786 |
- Secure the engine wiring harness to the right side of the engine by using one 5P-9085 Clip (32) and existing hardware.
 | |
| Illustration 33 | g00763467 |
Charge the System
Evacuate the air conditioner system. Charge the air conditioner system. The correct charge is 1.5 kg (3.3 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
Installation of the Seat
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 110-6393 | Instruction Plate |
- Install the seat. See the Operator's Station Disassembly and Assembly, "Seat and Seat Belts".
- Stamp 110-6393 Instruction Plate (1) with 1.5 kg (3.3 lb). Attach 110-6393 Instruction Plate to the front of the base of seat (A) .
 | |
| Illustration 34 | g00754799 |
- Separate the steering frame lock. Refer to the Disassembly and Assembly, "Steering Frame Lock - Seperate and Connect".