- Wheel Loader:
- 950G (PIN: 4BS1-UP; 2JS1-UP; 6NS1-UP; 3JW1-UP; 8JW1-UP; 5FW1-UP; 5MW1-UP)
- 962G (S/N: 5AS1-UP; 3BS1-UP; 5PR1-UP; 4PW1-UP; 6EW1-UP; 7BW1-UP; 6HW1-UP)
- 966G (S/N: 3ZS1-UP; 9RS1-UP; AAH1-UP; 3SW1-UP; 3PW1-UP; 8XW1-UP)
- 972G (S/N: 7LS1-UP; 1EW1-UP; AAW1-UP; 4WW1-UP; 6AW1-UP; 9GW1-UP)
- 962G (S/N: 5AS1-UP; 3BS1-UP; 5PR1-UP; 4PW1-UP; 6EW1-UP; 7BW1-UP; 6HW1-UP)
- Integrated Toolcarrier:
- IT62G (S/N: 6PS1-UP; AKP1-UP)
Introduction
The publication will give specific instructions for the installation of two air conditioner conversion arrangements.
- The following machines use the 192-1512 Air Conditioner Conversion Ar : 950G, 962G and IT62G.
- The following machines use the 192-5373 Air Conditioner Conversion Ar : 966G and 972G.
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. A 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 all the lines. Refer to the Testing and Adjusting section of Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134A Refrigerant", "Refrigerant Leakage Test". Replace the hose if the hose has a leak or the outside becomes brittle. Replace the hose with a new hose that is sealed and free of contaminants.
The correct use of the wrenches is very important when the 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 when 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 the Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134A Refrigerant", "Refrigerant Recovery".
Install the protective plugs or the caps on all components and all hoses that are disconnected.
The O-ring 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 the 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 192-1512 Air Conditioner Conversion Ar
| 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. |
 |
Note: Put identification marks on all hoses and on all wires for installation purposes. Plug the hoses. This will help to keep contaminants from entering the system.
Installation of the Evaporator Coil
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 126-5606 | Evaporator Coil As |
| 2 | 1 | 068-8993 | Grommet |
| 3 | 1 | 3E-5464 | Thermostat Switch |
| 4 | 2 | 8T-6631 | Screw |
| 5 | 2 | 3B-4501 | Lockwasher |
- Connect the steering frame lock. Refer to 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. |
|
- Remove the seat. Refer to the Machine System's Disassembly and Assembly, "Seat - Remove and Install".
Note: Lead with the back of the seat through the door in order to remove the seat from the cab.
- Open the hood.
- Open access door (A) on the left side of the cab.
 | |
| Illustration 1 | g00745574 |
- Remove air filter (B) .
 | |
| Illustration 2 | g00745583 |
- Loosen two screws (C). Remove the air filter cover (D) and the air filter.
 | |
| Illustration 3 | g00745590 |
- Remove three bolts (E) .
- Remove two bolts (F) .
 | |
| Illustration 4 | g00745592 |
- Remove four bolts (G) and cover panel (H) .
 | |
| Illustration 5 | g00745610 |
- Remove plastic cover (J).
 | |
| Illustration 6 | g00745618 |
- Disconnect electrical connections (K) .
 | |
| Illustration 7 | g00745622 |
- Remove four bolts (L) .
- Remove two washers (M) and two bolts (N) .
 | |
| Illustration 8 | g00745624 |
- Remove control (P) from plate (T) .
- Remove hardware (U) from plate (R) .
- Remove plate (R) from the cab heater.
- Remove 131-1622 Plate (T) .
- Insert 126-5606 Evaporator Coil As (1) into the cab heater.
 | |
| Illustration 9 | g00745633 |
- Install six bolts (V) .
 | |
| Illustration 10 | g00745637 |
- Remove the rivet from plate (T). Install one 068-8993 Grommet (2) into plate (T) .
 | |
| Illustration 11 | g00745642 |
- Feed tube (X) through grommet (2) .
- Install 3E-5464 Thermostat Switch (3) on the plate (T) with two 8T-6631 Screws (4) and with two 3B-4501 Lockwashers (5). Tighten the screws to a torque of 1.2 ± 0.2 N·m (10.62 ± 1.77 lb in).
- Measure the length of the tube (X) and mark the tube to a length of 340 + 0 - 20 mm (13.4 + 0.0 - 0.8 inch) from the end. Wrap the remaining tube on the back of the plate (T). Make sure that the tube is not kinked.
- Feed the tube (X) into the evaporator coil 340 ± 10 mm (13.4 ± 0.4 inch). Place the plate (T) on top of the cab heater.
 | |
| Illustration 12 | g00756822 |
- Secure the plate (T) to the cab heater with two bolts (L) .
- Install the control (P) on the plate (T) with two bolts (L) .
 | |
| Illustration 13 | g00756824 |
- Reconnect electrical connections (K) .
Installation of the Air Conditioning Lines in the Cab
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 130-1887 | Gasket |
| 2 | 1 | 126-6008 | Plate |
| 3 | 1 | 170-3447 | Plate |
| 4 | 1 | 170-3448 | Plate |
| 5 | 1 | 9X-7382 | O-Ring Seal |
| 6 | 1 | 126-6004 | Hose As |
| 7 | 1 | 5P-3928 | Sealing Coupling |
| 8 | 1 | 9X-7384 | O-Ring Seal |
| 9 | 1 | 5P-4106 | Nut |
| 10 | 1 | 9X-7381 | O-Ring Seal |
| 11 | 1 | 126-6005 | Hose As |
| 12 | 1 | 7K-3176 | Coupling |
| 13 | 1 | 9X-7383 | O-Ring Seal |
| 14 | 1 | 7K-3304 | Jam Nut |
Note: Apply PAG oil to all O-Ring seals prior to installation.
- Remove 130-2541 Plate and the hardware from the rear wall of the cab. The plate is located behind the seat mounting and above the cab floor. Dispose of 130-2541 Plate . Keep the hardware.
- Use the existing hardware in order to secure the following plates to the rear wall of the cab: one 126-6008 Plate (2), one 170-3447 Plate (3) and one 170-3448 Plate (4) .
 | |
| Illustration 14 | g00745654 |
View A-A | |
- Install one 9X-7382 O-Ring Seal (5) in the straight end of 126-6004 Hose Assembly (6). Connect hose (6) to the evaporator coil.
 | |
| Illustration 15 | g00745656 |
- Install one 9X-7384 O-Ring Seal (8) in 126-6004 Hose Assembly (6). Attach hose (6) to the coupling on the wall by using one 5P-3928 Sealing Coupling (7) and one 5P-4106 Nut (9) .
Tighten coupling (7) to 68 ± 7 N·m (50.1 ± 5.2 lb ft). Tighten nut (9) to 75 ± 5 N·m (55 ± 4 lb ft).
Note: The hose is located on the inside of the cab and the hardware is located on the outside of the cab.
- Install one 9X-7381 O-Ring Seal (10) in the straight end of the 126-6005 Hose Assembly (11). Connect hose (11) to the brass connector on the evaporator coil assembly .
- Install one 9X-7383 O-Ring Seal (13) in the opposite end of 126-6005 Hose Assembly (11). Use one 7K-3176 Coupling (12) and one 7K-3304 Jam Nut (14) to connect the opposite end of 126-6005 Hose Assembly (11) to the right hole in the plate (2) .
Tighten coupling (12) to 54 ± 7 N·m (39.8 ± 5.2 lb ft). Tighten nut (14) to 60 ± 5 N·m (44 ± 4 lb ft).
Note: The hose is located on the inside of the cab and the hardware is located on the outside of the cab.
Installation of the Refrigerant Compressor
Note: There are three different V-belts that are available for the compressor. Each V-belt is for the various attachments on the machine and the serial number of the machine. The mounting positions of the V-belts and most of the basic hardware are similar for each configuration. To determine the V-belt and hardware to use, look at the footnotes of the following table.
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 153-0689 (1) | Bracket |
| 2 | 2 | 6V-5196 (1) | Bolt |
| 3 | 4 | 9M-1974 (1) | Hard Washer |
| 4 | 4 | 8T-4196 | Bolt |
| 5 | 1 | 7E-7302 | Bracket |
| 6 | 1 | 106-5122 | Refrigerant Compressor |
| 7 | 1 | 3E-8028 (1) (2) | Bolt |
| 7 | 1 | 4Y-6353 (3) | Bolt |
| 8 | 7 | 8T-4121 | Hard Washer |
| 9 | 2 | 8T-4133 | Nut |
| 10 | 1 | 160-1821 (1) | V-Belt |
| 10 | 1 | 1W-9693 (2) | V-Belt |
| 10 | 1 | 1P-4334 (3) | 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 |
| ( 1 ) | This component is for machines that are equipped with a brake cooling system with the following serial numbers: 4BS1-425, 7BW1-397, 2JS1-612, 5AS1-275, 3BS1-422, 6PS1-379, 4YS1-713, 6WS1-436, 7BS1-551, 1CW1-345, 3JW1-733, 5FW1-812 and 4PW1-262. |
| ( 2 ) | This component is for machines with the following serial numbers: 4BS1-425, 7BW1-397, 2JS1-612, 5AS1-275, 3BS1-422, 6PS1-379, 4YS1-713, 6WS1-436, 7BS1-551, 1CW1-345, 3JW1-733, 5FW1-812 and 4PW1-262. |
| ( 3 ) | This component is for machines with the following serial numbers: 4BS426-UP, 7BW398-UP, 2JS613-UP, 5AS276-UP, 3BS423-UP, 6PS380-UP, 4YS714-UP, 6WS137-UP, 7BS552-UP, 1CW346-UP, 3JW734-UP, 5FW813-UP and 4PW263-UP. |
The compressor is mounted on a bracket that is off of the intake manifold on the right side of the engine.
- For machines with the following serial numbers, perform this step: 4BS1-425, 7BW1-397, 2JS1-612, 5AS1-275, 3BS1-422, 6PS1-379, 4YS1-713, 6WS1-436, 7BS1-551, 1CW1-345, 3JW1-733, 5FW1-812 and 4PW1-262. Use two 6V-5196 Bolts (2) and four 9M-1974 Hard Washers (3) to secure the 153-0689 Bracket (1) to the intake manifold. Remove the existing hardware.
 | |
| Illustration 16 | g00756829 |
- Use four 8T-4196 Bolts (4) to mount 7E-7302 Bracket (5) to the front housing of the engine.
 | |
| Illustration 17 | g00745663 |
- Use one Bolt (7), two 8T-4121 Washers (8), and one 8T-4133 Nut (9) in order to mount 106-5122 Refrigerant Compressor (6) to 7E-7302 Bracket (5) .
Insert bolt (7) through tab (A) in order to mount compressor (6) to bracket (5). Make sure that oil filler plug (B) on compressor (6) is at the top of the mounted compressor.
 | |
| Illustration 18 | g00756970 |
 | |
| Illustration 19 | g00762915 |
- Install the appropriate V-belt (10) to the compressor. Refer to Operation and Maintenance Manual, "V-Belts - Inspect/Adjust/Replace" in order to correctly adjust the V-belt.
Note: The initial belt tension for a new belt is 534 ± 22 N (120 ± 5 lb). The 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.
- Use one 8T-4195 Bolt (12) and one 8T-4121 Washer (8) to mount 9Y-1285 Strap (11) to bracket (5). Hand tighten the hardware.
 | |
| Illustration 20 | g00756835 |
- Use the following hardware in order to install 7C-3941 Plate (13) and the 126-2277 Guard Assembly (14) to compressor (6) : one 8T-4186 Bolt (15), two 8T-4121 Washers (8) and one 8T-4195 Bolt (12).
- Use the following hardware in order to secure strap (11) to plate (13) : one 8T-4186 Bolt (15), two 8T-4121 Washers (8), one 8T-4133 Nut (9), one 8T-4195 Bolt (12) and one 8T-4222 Plated Washer (16).
 | |
| Illustration 21 | g00745667 |
Section A-A | |
- Tighten all of the hardware once guard assembly (14) is secure on compressor (6) and on plate (13) .
Installation of the Condenser Core
The condenser core is mounted on the side of the radiator which is facing the engine.
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 125-2873 | Condenser Core |
| 2 | 6 | 8T-4121 | Hard Washer |
| 3 | 4 | 8T-4137 | Bolt |
| 4 | 1 | 125-8777 | Hinge |
| 5 | 1 | 146-4312 | Plate As |
| 6 | 2 | 8T-4136 | Bolt |
| 7 | 1 | 125-8776 | Plate |
| 8 | 7 | 6N-8744 | Mount |
| 9 | 14 | 8T-4222 | Plated Washer |
| 10 | 7 | 8T-4196 | Bolt |
- Install 125-8776 Plate (7) to the right side of 125-2873 Condenser Core (1). Install 125-8777 Hinge (4) to the left side of condenser (1). Use the following hardware: seven 6N-8744 Mounts (8), fourteen 8T-4222 Plated Washers (9) and seven 8T-4196 Bolts (10) .
 | |
| Illustration 22 | g00745705 |
- Install 146-4312 Plate Assembly (5) on the right side of the radiator (A) by using two 8T-4121 Washers (2) and two 8T-4136 Bolts (6).
 | |
| Illustration 23 | g00756846 |
Top view of right side of radiator | |
- Use two 8T-4121 Washer (2) and two 8T-4137 Bolts (3) to install 125-8777 Hinge (4) to the left side of the radiator. Finger tighten the bolts.
 | |
| Illustration 24 | g00756843 |
Top view of left side of the radiator | |
- Use two 8T-4121 Washers (2) and two 8T-4137 Bolts (3) to attach 125-8776 Plate (7) to plate (5) on the right side of the radiator.
 | |
| Illustration 25 | g00756849 |
Top view of left side of radiator and of condenser | |
Installation of the Air Conditioning Lines
Installation of the Refrigerant Accumulator
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 2 | 9X-7383 | O-Ring Seal |
| 2 | 1 | 151-4528 | Hose As |
| 3 | 1 | 151-5261 | Refrigerant Accumulator |
| 4 | 1 | 151-4527 | Hose As |
| 5 | 1 | 7X-0622 | Washer |
| 6 | 1 | 8T-4139 | Bolt |
| 7 | 1 | 6V-4357 | Clip |
| 8 | 1 | 6V-4356 | Clip |
Note: Apply PAG oil to all O-Ring seals prior to installation.
The refrigerant accumulator is located under the hood support. Connect the two hose assemblies to the air conditioner accumulator before mounting the air conditioner accumulator.
- Install one 9X-7383 O-Ring Seal (1) on the male end of 151-4528 Hose Assembly (2). Connect hose (2) to the top port of the 151-5261 Refrigerant Accumulator (3) .
 | |
| Illustration 26 | g00756860 |
- Install one 9X-7383 O-Ring Seal (1) on the male end of 151-4527 Hose Assembly (4). Connect hose (4) to the lower port of the air conditioner accumulator.
- Use the following hardware in order to mount refrigerant accumulator (3) to hood support: one 7X-0622 Washer (5), one 8T-4139 Bolt (6), one 6V-4357 Clip (7) and one 6V-4356 Clip (8) .
 | |
| Illustration 27 | g00756864 |
Top view of the refrigerant accumulator | |
Installation of the In-Line Refrigerant Dryer
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 106-3481 | Clamp As |
| 2 | 2 | 8T-4137 | Bolt |
| 3 | 3 | 8T-4121 | Hard Washer |
| 4 | 1 | 3E-3535 | In-Line Refrigerant Dryer |
| 5 | 1 | 8T-4136 | Bolt |
The in-line refrigerant dryer is located between the cab and the hood support.
- Use two 8T-4137 Bolts (2) and two 8T-4121 Washers (3) in order to install 106-3481 Clamp Assembly (1) .
 | |
| Illustration 28 | g00756867 |
- Install the 3E-3535 In-Line Refrigerant Dryer (4) in clamp (1) .
Installation of the Air Conditioning Lines
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 3 | 9X-7380 | O-Ring Seal |
| 2 | 5 | 9M-8406 | Clip |
| 3 | 1 | 6K-8178 | Clip |
| 4 | 5 | 8T-4121 | Hard Washer |
| 5 | 2 | 8T-4137 | Bolt |
| 7 | 1 | 9X-7383 | O-Ring Seal |
| 8 | 1 | 9X-7382 | O-Ring Seal |
| 9 | 1 | 4S-1962 | Clip |
| 10 | 2 | 9X-7381 | O-Ring Seal |
| 11 | 1 | 130-3083 | Hose As |
| 12 | 6 | 8M-2773 | Clip |
| 13 | 1 | 1S-6420 | Clip |
| 14 | 2 | 8T-4224 | Hard Washer |
| 15 | 1 | 6V-1889 | Clip |
| 16 | 1 | 8T-4136 | Bolt |
| 17 | 1 | 5P-3948 | Refrigerant Coupling Assembly |
| 18 | 1 | 3E-4053 | Air Conditioner Fitting |
| 19 | 1 | 3E-4056 | Air Conditioner Fitting |
| 20 | 1 | 8T-4133 | Nut |
| 21 | 1 | 130-3082 | Hose As |
| 22 | 1 | 130-5889 | Hose As |
| 23 | 1 | 5P-3929 | Refrigerant Coupling Assembly |
| 24 | 1 | 9X-7384 | O-Ring Seal |
| 25 | 1 | 1P-6356 | Plate |
| 26 | 1 | 8T-6466 | Bolt |
| 27 | 1 | 8T-2561 | Hard Washer |
| 28 | 2 | 103-6100 | Quick Coupler |
Note: Apply PAG oil to all O-Ring seals prior to installation.
- Install one 9X-7380 O-Ring Seal (1) in 130-3082 Hose As (21). Connect hose (21) to 103-6100 Quick Coupler (28).
 | |
| Illustration 29 | g00756879 |
- Route hose (21) along the left side of the machine to the condenser. Install one 9X-7380 O-Ring Seal (1) in the opposite end of 130-3082 Hose Assembly (21). Connect hose (21) to the lower port on the condenser.
- Secure hose (21) to the rear frame (B) with the following hardware:
- Install one 9X-7382 O-Ring Seal (8) in 151-4527 Hose As (C). Connect 3E-4056 Air Conditioner Fitting (19) to hose (C) .
 | |
| Illustration 30 | g00756893 |
- Secure hose (C) with one 4S-1962 Clip (9) to bracket (E) on the engine.
 | |
| Illustration 31 | g00756904 |
- Install one 9X-7381 O-Ring Seal (10) in 130-3083 Hose Assembly (11). Connect 3E-4053 Air Conditioner Fitting (18) to hose (11) .
 | |
| Illustration 32 | g00756905 |
- Route hose (11) along the right side of the engine, under the engine, and up to the top port of the condenser. Install one 9X-7381 O-Ring Seal (10) in hose (11). Connect hose (11) to the upper port of the condenser.
- Use the following hardware in order to secure the hose assembly (11) to the frame: six 8M-2773 Clips (12), one 1S-6420 Clip (13), two 8T-4224 Hard Washers (14), one 6V-1889 Clip (15), one 8T-4136 Bolt (16), one 8T-4133 Nut (20) and three 8T-4121 Washers (4).
- Connect 3E-4053 Air Conditioner Fitting (18) and 3E-4056 Air Conditioner Fitting (19) to the compressor. Use one 1P-6356 Plate (25), one 8T-6466 Bolt (26), and one 8T-2561 Hard Washer (27) .
Torque bolt (26) to 25 ± 7 N·m (18.4 ± 5.1 lb ft).
 | |
| Illustration 33 | g00756915 |
Front view of the compressor | |
- Install one 9X-7384 O-Ring Seal (24) in 151-4528 Hose Assembly (F). Connect 5P-3929 Refrigerant Coupling Assembly (23) to hose (F). Connect coupling (23) to the right port on the exterior wall of the cab.
Tighten coupling (23) on hose (F) to a torque of 68 ± 7 N·m (50.1 ± 5.2 lb ft). Tighten coupling (23) on the right port on the wall of the cab to a torque of 54 ± 1 N·m (39.8 ± 0.7 lb ft).
 | |
| Illustration 34 | g00756908 |
- Install one 9X-7383 O-Ring Seal (7) to 130-5889 Hose Assembly (22). Connect 5P-3948 Refrigerant Coupling Assembly (17) to hose (22). Connect Coupling (17) to the left port on the exterior wall of the cab.
Tighten coupling (17) on hose (22) to a torque of 54 ± 7 N·m (39.8 ± 5.2 lb ft). Tighten coupling (17) to the left port on the wall of the cab to a torque of 49 ± 1 N·m (36.1 ± 0.7 lb ft).
- Install one 9X-7380 O-Ring Seal (1) in hose (22). Connect hose (22) to 103-6100 Quick Coupler (28) .
- Connect 103-6100 Quick Couplers (27) from hose (22) and from hose (21) to dryer (G) .
 | |
| Illustration 35 | g00762909 |
Installation of Electrical Connections for the Compressor
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 8T-4133 | Nut |
| 2 | 1 | 130-5890 | Air Conditioner Harness |
| 3 | 1 | 8T-4186 | Bolt |
| 4 | 2 | 3S-2093 | Cable Strap |
| 5 | 1 | 106-8704 | Arc Suppressor |
| 6 | 1 | 114-5333 | Pressure Switch |
| 7 | 2 | 130-5300 | Clip |
| 8 | 1 | 8M-2770 | Clip |
| 9 | 2 | 8T-4121 | Hard Washer |
- Connect 130-5890 Air Conditioner Harness As (2) to the engine harness. Connect the end of harness (2) that is called "A/C Clutch" to the two green wires from the compressor. Connect the end of harness (2) that is called "A/C Switch" to 114-5333 Pressure Switch (6) .
 | |
| Illustration 36 | g00756910 |
 | |
| Illustration 37 | g00756912 |
- Connect switch (6) to the valve on the back of the compressor.
- Secure the wires with the following items: one 3S-2093 Cable Strap (4), two 130-5300 Clips (7), one 8M-2770 Clip (8), one 8T-4186 Bolt (3), one 8T-4133 Nut (1), and two 8T-4121 Hard Washer (9) .
- Connect 106-8704 Arc Suppressor (5) to the remaining connector on 130-5890 Air Conditioner Harness As (2). Secure arc suppressor (5) with one 3S-2093 Cable Strap (4) .
Charge the Air Conditioning System
Charge the air conditioning system. The correct charge is 2.3 kg (5.0 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134A Refrigerant", and Special Publication, NEDG7006, "Air Conditioning Reference Guide".
Installation of Cab Panels
- Install the plastic cover (J) .
 | |
| Illustration 38 | g00756918 |
- Install four bolts (G) and cover panel (H) .
 | |
| Illustration 39 | g00756919 |
- Install two bolts (F) .
 | |
| Illustration 40 | g00756923 |
- Install three bolts (E) .
 | |
| Illustration 41 | g00756924 |
- Tighten two screws (C). Install the air filter cover (D) and the air filter.
- Install the air filter (B) that is located on the left side of cab.
 | |
| Illustration 42 | g00756926 |
- Close the access door (A) .
 | |
| Illustration 43 | g00756927 |
- Close the engine hood.
Installation of the Seat
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 110-6393 | Instruction Plate |
- Install the Seat. Refer to the Machine System's Disassembly and Assembly, "Seat - Remove and Install".
- Stamp the amount of refrigerant of 2.3 kg (5.0 lb) on 110-6393 Plate (1). Attach plate (1) on the lower left of seat base (A) .
 | |
| Illustration 44 | g00756916 |
Installation of the 192-5373 Air Conditioner Conversion Ar
Note: Put identification marks on all hoses and on all wires for installation purposes. Plug the hoses. This will help to keep contaminants from entering the system.
Installation of the Evaporator Coil
For the installation of the evaporator coil, refer to ""Installation of Evaporator Coil" " for the 192-1512 Air Conditioner Conversion Ar .
Installation of the Air Conditioning Lines in the Cab
For the installation of the lines, refer to ""Installation of the Air Conditioning Lines in the Cab" " for the 192-1512 Air Conditioner Conversion Ar .
Installation of the Refrigerant Compressor
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 3E-1906 | Refrigerant Compressor |
| 2 | 1 | 7W-4973 | Bracket |
| 3 | 2 | 5S-7383 | Bolt |
| 4 | 1 | 8T-9389 | Bolt |
| 5 | 2 | 6V-8188 | Nut |
| 6 | 2 | 7W-4974 | Plate |
| 7 | 1 | 6V-4432 | Bolt |
| 8 | 3 | 8T-4223 | Hard Washer |
| 9 | 1 | 8F-0492 | Spacer |
| 10 | 13 | 8T-4896 | Hard Washer |
| 11 | 6 | 6V-8801 | Nut |
| 12 | 1 | 8T-4835 | Bolt |
| 13 | 1 | 7W-4978 | Nut |
| 14 | 1 | 8T-2502 | Bolt |
| 15 | 1 | 7C-8434 | Bracket |
| 16 | 1 | 4Y-5911 | Strap |
| 17 | 1 | 1P-9744 | V-Belt |
| 18 | 6 | 4L-9337 | Bolt |
- Use the following hardware to secure the 7W-4973 Bracket (2) to the engine block: two 5S-7383 Bolts (3), one 8T-9389 Bolt (4) and one 6V-8188 Nut (5) .
 | |
| Illustration 45 | g00756930 |
- Use the following hardware to secure two 7W-4974 Plates (6) to 3E-1906 Refrigerant Compressor (1) : four 4L-9337 Bolts (18), eight 8T-4896 Washers (10) and four 6V-8801 Nuts (11) .
 | |
| Illustration 46 | g00756932 |
- Use the following hardware in order to mount 7C-8434 Bracket (15) to Refrigerant Compressor (1) : two 4L-9337 Bolts (18), four 8T-4896 Washers (10) and two 6V-8801 Nuts (11) .
Insert bolt (18) through tabs (A) in order to mount compressor (1) to bracket (15). Make sure that oil filler plug (B) on compressor (1) is at the top of the mounted compressor.
 | |
| Illustration 47 | g00756934 |
| | |
| Illustration 48 | g00762915 |
- Use the following hardware in order to mount Refrigerant Compressor (1) to the Bracket (2) : one 6V-4432 Bolt (7), two 8T-4223 Hard Washers (8) and one 6V-8188 Nut (5) .
Note: Hand tighten the hardware.
- Use the following hardware in order to mount 4Y-5911 Strap (16) to the engine: one 8F-0492 Spacer (9), one 8T-4223 Hard Washer (8) and one 8T-4835 Bolt (12) .
Note: Hand tighten the hardware.
- Use the following hardware in order to attach Strap (16) to Bracket (15) : one 8T-2502 Bolt (14), one 8T-4896 Hard Washer (10) and one 7W-4978 Nut (13) .
Note: Hand tighten the hardware.
- Install 1P-9744 V-Belt (17) to Refrigerant Compressor (1). For additional information on the Installation and on the Adjustment of the V-belt, refer to the Operation and Maintenance Manual, "V-Belts - Inspect/Adjust/Replace".
Note: The initial belt tension for a new belt is 534 ± 22 N·m (120.1 ± 4.9 lb). The belt tension for a used belt is 400 ± 44 N (89.9 ± 9.9 lb). A used belt is a belt that has a minimum of thirty minutes of operation.
- Tighten all hardware.
Installation of the Condenser Core
The condenser is mounted on the side of the radiator which is facing the engine.
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 4E-1384 | Conical Bumper |
| 2 | 1 | 5V-8780 | Knob |
| 3 | 4 | 6N-8744 | Mount |
| 4 | 2 | 7X-0632 | Hard Washer |
| 5 | 1 | 112-5345 | Door Latch Assembly |
| 6 | 1 | 130-8832 | A/C Condenser Core |
| 7 | 1 | 163-3260 | Bracket |
| 8 | 1 | 165-4974 | Hinge |
| 9 | 4 | 5C-2890 | Nut |
| 10 | 1 | 5C-7261 | Nut |
| 11 | 2 | 8T-4121 | Washer |
| 12 | 4 | 8T-4123 | Washer |
| 13 | 2 | 8T-4137 | Bolt |
| 14 | 4 | 8T-4195 | Bolt |
| 15 | 6 | 8T-4222 | Plated Washer |
| 16 | 4 | 9X-8256 | Washer |
- Install 112-5345 Door Latch Assembly (5) to 163-3260 Bracket (7) with four 5C-2890 Nuts (9) and four 9X-8256 Washers (16). Tighten nuts (9) to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft).
 | |
| Illustration 49 | g00756939 |
- Apply thread lock to the male threads of 112-5345 Door Latch Assembly (5). Install 5V-8780 Knob (2) on the male threads. Hand tighten knob (2) .
- Align the holes (A) on 163-3260 Bracket As (7) to the holes on left side of the condenser (6). Install the following items in each hole (A) : one 6N-8744 Mount (3), one 7X-0632 Washer (4), one 8T-4123 Washer (12), one 8T-4195 Bolt (14) and one 8T-4222 Washer (15) .
 | |
| Illustration 50 | g00756942 |
- Align the holes (B) in 130-8832 A/C Condenser Core (6) to the holes on 165-4974 Hinge (8). Install the following items at each hole (B) : one 6N-8744 Mount (3), one 8T-4123 Washer (12), one 8T-4195 Bolt (14) and two 8T-4222 Washers (15) .
- Attach 165-4974 Hinge (8) to the radiator frame (C) by using two 8T-4121 Hard Washers (11) and two 8T-4137 Bolts (13) .
 | |
| Illustration 51 | g00757238 |
- Mount one 4E-1384 Conical Bumper (1) to the radiator frame with one 5C-7261 Nut (10). In order to adjust the bumper, close the condenser core until there is no contact. Turn the bumper counterclockwise until the bumper contacts the bracket assembly. Unlatch the condenser core. Rotate the bumper counterclockwise by one and one-half turns and then tighten the nut.
 | |
| Illustration 52 | g00756947 |
Installation of the Refrigerant Accumulator
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 151-5261 | Refrigerant Accumulator |
| 2 | 1 | 6V-4356 | Clip |
| 3 | 1 | 6V-4357 | Clip |
| 4 | 1 | 8T-4223 | Hard Washer |
| 5 | 1 | 8T-4139 | Bolt |
| 6 | 2 | 9X-7383 | O-Ring Seal |
| 7 | 1 | 138-8482 | Hose As |
| 8 | 1 | 138-8502 | Hose As |
| 9 | 1 | 5P-0801 | Seal |
Note: Apply PAG oil to all O-Ring seals prior to installation.
The refrigerant accumulator is located under the hood support. Connect the two hose assemblies to the air conditioner accumulator before mounting the air conditioner accumulator.
- Install one 9X-7383 O-Ring Seal (6) in the male end of 138-8482 Hose Assembly (7). Connect hose (7) to the top port of the 151-5261 Refrigerant Accumulator (1) .
 | |
| Illustration 53 | g00756948 |
- Install one 9X-7383 O-Ring Seal (6) on the male end of the 138-8502 Hose Assembly (8). Connect hose (6) to the lower port of the Refrigerant Accumulator (1) .
- Use the following hardware in order to mount refrigerant accumulator (1) to the hood support: one 8T-4223 Hard Washer (4), one 8T-4139 Bolt (5), one 6V-4356 Clip (2), one 6V-4357 Clip (3) and one 5P-0801 Seal (9) .
Place seal (9) between accumulator (1) and clips (2) and (3) in order to keep the accumulator from vibrating.
Installation of the In-Line Refrigerant Dryer
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 106-3481 | Clamp As |
| 2 | 2 | 8T-4137 | Bolt |
| 3 | 2 | 8T-4121 | Hard Washer |
| 4 | 1 | 3E-3535 | In-Line Refrigerant Dryer |
| 5 | 1 | 8T-4136 | Bolt |
The in-line refrigerant dryer is located between the cab and the hood support.
- When you install 106-3481 clamp assembly (1), use two 8T-4137 Bolts (2) and two 8T-4121 Hard Washers (3) .
 | |
| Illustration 54 | g00756952 |
Installation of the Air Conditioning Lines
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | 138-8481 | Hose As |
| 2 | 1 | 5P-3948 | Refrigerant Coupling Assembly |
| 3 | 1 | 9X-7383 | O-Ring Seal |
| 4 | 4 | 9M-8406 | Clip |
| 5 | 3 | 9X-7380 | O-Ring Seal |
| 6 | 1 | 5P-3929 | Refrigerant Coupling Assembly |
| 7 | 1 | 9X-7384 | O-Ring Seal |
| 8 | 1 | 9X-7382 | O-Ring Seal |
| 9 | 1 | 3S-8665 | Clip |
| 10 | 1 | 163-3131 | Hose As |
| 11 | 2 | 9X-7381 | O-Ring Seal |
| 12 | 7 | 5K-5338 | Clip |
| 13 | 1 | 7W-0534 | Washer |
| 14 | 10 | 8T-4121 | Hard Washer |
| 15 | 8 | 8T-4136 | Bolt |
| 16 | 3 | 8T-4133 | Nut |
| 17 | 1 | 3V-0778 | Bracket |
| 18 | 1 | 5P-7611 | Grommet |
| 19 | 1 | 163-3134 | Hose As |
| 20 | 2 | 118-6878 | Bracket |
| 21 | 1 | 3E-4053 | Air Conditioner Fitting |
| 22 | 1 | 125-2796 | Fitting As |
| 23 | 1 | 8T-6466 | Bolt |
| 24 | 1 | 8T-2561 | Hard Washer |
| 25 | 1 | 1P-6356 | Plate |
| 26 | 2 | 103-6100 | Quick Coupler |
Note: Apply PAG oil to all O-Ring seals prior to installation.
- Install one 9X-7384 O-Ring Seal (7) in 138-8482 Hose Assembly (A). Connect hose (A) to 5P-3929 Coupling (6). Connect 5P-3929 Coupling (6) to the fitting on the back of the cab.
Tighten coupling (6) to hose (A) to a torque of 68 ± 7 N·m (50.1 ± 5.2 lb ft). Tighten the final connection to the cab to a torque of 54 ± 1 N·m (39.8 ± 0.7 lb ft).
 | |
| Illustration 55 | g00756954 |
- Install one 9X-7380 O-Ring Seal (5) in the straight end of 138-8481 Hose Assembly (1). Connect hose (1) to 103-6100 Quick Disconnect (26) .
- Install one 9X-7383 O-Ring Seal (3) in 138-8481 Hose Assembly (1). Connect 5P-3948 Refrigerant Coupling Assembly (2) to hose (1). Install one 9X-7383 O-Ring Seal (3) to 5P-3948 Refrigerant Coupling Assembly (2). Connect coupling (2) to the air conditioning lines for the cab.
Tighten coupling (2) to hose (1) to a torque of 54 ± 1 N·m (39.8 ± 0.7 lb ft). Tighten the final connection to the cab with a torque of 49 ± 1 N·m (36.1 ± 0.7 lb ft).
- Secure 138-8481 Hose Assembly (1) to the existing boss with one 9M-8406 Clip (4) and the existing bolt.
- Install one 9X-7380 O-Ring Seal (5) in 163-3134 Hose Assembly (19). Connect hose (19) to 103-6100 Quick Coupler (26) .
- Install one 9X-7382 O-Ring Seal (8) to 138-8502 Hose Assembly (B). Connect hose (B) to 125-2796 Fitting Assembly (22).
 | |
| Illustration 56 | g00756956 |
- Install one 9X-7381 O-Ring Seal (11) in 163-3131 Hose Assembly (10). Connect 3E-4053 Air Conditioner Fitting (21) to hose (10).
- Install fitting assembly (22) and air conditioner fitting (21) to the rear of the compressor by using one 1P-6356 Plate (25), one 8T-2561 Hard Washer (24) and one 8T-6466 Bolt (23) .
Note: 125-2796 Fitting As (22) should attach to the suction port of the compressor. 3E-4053 Air Conditioner Fitting (21) should attach to the discharge port on the compressor.
- Install 5P-7611 Grommet (18) into the fan shroud.
 | |
| Illustration 57 | g00756958 |
- Install two 118-6878 Brackets (20) to the frame. For the rear bracket (20), use one 8T-4121 Hard Washer (14) and one 8T-4133 Nut (16). For the front bracket (20), use one 8T-4121 Hard Washer (14) and one 8T-4136 Bolt (15) .
 | |
| Illustration 58 | g00756959 |
- Route 163-3134 Hose Assembly (19) along the frame, through 5P-7611 Grommet (18) in the fan shroud and over the radiator. Install one 9X-7380 O-Ring Seal (5) in hose (19). Connect 163-3134 Hose Assembly (19) to the condenser.
 | |
| Illustration 59 | g00756962 |
- Route 163-3131 Hose Assembly (10) along the frame, through 5P-7611 Grommet (18) in the fan shroud and over the top of the radiator. Install one 9X-7381 O-Ring Seal (11) to 163-3131 Hose Assembly (10). Connect hose (10) to the condenser.
- Secure 138-8502 Hose Assembly (B), 163-3131 Hose Assembly (10), and 163-3134 Hose Assembly (19). Use the following hardware:
- Attach 103-6100 Quick Couplers (26) that are located on the ends of hoses (1) and (19) to the ends of the 3E-3535 Receiver-Dryer Gp .
 | |
| Illustration 60 | g00762978 |
Installation of Electrical Connections
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 4 | 3S-2093 | Strap |
| 2 | 1 | 106-8704 | Arc Suppressor |
| 3 | 1 | 114-5333 | Switch |
| 4 | 2 | 130-5300 | Clip |
| 5 | 2 | 5S-7382 | Bolt |
| 6 | 2 | 6V-8801 | Nut |
| 7 | 2 | 8T-4896 | Hard Washer |
| 8 | 1 | 9X-7378 | Seal |
- Install two 130-5300 Clips (4) to the rear of the A/C Compressor. Use the following items to install each clip (4) : one 5S-7382 Bolt (5), one 6V-8801 Nut (6) and one 8T-4896 Washer (7) .
 | |
| Illustration 61 | g00756965 |
- Connect the green wires (A) from the compressor to the connector (B) with wire 513-OR (B) and with wire 522-WH from the engine harness. Secure the connection into clip (4). Secure wires with two 3S-2093 Straps (1) .
- Connect 114-5333 Switch Assembly (3) to connector (C) with wire 513-OR and with wire 521-YE. Secure the connector in Clip (4). Install 9X-7378 Seal (8) onto switch (3). Connect switch (3) to the compressor. Secure the wires of the switch (3) with 3S-2093 Strap (1) .
- Connect 106-8704 Arc Suppressor (2) to the engine harness. Secure arc suppressor (2) with 3S-2093 Strap (1) .
 | |
| Illustration 62 | g00756967 |
Charge the Air Conditioning System
Charge the air conditioning system. The correct charge is 2.3 kg (5.0 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG7006, "Air Conditioning Reference Guide" for the correct tools.
Installation of the Seat
For installation of the seat, refer to ""Installation of the Seat" " for 192-1512 Air Conditioner Conversion Ar .
Installation of Cab Panels
Install the cab panels. Refer toInstallation of Cab Panels for 192-1512 Air Conditioner Kit .