Installation Instructions for Air Conditioner Conversion Arrangements for D6R, D7R, and D8RTrack-Type Tractors{7320} Caterpillar

Track-Type Tractor:

D6R (S/N: 2YN1-UP; 9ZS1-UP; 2HM1-UP; 3ZN1-UP; 1RW1-UP; 4FM1-UP; 4MN1-UP; 6MR1-UP; 4JR1-UP; 5LN1-UP; 7GR1-UP; 9BM1-UP; 6JN1-UP; 8XN1-UP; 7KN1-UP; 9MN1-UP; 8LN1-UP; 4HN1-UP; 9PN1-UP; 8TM1-UP)

D7R (S/N: 2HR1-UP; 9HM1-UP; 2EN1-UP; 3DN1-UP; 5KZ1-UP)

D8R (S/N: 7XM1-UP; 9EM1-UP)

Introduction

This publication will give specific instructions for the field installation of the following air conditioner groups:

• 192-1508 Air Conditioner Conversion Ar is for the D6R Track-Type Tractor.

• 192-1509 Air Conditioner Conversion Ar is for the D7R Track-Type Tractor.

• 192-1510 Air Conditioner Conversion Ar is for the D8R Track-Type Tractor.

Note: Do not use these air conditioner kits on machines with the following attachments: waste disposal arrangement, solid engine doors (non-vented), reversible fan and Flexxaire fan.

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". 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

Table 1

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 192-1508 Air Conditioner Conversion Ar for the D6R Track-Type Tractor

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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.

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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 keep contaminants from entering the system.

Note: This air conditioner kit is not used on the machines with the following arrangements:

• Waste disposal

• Engine enclosures with solid doors

• Reversible fan

• Flexxaire fan

Machine Preparation

1. Remove the engine enclosure on right side and on the left side of the machine. Remove the hood. Refer to the Disassembly and Assembly, "Hood - Remove and Install".

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Illustration 1	g00757144

2. Remove cover (A) and the filter from the top of the housing by loosening two knobs (B) .

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Illustration 2	g00756801

3. Remove four bolts (C) and four washers. Remove plate (D) and the gasket. Retain all parts for later assembly.

Install the Compressor

Table 2

Required Parts
Item	Qty	Part Number	Description
1	1	3E-1906	Refrigerant Compressor
2	2	7W-4974	Plate
3	6	4L-9337	Bolt
4	14	8T-4896	Hard Washer
5	7	6V-8801	Nut
6	1	7C-8434	Bracket
7	1	7C-2164	Block
8	1	8T-2501	Bolt
9	1	4N-4942	Adjustment Rod
10	2	6B-6684	Full Nut
11	1	3E-4054	Air Conditioner Fitting
12	1	3E-4080	Air Conditioner Fitting
13	1	1P-6356	Plate
14	2	9X-7385	O-Ring Seal
15	1	8T-6466	Bolt
16	1	5P-1075	Hard Washer
17	1	114-5333	Pressure Switch
18	1	9X-7378	O-Ring Seal
19	1	7W-4973	Bracket
20	2	5S-7383	Bolt
21	1	8T-9389	Bolt
22	2	6V-8188	Nut
23	1	6V-4432	Bolt
24	3	8T-4223	Hard Washer
25	1	8T-4835	Bolt
26	1	1K-0505	Washer
27	1	1P-9744	V-Belt

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Illustration 3	g00757464

1. Attach two 7W-4974 Plates (2) to 3E-1906 Refrigerant Compressor (1). Use four 4L-9337 Bolts (3), eight 8T-4896 Hard Washers (4), and four 6V-8801 Nuts (5) .

   Note: The mounting hole for attaching to the engine mounting bracket is offset. Install brackets (2) with the offset hole to the left of center of the compressor (1) .

   Note: Ensure that oil filler plug (A) is oriented on the horizontal axis that runs through the center of compressor. See Illustration 3.

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Illustration 4	g00757477

2. Attach 7C-8434 Bracket (6) to compressor (1). Use two 4L-9337 Bolts (3), four 8T-4896 Hard Washers (4), and two 6V-8801 Nuts (5) .

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Illustration 5	g00757498

3. Attach 7C-2164 Block (7) to 7C-8434 Bracket (6). Use one 8T-2501 Bolt (8), one 6V-8801 Nuts (5), and two 8T-4896 Hard Washer (4). Only finger tighten the bolt and the nut.

4. Attach 4N-4942 Adjustment Rod (9). Use two 6B-6684 Full Nut (10). Only finger tighten the nuts.

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Illustration 6	g00757557
Front View

5. Remove the covers from the ports for the air conditioner fittings on the back of compressor (1). Discard the covers. Install one 9X-7385 O-Ring Seal (14) on each port.

6. Attach 3E-4080 Air Conditioner Fitting (12) and 3E-4054 Air Conditioner Fitting (11) onto the ports on the rear of compressor (1). Use one 1P-6356 Plate (13), one 8T-6466 Bolt (15), and one 5P-1075 Hard Washer (16) .

   Tighten bolt (15) to a torque of 25 ± 7 N·m (18.4 ± 5.1 lb ft).

7. Remove the cover from the port for the pressure switch. Discard the cover.

8. Install one 9X-7378 O-Ring Seal (18) and one 114-5333 Pressure Switch (18) onto the port.

   Tighten pressure switch (18) to a torque of 8.2 ± 1.4 N·m (72.5 ± 12.4 lb in).

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Illustration 7	g00757583
Front view

9. Attach 7W-4973 Bracket (19) to the front of the engine. Use two 5S-7383 Bolts (20), one 8T-9389 Bolt (21), and one 6V-8188 Nut (22) .

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Illustration 8	g00757623

10. Attach two 7W-4974 Plates (2) to 7W-4973 Bracket (19). Use one 6V-8188 Nut (22), one 6V-4432 Bolt (23), and two 8T-4223 Hard Washers (24) .

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Illustration 9	g00757635
Front view

11. Slip 1P-9744 V-Belt (27) onto the compressor and onto pulley (B) on the crankshaft.

12. Attach 4N-4942 Adjustment Rod (9) onto the front engine cover. Use one 8T-4835 Bolt (25), one 8T-4223 Hard Washer (24), and one 1K-0505 Washer (26) .

13. Adjust the tension in 1P-9744 V-Belt (27). Use 6B-6684 Full Nut (10). Refer to the Operation and Maintenance Manual, "Air Conditioner Belt - Inspect/Adjust/Replace" for additional information.

    The initial tension in a new V-belt should be 534 ± 22 N (120 ± 5 lb). After at least 30 minutes of operation, the tension in the V-belt should be 400 ± 44 N (90 ± 10 lb).

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Illustration 10	g00757658
Front view

14. Tighten one nut (5) and one bolt (8) .

Install the Condenser

Table 3

Required Parts
Item	Qty	Part Number	Description
1	1	110-2723	Bracket
2	4	8T-8919	Bolt
3	4	1S-4305	Washer
4	4	6N-8744	Mount
5	2	110-3844	Bracket
6	4	6V-8801	Nut
7	4	7X-0578	Hard Washer
8	1	123-0913	Condenser
9	6	4L-6454	Bolt
10	6	8T-4896	Hard Washer
11	1	110-2722	Bracket

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Illustration 11	g00757699

1. Remove four bolts (A) from the radiator guard. Discard bolts (A) .

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Illustration 12	g00757700

2. Install 110-2723 Bracket (1) to the radiator housing. Use two 8T-8919 Bolts (2) and two 1S-4305 Washers (3) .

   Note: Hand tighten all bolts until the condenser is installed.

3. Install two 6N-8744 Mounts (4) into the mounting holes on one 110-2723 Bracket (1) .

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Illustration 13	g00757705

4. Attach 110-3844 Bracket (5) to 110-2723 Bracket (1). Use two 6V-8801 Nuts (6) and two 7X-0578 Hard Washers (7) .

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Illustration 14	g00757708

5. Attach 123-0913 Condenser (8) to 110-3844 Bracket (5). Use three 4L-6454 Bolts (9) and three 8T-4895 Washers (10) .

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Illustration 15	g00757707

6. Install 110-2722 Bracket (11) to the right side of the radiator. Use two 8T-8919 Bolts (2) and two 1S-4305 Washers (3) .

7. Install two 6N-8744 Mounts (4) into the mounting holes on one 110-2722 Bracket (11) .

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Illustration 16	g00757709

8. Attach 110-3844 Bracket (5) to 110-2722 Bracket (11). Use two 6V-8801 Nuts (6) and two 7X-0578 Hard Washers (7) .

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Illustration 17	g00757710

9. Attach 123-0913 Condenser (8) to 110-3844 Bracket (5). Use three 4L-6454 Bolts (9) and three 8T-4895 Washers (10) .

10. Secure the condenser to the radiator by tightening all fasteners.

Install the Evaporator

Table 4

Required Parts
Item	Qty	Part Number	Description
1	2	2V-1937	Grommet
2	1	5P-0892	Seal
3	1	7T-9426	Grommet
4	1	8C-5682	Tee
5	1	5P-4829	Tube
6	1	7T-9793	Valve
7	1	6V-2372	Barbed Elbow
8	1	109-6406	Coil
9	2	8T-4191	Bolt
10	1	144-0195	Hose
11	1	3E-5464	Thermostat Switch
12	2	6L-7159	Screw
13	1	1V-3113	Clip
14	1	2A-3211	Washer
15	1	7S-4346	Screw
16	2	5P-1075	Hard Washer

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Illustration 18	g00757000
Side view of the housing for the evaporator coil

1. Remove two bolts (D) and two washers. Remove plate (A) and plate (B) from the top of the heater core (C). Retain plate (A) for later use.

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Illustration 19	g00757006

2. Insert 2V-1937 Grommet (1) into plate (B) .

3. Cut one 380 mm (15 inch) length of 5P-5643 Seal (2). Apply the seal (2) to the lower edge of plate (B) .

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Illustration 20	g00757019
Front view of the housing for the evaporator coil

4. Remove two bolts (E), two washers (F) and one nut (G) from heater coil (C). Retain the removed items for later use.

5. Cut three lengths of 5P-4829 Tube (5) :
   • One length of 360 mm (14.1 inch) (H)

   • One length of 200 mm (7.9 inch) (J)

   • One length of 135 mm (5.3 inch) (K)

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Illustration 21	g00757071

6. Insert the 135 mm (5.3 inch) piece (K) of 5P-4829 Tube (5) in 7T-9426 Grommet (3) .

7. Insert all three cut lengths of 5P-4829 Tube (5) into 8C-5682 Tee (4). Refer to Illustration 21.

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Illustration 22	g00757278

8. Cut one 700 mm (27.5 inch) length of 5P-4829 Tube (5). Moisten 7T-9793 Valve (6) with refrigerant oil. Insert valve (6) 76 mm (3.0 inch) from one end.

9. On the opposite end of the 700 mm (27.5 inch) length of 5P-4829 Tube (5), install 6V-2372 Barbed Elbow (7) .

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Illustration 23	g00757293
Side view

10. Remove plug (L) from the bottom of the housing.

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Illustration 24	g00757295
Front view

11. Insert grommet (3) with hose (5) into the hole.

12. Connect the 200 mm (7.9 inch) length and the 360 mm (14.1 inch) length of tube (5) to the drain outlets on the bottom of the drain pan (M) .

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Illustration 25	g00757302
Front view

13. Connect the 135 mm (5.3 inch) length of tube (5) to 6V-2372 Barbed Elbow (7) that is on the 700 mm (27.5 inch) length of tube (5) .

14. Route the 700 mm (27.5 inch) length of tube (5) around the heater hoses. Allow tube (5) to drain into the engine compartment.

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Illustration 26	g00757303
Side view

15. Cut 5P-0892 Seal (2) to a length of 380 ± 3 mm (15 ± 0.1 inch). Install the length of seal (2) to the edge of the drain pan (M) .

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Illustration 27	g00757304
Front view

16. Install 109-6406 Coil (8) into the mounting bracket. Use two bolts (E), two washers (F), and one nut (G) .

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Illustration 28	g00757305

17. Remove two bolts (P) from the bottom of the instrument panel. Lift the instrument panel (N) and then pull out instrument panel (N) .

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Illustration 29	g00757325

18. Install 2V-1937 Grommet (1) into the hole in the cab firewall.

19. Mount 3E-5464 Thermostat Switch (11) on the mounting plate on the blower housing. Use two 6L-7159 Screws (12) .

20. Route the capillary tube through 2V-1937 Grommet (1) .

21. Secure the capillary tube with the following items: one 1V-3113 Clip (13), one 2A-3211 Washer (14) and one 7S-4346 Screw (15)

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Illustration 30	g00757312

22. Locate wire 522-WH (R) and wire 200-BK (T). Connect wire 522-WH (R) and wire 200-BK (T) to 3E-5464 Thermostat Switch (11) .

    Note: Wires (R) and (T) may be connected to either terminal on switch (11) .

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Illustration 31	g00757305

23. Insert instrument panel (N) into the console. Install two bolts (P) in the bottom of the instrument panel (N) .

24. Cut 144-0195 Hose (10) to a length of 100 mm (3.9 inch). Insert the capillary tube of 3E-5464 Thermostat Switch (11) into hose (10) .

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Illustration 32	g00757377

25. Install plate (B) and then install plate (A). Use two 8T-4191 Bolts (9) and two 5P-1075 Hard Washers (16) .

    Note: Make sure that plate (B) fits into the lip at the back of the housing. Make sure that seal (2) on plate (B) is over coil (8) .

26. Carefully insert the capillary tube of switch (11) through grommet (1) and into coil (8) .

    Note: The capillary tube must be inserted at least 180 mm (7.1 inch) into the coil.

    Note: The capillary tube is easily damaged. Be very careful not to damage the capillary tube during installation.

Install the Hoses, the Accumulator and the Receiver

Table 5

Required Parts
Item	Qty	Part Number	Description
1	1	7T-8894	Grommet
2	1	7T-8895	Grommet
3	3	9X-7381	O-Ring Seal
4	3	9X-7380	O-Ring Seal
5	1	108-6544	Hose As
6	2	9X-7382	O-Ring Seal
7	2	9X-7383	O-Ring Seal
8	1	108-6541	Hose As
9	5	3S-2093	Cable Strap
10	2	103-6100	Quick Coupler
11	2	116-6202	Boot
12	3	6V-1228	Clip
13	1	6K-1641	Clip
14	10	4L-6454	Bolt
15	12	8T-4896	Hard Washer
16	1	8E-3430	Strip
17	1	4S-1962	Clip
18	1	151-5261	Refrigerant Accumulator
19	1	8R-3393	Strap
20	1	128-5924	Clamp
21	1	108-6542	Hose As
22	1	6Y-1789	Hose As
23	2	3S-8664	Clip
24	1	8N-3293	Bracket
25	2	9B-7237	Bolt
26	2	6V-8801	Nut
27	1	7N-1277	Bracket
28	1	5P-8167	Bolt
29	1	108-6538	Bar
30	1	3E-3535	In-Line Refrigerant Dryer
31	1	109-1633	Clip
32	1	109-1634	Clip
33	1	108-6543	Hose As
34	1	106-8704	Arc Suppressor
35	1	4P-7581	Clip
36	1	4P-8134	Clip
37	2	8T-2561	Hard Washer

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NOTICE
Secure all hoses per instructions. Lubricate all O-rings with R-134a refrigerant oil before installation. Keep all fittings and all O-rings protected during the installation in order to prevent the contamination of the air conditioning system.

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Illustration 33	g00766989

1. Install one 9X-7381 O-Ring Seal (3) and one 9X-7380 O-Ring Seal (4) into either end of 108-6544 Hose As (5). Install one 7T-8895 Grommet (1) onto hose (5). Face grommet (1) toward the larger fitting on hose (5) .

2. Install one 9X-7382 O-Ring Seal (6) and one 9X-7383 O-Ring Seal (7) into either end of 108-6541 Hose As (8). Install one 7T-8894 Grommet (2) onto hose (8). Face grommet (2) toward the elbow in hose (8) .

3. Remove the two plugs in the bottom of the housing for the evaporator coil.

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Illustration 34	g00757737

4. Route 108-6544 Hose As (5) through floor of the housing for the evaporator coil. Connect hose (5) to the smallest fitting on the evaporator coil.

   Note: Use two wrenches when you secure the hose fitting to the evaporator coil in order to minimize damage to the hoses and to the coil.

5. Route 108-6541 Hose As (8) through the floor of the housing for the evaporator coil. Connect hose (8) to the largest fitting on the evaporator coil.

   Note: Use two wrenches when you secure the hose fitting to the evaporator coil in order to minimize damage to the hoses and to the coil.

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Illustration 35	g00757768
Front view

6. Install 7T-8895 Grommet (1) and 7T-8894 Grommet (2) into the floor of the housing. Secure the grommets to the hoses by using one 3S-2093 Cable Strap (9) for each hose.

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Illustration 36	g00757777
Side view

7. Attach one 103-6100 Quick Coupler (10) to the free end of 108-6544 Hose As (5). Connect one 116-6202 Boot (11) to coupler (10) .

8. Route both hoses (5) and (8) together. Secure both hoses to the tractor frame.

   1. Use one 6K-1228 Clip (13) to secure hose (8).

   2. Use one 6K-8178 Clip (13) to secure hose (5) .

   3. Use one 4L-6454 Bolt (14) and one 8T-4896 Hard Washer (15) to secure clip (13) to the tractor frame.

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Illustration 37	g00757953
Front view

9. Continue to route hose (8) along the oil cooler and under the engine. Secure hose (8) .

   1. Attach 8E-3430 Strip (16) to the oil cooler. Secure hose (8) to strip (16). Use one 4S-1962 Clip (17), one 4L-6454 Bolt (14), and one 8T-4896 Hard Washer (15) .

   2. Secure hose (8) to two existing bosses on each side of the chassis. Use two 6V-1228 Clip (12), two 4L-6454 Bolt (14), and two 8T-4896 Hard Washer (15) .

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Illustration 38	g00757978
Side view

10. Attach 186-6189 Refrigerant Accumulator (18) to the engine frame. Use one 8R-3393 Strap (19), one 128-5924 Clamp (20), two 4L-6454 Bolts (14), two 8T-2561 Hard Washers (15), and two 8T-2561 Hard Washers (37) .

11. Attach 108-6541 Hose As (8) to 186-6189 Refrigerant Accumulator (18) .

    Note:

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Illustration 39	g00757986
Side view

12. Lubricate one 9X-7382 O-Ring Seal (6) and one 9X-7383 O-Ring Seal (7). Install O-ring (6) and O-ring (7) into either end of 108-6542 Hose As (21) .

13. Attach 108-6542 Hose As (21) to the bottom fitting on 151-5261 Refrigerant Accumulator (18). Attach the opposite end of hose (21) to the suction port (A) of the compressor.

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Illustration 40	g00758002
Front view

14. Lubricate two 9X-7381 O-Ring Seals (3). Install one seal on either end of 6Y-1789 Hose As (22) .

15. Attach 6Y-1789 Hose As (22) to the inlet port on the condenser (C) and to the discharge port (D) on the compressor.

16. Secure hose (22) at the fan guard. Using one 8T-4896 Hard Washer (15), one 3S-8664 Clip (23), one 9B-7237 Bolt (25), 7N-1277 Bracket (27) and one 5P-8167 Bolt (28) .

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Illustration 41	g00758114

17. Install 108-6538 Bar (29) onto the bracket for the ether canister. Use three 4L-6454 Bolts (14) and three 8T-4896 Hard Washers (15) .

    Note: The ether canister may need to be removed.

18. Install 3E-3535 In-Line Refrigerant Dryer (30) onto 108-6538 Bar (29). Use one 109-1633 Clip (31), one 109-1634 Clip (32), one 4L-6454 Bolt (14), and one 8T-4896 Hard Washer (15) .

19. Lubricate two 9X-7380 O-Ring Seals (4). Install one O-ring seal (4) on either end of 108-6543 Hose As (33) .

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Illustration 42	g00758123
Side view

20. Attach one 103-6100 Quick Coupler (10) to the end of hose (33) without the elbow. Attach one 116-6202 Boot (11) to quick coupler (10) .

21. Attach the end of 108-6543 Hose As (33) with the elbow to the small port on condenser (13) .

22. Connect hoses (5) and (33) to refrigerant dryer (30) by using the quick disconnects.

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Illustration 43	g00758139
Front view of the compressor

23. Secure hose (22) at the rear flange of the compressor. Use one 4L-6454 Bolt (9), two 8T-4896 Hard Washers (15), one 8N-3293 Bracket (24), one 9B-7237 Bolt (25), two 6V-8801 Nuts (26), and one 3S-8664 Clip (23) .

24. Locate the engine wiring harness in the lower front engine area. Attach 106-8704 Arc Suppressor (34) to the engine wiring harness. Secure arc suppressor (34) by using one 4P-7581 Clip (35) and one 3S-2093 Cable Strap (9) .

25. Attach one connector from the engine wiring harness to 114-5333 Pressure Switch (C). Secure the connectors by using 4P-8134 Clip (36) and one 3S-2093 Cable Strap (9) .

26. Connect the green wire from compressor (13) to the engine wiring harness.

27. Secure the wire from pressure switch (E) by using one 3S-2093 Cable Strap (9) .

Final inspection, Charging and Performance Tests

Table 6

Required Parts
Item	Qty	Part Number	Description
1	1	110-6393	Instruction Plate

1. Perform a visual inspection of all components. Make sure that all of the connections are secure. Make sure that all fasteners are tightened. Make sure that the hoses are not kinked.

2. Evacuate the system for 60 minutes. Charge the air conditioner system. The correct charge is 1.6 kg (3.5 lb). Refer to the Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigrant" for the correct procedure. Refer to the Special Publication, NEDG5056, "Air Conditioning Tools".

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Illustration 44	g00756801

3. Install plate (D) and the gasket. Use four bolts (C) and four washers.

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Illustration 45	g00757144

4. Install cover (A) and the filter on the top of the housing by tightening two knobs (B) .

5. Install the engine enclosure on right side and on the left side of the machine. Install the hood. Refer to the Disassembly and Assembly, "Hood - Remove and Install".

6. Start the engine. Increase engine speed to approximately 1200 rpm. Verify that the system is cooling the inside of the cab.

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Illustration 46	g00758191

7. Stamp 110-6393 Instruction Plate (1) with 1.6 kg (3.5 lb). Attach plate (1) to the left side of the dash above the cab louver. The plate needs to be seen through the window on the cab door.

Installation of the 192-1509 Air Conditioner Conversion Ar for the D7R Track-Type Tractor

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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.

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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 keep contaminants from entering the system.

Note: This air conditioner kit is not used on the machines with the following arrangements:

• Waste disposal

• Engine enclosures with solid doors

• Reversible fan

• Flexxaire fan

Prepare the Tractor

1. Remove the engine enclosure on right side and on the left side of the machine. Remove the hood. Refer to the Disassembly and Assembly, "Hood - Remove and Install".

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Illustration 47	g00757144

2. Remove cover (A) and the filter from the top of the housing by loosening two knobs (B) .

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Illustration 48	g00756801

3. Remove four bolts (C) and four washers. Remove plate (D) and the gasket. Retain all parts for later assembly.

Install the Compressor

To install the compressor, refer to ""Install the Compressor" " for the 192-1508 Air Conditioner Conversion Ar for the D6R Track-Type Tractor.

Install the Condenser

Table 7

Required Parts
Item	Qty	Part Number	Description
1	1	110-6928	Support
2	1	114-4398	Bracket
3	1	105-9227	Condenser
4	6	4L-6454	Bolt
5	6	8T-4896	Hard Washer
6	1	114-4397	Plate
7	8	9B-7237	Bolt
8	5	5P-1075	Hard Washer
9	1	110-6897	Bracket
10	1	114-4399	Bracket
11	6	8T-4835	Bolt
12	6	5P-1076	Hard Washer
13	1	110-6891	Bracket
14	4	9L-8781	Washer
15	4	6N-8744	Mount
16	1	114-4400	Baffle
17	1	122-3324	Bracket
18	1	5S-7379	Bolt

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Illustration 49	g00758438

1. Remove six bolts (A) and six washers. Discard bolts (A) and washers.

2. Remove two bolts (B) and two washers. Discard bolts (B) and washers.

3. Remove two bolts (C), two nuts (D), and two washers. Discard bolts (C) and washers. Retain nuts (D) for later use.

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Illustration 50	g00758439

4. Remove six bolts (E) and six washers. Remove four bolts (F) and four washers. Discard bolts (E) and washers. Retain bolts (F) and washers.

5. Remove guard (G). Discard guard (G) .

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Illustration 51	g00758492

6. Install 110-6928 Support (1) into the fan guard assembly. Secure support (1) with nuts (D) .

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Illustration 52	g00758503

7. Attach 114-4398 Bracket (2) to the left side of 105-9227 Condenser (3) by using two 4L-6454 Bolts (4) and two 8T-4896 Hard Washers (5) .

8. Attach 114-4397 Plate (6) to 105-9227 Condenser (3) by using two 9B-7237 Bolts (7) and two 5P-1075 Hard Washers (8) .

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Illustration 53	g00758505

9. Attach 110-6897 Bracket (9) to the right side of condenser (3). Use four 4L-6454 Bolts (4) and four 8T-4896 Hard Washers (5) .

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Illustration 54	g00758532

10. Install 114-4399 Bracket (10) to the left side of the radiator guard. Use three 8T-4835 Bolts (11), three 5P-1076 Hard Washers (12), one 9B-7237 Bolt (7) and one 5P-1075 Hard Washer (8) .

11. Install 110-6891 Bracket (13) to the right side of the radiator guard. Use three 8T-4835 Bolts (11), three 5P-1076 Hard Washers (12), one 9B-7237 Bolt (7) and one 5P-1075 Hard Washer (8) .

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Illustration 55	g00758533

12. Install condenser (3) and the assembled brackets. Mount bracket (2) to bracket (10). Use two 9L-8781 Washers (14), two 9B-7237 Bolts (7), and two 6N-8744 Mounts (15) .

13. Mount bracket (9) to bracket (13). Use two 9L-8781 Washers (14), two 9B-7237 Bolts (7), and two 6N-8744 Mounts (15) .

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Illustration 56	g00758580

14. Install 114-4400 Baffle (16) onto the radiator guard. Use four bolts (F) and washers.

15. Install 122-3324 Bracket (17) by using one 5S-7379 Bolt (18) .

Install the Evaporator

To install the evaporator, refer to ""Install the Evaporator" " for the 192-1508 Air Conditioner Conversion Ar for the D6R Track-Type Tractor.

Install the Hoses, the Accumulator and the In-Line Dryer

Table 8

Required Parts
Item	Qty	Part Number	Description
1	3	9X-7381	O-Ring Seal
2	1	108-8524	Hose As
3	1	7T-8895	Grommet
4	2	9X-7382	O-Ring Seal
5	1	108-8525	Hose As
6	1	7T-8894	Grommet
7	5	3S-2093	Cable Strap
8	2	103-6100	Quick Coupler
9	2	116-6202	Boot
10	2	8N-3293	Bracket
11	8	4L-6454	Bolt
12	3	6V-8801	Nut
13	14	8T-4896	Hard Washer
14	1	8E-3430	Strip
15	1	4L-9337	Bolt
16	2	6D-1641	Clip
17	1	1S-1015	Clip
18	1	7X-0331	Bolt
19	4	8T-4223	Hard Washer
20	2	8S-0948	Clip
21	1	111-2304	Bracket
22	1	151-5261	Refrigerant Accumulator
23	1	8R-3393	Strap
24	1	128-5924	Clamp
25	3	5M-3062	Bolt
26	2	8T-2561	Hard Washer
27	2	9X-7383	O-Ring Seal
28	1	108-6542	Hose As
29	1	6Y-1789	Hose As
30	2	3S-8664	Clip
31	1	4P-8134	Clip
32	1	106-8704	Arc Suppressor
33	1	4P-7581	Clip
34	3	9X-7380	O-Ring Seal
35	1	108-8523	Hose As
36	2	7N-1277	Bracket
37	1	9M-8406	Clip
38	1	8T-2502	Bolt
39	1	3E-3535	In-Line Refrigerant Dryer
40	1	109-1633	Clip
41	1	109-1634	Clip
42	2	5P-2228	Bolt
43	1	9B-7237	Bolt
44	1	108-6538	Bar

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NOTICE
Secure all hoses per instructions. Lubricate all O-rings with R-134A refrigerant oil before installation. Keep all fittings and all O-rings protected during the installation in order to prevent the contamination of the air conditioning system.

1. Lubricate one 9X-7381 O-Ring Seal (1). Install O-ring seal (1) into the larger fitting of 108-8524 Hose As (2). Install one 7T-8895 Grommet (3). Face grommet (3) toward the fitting without O-ring seal (1) .

2. Lubricate one 9X-7382 O-Ring Seal (4). Install one O-ring seal (4) into the straight end of 108-8525 Hose As (5). Install one 7T-8894 Grommet (6) onto hose (5). Face grommet (6) toward the bent fitting on hose (5) .

3. Remove the two plugs in the bottom of the housing for the evaporator coil.

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Illustration 57	g00758820
Front view

4. Route hose (2) through the floor of the housing. Connect hose (2) to the smaller fitting on the evaporator coil.

   Note: Use two wrenches when you secure the hose fitting to the evaporator coil in order to minimize damage to the hoses and to the coil.

5. Route hose (5) through the floor of the housing. Connect hose (5) to the larger fitting on the evaporator coil.

   Note: Use two wrenches when you secure the hose fitting to the evaporator coil in order to minimize damage to the hoses and to the coil.

6. Install grommet (3) and grommet (6) into the floor of the housing. Secure the grommets to the hoses by using one 3S-2093 Cable Strap (7) for each grommet.

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Illustration 58	g00758821
Side view

7. Lubricate one 9X-7380 O-Ring Seal (34). Install O-ring seal (34) into the free end of hose (2). Connect one 103-6100 Quick Coupler (8) to the free end of hose (2). Connect one 116-6202 Boot (9) to quick coupler (8) .

8. Remove clip (A) on the aftercooler. Attach one 8N-3293 Bracket (10) to the aftercooler. Use the hardware from clip (A) .

9. Route hose (2) and hose (5) together. Secure hose (2), hose (5), and hose (B) to bracket (10). Use one clip (A), one 4L-6454 Bolt (11), one 6V-8801 Nut (12), two 8T-4896 Hard Washers (13), and one 6D-1641 Clip (16) .

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Illustration 59	g00758823
Front View

10. Secure 8E-3430 Strip (14) to the fuel filter mounting by using one 4L-9337 Bolt (15) .

11. Secure hoses (2) and (5) to strip (14) by using one 6D-1641 Clip (16), one 4L-6454 Bolt (11), and one 8T-4896 Hard Washer (13) .

12. Secure hose (5) to the front engine housing. Use one 1S-1015 Clip (17), one 7X-0331 Bolt (18), and two 8T-4223 Hard Washers (19) .

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Illustration 60	g00758826
Front View

13. Continue to route hose (5) under the engine. Secure hose (5) in two additional locations. For each location, use one 4L-6454 Bolt (11), one 8T-4896 Hard Washer (13), and one 8S-0948 Clip (20) .

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Illustration 61	g00759057
Front view

14. Attach 111-2304 Bracket (21) to the right side of the tractor frame by using two 8T-4223 Hard Washers (19) and two 5P-2228 Bolts (42) .

15. Attach 151-5261 Refrigerant Accumulator (22) to bracket (21). Use one 8R-3393 Strap (23), one 128-5924 Clamp (24), two 5M-3062 Bolts (25), and two 8T-2561 Hard Washers (26) .

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Illustration 62	g00758830
Side view

16. Lubricate one 9X-7383 O-Ring Seal (27). Install O-ring seal (27) into the free end of hose (5) .

17. Attach hose (5) to the upper port on accumulator (22) .

18. Lubricate one 9X-7383 O-Ring Seal (27). Install O-ring seal (27) into one end of 108-6542 Hose As (28). Attach hose (28) with O-ring seal (27) to the lower port of accumulator (22) .

19. Install one 9X-7382 O-Ring Seal (4) into the other end of hose (28). Connect hose (28) to the suction port on the compressor (C) .

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Illustration 63	g00758831
Side View

20. Lubricate two 9X-7381 O-Ring Seal (1). Install one O-ring seal (1) into each end of 6Y-1789 Hose As (29) .

21. Attach one end of hose (29) to the condenser (D). Attach the other end of hose (29) to the compressor (C) .

22. Secure hose (29) to condenser (D). Use one 7N-1277 Bracket (36), one 3S-8664 Clip (30), one 5M-3062 Bolt (25), and one 8T-4896 Hard Washer (13) .

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Illustration 64	g00759010
Front view of the compressor

23. Attach one 8N-3293 Bracket (10) to the compressor (C). Use one 6V-8801 Nut (12), two 8T-4896 Hard Washer (13), and one 9B-7237 Bolt (43) .

24. Secure hose (29) and one 4P-8134 Clip (31) to bracket (10). Use one 3S-8664 Clip (30), one 4L-6454 Bolt (11), one 6V-8801 Nut (12), and two 8T-4896 Hard Washers (13) .

25. Locate the engine wiring harness in the lower front engine area. Attach one 106-8704 Arc Suppressor (32) to the engine wiring harness. Secure arc suppressor (32) to the front engine housing by using one 4P-7581 Clip (33) .

26. Attach one connector from the engine wiring harness to 114-5333 Pressure Switch (E). Secure the connection to clip (31) by using one 3S-2093 Cable Strap (7) .

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Illustration 65	g00759011
Top view

27. Lubricate two 9X-7380 O-Ring Seal (34). Install one O-ring seal (34) into each end of 108-8523 Hose As (35) .

28. Connect the end of hose (35) with the 90° fitting to the condenser (D) .

29. On the end of hose (35) with the 45° fitting, install one 103-6100 Quick Coupler (8) and one 116-6202 Boot (9) .

30. Attach 7N-1277 Bracket (36) to the tractor frame by using existing hardware. Secure hose (35) to bracket (36) by using one 9M-8406 Clip (37), one 8T-2502 Bolt (38), and one 8T-4896 Hard Washer (13) .

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Illustration 66	g00759035
Top view

31. Install 108-6538 Bar (44) to the bracket for the ether aid (F). Use two 4L-6454 Bolts (11) and two 8T-4896 Hard Washers (13) .

32. Attach 3E-3535 In-Line Refrigerant Dryer (39) to bar (38) by using one 109-1633 Clip (40), one 109-1634 Clip (41), one 4L-6454 Bolt (11), and one 8T-4896 Hard Washer (13) .

33. Attach hose (2) and hose (35) to dryer (39) .

Final Inspection, Charging and Performance Tests

Table 9

Required Parts
Item	Qty	Part Number	Description
1	1	110-6393	Instruction Plate

Refer to ""Final Inspection, Charging and Performance Tests" " for the 192-1508 Air Conditioner Conversion Ar for the D6R Track-Type Tractor.

Installation of the 192-1510 Air Conditioner Conversion Ar for the D8R Track-Type Tractor

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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.

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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 keep contaminants from entering the system.

Note: This air conditioner kit is not used on the machines with the following arrangements:

• Waste disposal

• Engine enclosures with solid doors

• Reversible fan

• Flexxaire fan

Machine Preparation

1. Remove the hood. Refer to Disassembly and Assembly, "Hood and Dust Ejector - Remove" for your machine.

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Illustration 67	g00757738

2. Loosen two knobs and remove cover (A). Remove four bolts (B) that secure cover (C). Remove cover (C) from the housing.

Installation of the Evaporator Core

Table 10

Required Parts for the Installation of the Evaporator
Item	Qty	Part Number	Description
1	1	5P-4829	Tube
2	1	8C-5682	Tee
3	2	7T-9426	Grommet
4	1	7T-9793	Valve
5	1	6V-2372	Barbed Elbow
6	1	3S-2093	Cable Strap
7	1	7T-8894	Grommet
8	1	156-4678	Hose As
9	2	9X-6772	Cable Strap
10	1	156-4677	Hose As
11	1	5P-0892	Seal
12	1	105-7706	Evaporator Coil
13	1	9X-7382	O-Ring Seal
14	1	9X-7381	O-Ring Seal
15	2	2V-1937	Grommet
16	2	5P-8167	Bolt
17	2	5P-1075	Hard Washer
18	1	3E-5465	Thermostat Switch
19	1	2P-4339	Jam Nut
20	1	1V-3113	Clip
21	1	2A-3211	Washer
22	1	7S-4346	Screw
23	1	2V-0099	Knob

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Illustration 68	g00757759
Left side view

1. Remove two bolts (A) and washers (B) from plate (C). Remove plate (C) from the housing. Retain the hardware for later use.

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Illustration 69	g00757761
Front view

2. Remove two bolts (D), two washers (E), and nut (F) from the heater core. Retain hardware for later use.

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Illustration 70	g00757765
Right side view

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Illustration 71	g00757786
Left side view

3. Remove three plugs (G) from the cab pressurizer.

4. Cut four lengths of 5P-4829 Tube (1) :
   • One length of 360 ± 3 mm (14.2 ± 0.12 inch) (H)

   • One length of 200 ± 3 mm (7.9 ± 0.12 inch) (J)

   • One length of 50 ± 3 mm (2.0 ± 0.12 inch) (K)

   • One length of 1200 ± 3 mm (47.2 ± 0.12 inch) (L)

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Illustration 72	g00757789

5. Connect the 360 ± 3 mm (14.2 ± 0.12 inch), the 200 ± 3 mm (7.9 ± 0.12 inch), and the 50 ± 3 mm (2.0 ± 0.12 inch) pieces of 5P-4829 Tube (1) with 8C-5682 Tee (2). Refer to Illustration 72.

6. Insert the 50 ± 3 mm (2.0 ± 0.12 inch) piece of 5P-4829 Tube (1) into 7T-9426 Grommet (3) .

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Illustration 73	g00757791
Front view

7. Connect the 360 ± 3 mm (14.2 ± 0.12 inch) and the 200 ± 3 mm (7.9 ± 0.12 inch) piece of 5P-4829 Tube (1) to the bottom of the condensate drain. Insert 7T-9426 Grommet (3) into the side of the cab pressurizer.

   Note: The 360 ± 3 mm (14.2 ± 0.12 inch) piece of 5P-4829 Tube (1) connects to the right hand side of the condensate drain.

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Illustration 74	g00757794
(X) 75 ± 5 mm (3 ± 0.2 inch)

8. Install 7T-9793 Valve (4) into the end of the 1200 ± 3 mm (47.2 ± 0.12 inch) piece of 5P-4829 Tube (1). Insert 7T-9793 Valve (4) 75 ± 5 mm (3 ± 0.2 inch) from the end of the tube.

9. Insert 6V-2372 Barbed Elbow (5) into the end of the 1200 ± 3 mm (47.2 ± 0.12 inch) piece (L) of 5P-4829 Tube (1) .

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Illustration 75	g00757796
Left side view

10. Connect the 1200 ± 3 mm (47.2 ± 0.12 inch) piece of 5P-4829 Tube (1) and 6V-2372 Barbed Elbow (5) to the 50 ± 3 mm (2.0 ± 0.12 inch) piece of 5P-4829 Tube (1). Secure the end of 5P-4829 Tube (1) to the wiring harness with 3S-2093 Cable Strap (6) .

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Illustration 76	g00757807
Left side view

11. Slide 7T-8894 Grommet (7) over 156-4678 Hose As (8). Attach 9X-6772 Cable Strap (9) to the bottom of 7T-8894 Grommet (7) .

    Note: Do not tighten 9X-6772 Cable Strap (9) at this time.

12. Insert 7T-8894 Grommet (7) and 156-4678 Hose As (8) through the bottom of the cab pressurizer.

    Note: The 156-4678 Hose As (8) goes through the hose at the rear of the cab pressurizer.

13. Slide 7T-9426 Grommet (3) over 156-4677 Hose As (10). Attach 9X-6772 Cable Strap (9) to the bottom of 7T-9426 Grommet (3) .

    Note: Do not tighten 9X-6772 Cable Strap (9) at this time.

14. Insert 7T-9426 Grommet (3) and 156-4677 Hose As (10) through the bottom of the cab pressurizer.

    Note: The 156-4677 Hose As (10) goes through the hole at the front of the cab pressurizer.

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Illustration 77	g00757821
Left side view

15. Cut 5P-0892 Seal (11) to a length of 380 ± 3 mm (15 ± 0.12 inch). Place 5P-0892 Seal (11) at the front of the condensate drain.

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Illustration 78	g00757822
Front view

16. Install 105-7706 Evaporator Coil (12) to the cab pressurizer. Install two bolts (D), two washers (E), and nut (F) to secure 105-7706 Evaporator Coil (12) to the heater core.

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Illustration 79	g00757842

17. Use 9X-7382 O-Ring Seal (13) to connect 156-4678 Hose As (8) to 105-7706 Evaporator Coil (12). Use 9X-7381 O-Ring Seal (14) to connect 156-4677 Hose As (10) to 105-7706 Evaporator Coil (12) .

    Note: Tighten 9X-6772 Cable Straps (9) at this time.

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Illustration 80	g00757857
Left side view

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Illustration 81	g00757858
Top view

18. Insert 2V-1937 Grommet (15) into the wall of the cab. Insert 2V-1937 Grommet (15) into plate (C) .

19. Cut 5P-0892 Seal (11) to a length of 380 ± 3 mm (15 ± 0.12 inch). Place 5P-0892 Seal (11) at the front of plate (C) .

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Illustration 82	g00757866

20. Install plate (C) over the top of the evaporator coils. Install two bolts (A) and washers (B) to plate (C). Install two 5P-8167 Bolts (16) and two 5P-1075 Hard Washers (17) to plate (C) .

    Note: Make sure that plate (C) slides under the lip of the housing during installation.

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Illustration 83	g00757879

21. Remove two bolts (M) from each side of the instrument panel. Tilt instrument panel (N) in order to unhook the cable. Remove instrument panel (N) .

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Illustration 84	g00757880
Front view

22. Loosen the two set screws on two knobs (P). Remove two knobs (P) from the blower assembly.

23. Remove four screws (R) that secure plate (T) to the blower assembly. Remove plate (T) from the blower assembly.

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Illustration 85	g00757905
Front view (Y) 35.5 mm (1.4 inch) (Z) 38 mm (1.5 inch)

24. Drill a 11.40 ± 0.25 mm (0.45 ± 0.01 inch) hole in plate (T). The hole must be 35.5 mm (1.4 inch) from the bottom of plate (U). The hole must be 38 mm (1.5 inch) from the right edge of plate (T).

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Illustration 86	g00757895
Left side view

25. Install 3E-5465 Thermostat Switch (18) to the blower assembly. Install 2P-4339 Jam Nut (19) to 3E-5465 Thermostat Switch (18). Tighten jam nut (19) to a torque of 3.4 ± 0.6 N·m (30 ± 5 lb in).

26. Route the capillary tube of 3E-5465 Thermostat Switch (18) through 2V-1937 Grommet (15) .

27. Secure the capillary tube to the blower housing with the following components: 1V-3113 Clip (20), 2A-3211 Washer (21) and 7S-4346 Screw (22) .

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Illustration 87	g00757894
Front view

28. Reinstall plate (T). Install four screws (R) that secure plate (T) to the blower assembly. Install 2V-0099 Knob (23) to 3E-5465 Thermostat Switch (18). Install two knobs (P). Tighten the set screw on knobs (23) and (P) .

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Illustration 88	g00757879

29. Install instrument panel (N). Tilt instrument panel (N) in order to hook the cable. Install two bolts (M) to each side of instrument panel (N).

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Illustration 89	g00757907
Front view

30. Route the capillary tube through 2V-1937 Grommet (15). Make sure that the capillary tube is inserted into the at least 150 mm (6 inch) into 105-7706 Evaporator Coil (12) .

    Note: Make sure that the capillary tube is not damaged during installation. The capillary tube can be easily damaged during installation.

Install the Air Conditioning Compressor

Table 11

Required Parts for the Installation of the Compressor
Item	Qty	Part Number	Description
1	1	7C-7595	Bracket
2	1	3E-1906	Refrigerant Compressor
3	3	4L-9337	Bolt
4	10	8T-4896	Hard Washer
5	5	6V-8801	Nut
6	1	7C-7594	Bracket
7	1	8T-0288	Bolt
8	2	5P-1075	Hard Washer
9	2	4P-7581	Clip
10	1	8S-5383	Block
11	1	5P-2424	Bolt
12	6	8T-4223	Hard Washer
13	1	6V-8188	Nut
14	1	1S-4698	Rod
15	2	7X-0448	Nut
16	1	9X-7378	O-Ring Seal
17	1	114-5334	Pressure Switch
18	2	9X-7385	O-Ring Seal
19	1	3E-4053	Air Conditioner Fitting
20	1	3E-4054	Air Conditioner Fitting
21	1	1P-6356	Plate
22	1	8T-6466	Bolt
23	1	2S-9506	V-Belt
24	1	7C-7589	Compressor Support Assembly
25	2	9F-8759	Spacer
26	2	8T-9389	Bolt
27	1	110-6937	Bracket
28	1	8N-3525	Spacer
29	2	5P-2566	Bolt
30	1	4L-6454	Bolt
31	1	8T-2561	Hard Washer
32	1	7X-0346	Bolt
33	1	7X-0515	Hard Washer
34	1	5S-7383	Bolt

1. Remove the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install" for your machine.

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Illustration 90	g00758962
Front view

2. Attach 7C-7595 Bracket (1) to the front of 3E-1906 Refrigerant Compressor (2) with the following components: two 4L-9337 Bolts (3), four 8T-4896 Hard Washers (4) and two 6V-8801 Nuts (5) .

3. Attach 7C-7594 Bracket (6) to the rear of refrigerant compressor (2) with the following components: 4L-9337 Bolt (3), two 8T-4896 Hard Washers (4), two 6V-8801 Nuts (5), 5S-7383 Bolt (7), 5P-1075 Hard Washer (8) and 4P-7581 Clip (9) .

   Note: 4P-7581 Clip (9) is placed on the left rear of refrigerant compressor (2) .

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Illustration 91	g00758963
Right side view

4. Attach 8S-5383 Block (10) to 7C-7595 Bracket (1) with the following components: 5P-2424 Bolt (11), two 8T-4223 Hard Washers (12) and 6V-8188 Nut (13) .

5. Install 1S-4698 Rod (14) and two 7X-0448 Nuts (15) to 8S-5383 Block (10) .

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Illustration 92	g00758964
Rear view

6. Remove the cap from the rear of refrigerant compressor (2). Discard the cap. Install 9X-7378 O-Ring Seal (16) and 114-5334 Pressure Switch (17) to the rear of refrigerant compressor (2) .

7. Remove the cover from the rear of refrigerant compressor (2). Discard the cover. Install the following components to the rear of refrigerant compressor (2) : 5P-1075 Hard Washer (8), two 9X-7385 O-Ring Seals (18), 3E-4053 Air Conditioner Fitting (19), 3E-4054 Air Conditioner Fitting (20), 1P-6356 Plate (21) and 8T-6466 Bolt (22) .

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Illustration 93	g00759074
Right side view

8. Remove the tension from the belt tensioner. Remove the three V-belts from the fan drive. Place 2S-9506 V-Belt (23) to the rear slot on the fan drive.

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Illustration 94	g00758965
Front view

9. Remove plate (A), four bolts (B), and the washers from the cylinder head and the front housing. Keep the hardware for assembly purposes.

10. Remove six bolts (C), the washers, and two nuts from brackets (D) and (E). Remove brackets (D) and (E) from the cylinder head. Save bolts (C), the washers, the nuts, and bracket (D) for assembly purposes. Discard the remaining hardware.

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Illustration 95	g00758966
Right side view

11. Remove the top two bolts (F) and the washers from the fan drive.

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Illustration 96	g00759046

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Illustration 97	g00759047

12. Install 7C-7589 Compressor Support Assembly (24) to the front of the cylinder head. Use six bolts (C), the washers, and two nuts to attach compressor support assembly (24) to the cylinder head and to bracket (D) .

13. Install plate (A) to the cylinder head and the front housing. Install four bolts (B), and the washers that secure plate (A) to the cylinder head and the front housing.

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Illustration 98	g00758967
Right side view

14. Use two 9F-8759 Spacers (25), two 8T-9389 Bolts (26), and two 8T-4223 Hard Washers (12) to install 110-6937 Bracket (27) to the fan drive.

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Illustration 99	g00758969
Right side view

15. Use the following components to secure refrigerant compressor (2) to compressor support assembly (24) : 8N-3525 Spacer (28), two 5P-2566 Bolts (29), two 8T-4223 Hard Washers (12), 4L-6454 Bolt (30), 8T-2561 Hard Washer (31), 5S-7383 Bolt (34), 4P-7581 Clip (9), two 8T-4896 Hard Washers (4) and one 6V-8801 Nut (5) .

16. Install 7X-0346 Bolt (32) and 7X-0515 Hard Washer (33) to secure rod (14) to bracket (24) and to bracket (27) .

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Illustration 100	g00758970
Right side view

17. Place V-belt (23) over refrigerant compressor (2). Adjust the tension on the V-belt. The correct tension for a new V-belt should be 534 ± 22 N (120 ± 5 lb). The correct tension for a V-belt that has been used for at least 30 minutes is 400 ± 44 N (90 ± 10 lb).

18. Install the three V-belts to the fan drive.

19. Install the muffler. Refer to Disassembly and Assembly, "Muffler - Remove and Install" for your machine.

Install the Condenser

Table 12

Required Parts for the Installation of the Condenser
Item	Qty	Part Number	Description
1	1	105-9227	Condenser
2	1	110-6898	Bracket
3	8	5M-3062	Bolt
4	9	8T-4896	Hard Washer
5	1	110-6897	Bracket
6	1	110-6928	Support
7	6	8T-4835	Bolt
8	1	110-6896	Bracket As
9	2	9B-7237	Bolt
10	6	5P-1075	Hard Washer
11	1	110-6891	Bracket
12	4	4L-9337	Bolt
13	4	9L-8781	Washer
14	4	6N-8744	Mount
15	1	112-2625	Baffle
16	2	4L-6454	Bolt
17	1	110-6918	Support
18	1	7N-1277	Bracket
19	2	7D-7233	Clip
20	1	5S-7379	Bolt
21	2	6V-8801	Nut
22	1	108-8717	Bracket
23	2	8T-8917	Bolt
24	2	8T-4223	Hard Washer

1. Remove the hydraulic oil cooler (if equipped). Refer to Disassembly and Assembly, "Hydraulic Oil Cooler - Remove and Install" for your machine.

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Illustration 101	g00758760
Left side view

2. Remove bolts (A) and the washers from brackets (B). Remove brackets (B) from the radiator. Discard the hardware.

   Note: Step 2 is only for machines that are equipped with a hydraulic oil cooler.

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Illustration 102	g00758541
Rear view

3. Remove 10 bolts (C), the washers, and two nuts (D) from fan guard (E). Remove the clip, the bracket, and bolt (F) from the fan guard and the water line. Remove fan guard (E) from the radiator. Save nuts (D) for assembly purposes. Discard the remaining hardware.

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Illustration 103	g00758543
Rear view

4. Remove three bolts (G) and the washers from the left side of the radiator shield. Reinstall two of bolts (G) and the washers in two holes (H). Remove three bolts (G) from the right side of the radiator shield. Discard the remaining hardware.

5. Remove four bolts (J) and the washers from the top of the radiator shield. Save the bolts for assembly purposes.

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Illustration 104	g00758544
Rear view

6. Attach the following items to the left side of 105-9227 Condenser (1) : 110-6898 Bracket (2), four 5M-3062 Bolts (3) and four 8T-4896 Hard Washers (4) .

7. Attach the following items to the right side of 105-9227 Condenser (1) : 110-6897 Bracket (5), three 5M-3062 Bolts (3) and three 8T-4896 Hard Washers (4) .

   Note: The top hole on the right side should be left open for later use.

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Illustration 105	g00758545
Rear view

8. Install 110-6928 Support (6) to the lower fan guard. Secure 110-6928 Support (6) to the lower fan guard with nuts (D) .

9. Use three 8T-4835 Bolts (7) to mount 110-6896 Bracket As (8) to the left side of the radiator. Use 9B-7237 Bolt (9) and 5P-1075 Hard Washer (10) to secure 110-6896 Bracket As (8) to the fan guard.

10. Use three 8T-4835 Bolts (7) to mount 110-6891 Bracket As (11) to the right side of the radiator. Use 9B-7237 Bolt (9) and 5P-1075 Hard Washer (10) to secure 110-6891 Bracket As (11) to the fan guard.

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Illustration 106	g00758546
Rear view

11. Use the following components to secure condenser (1) to the radiator: four 4L-9337 Bolts (12), four 9L-8781 Washers (13) and four 6N-8744 Mounts (14) .

12. Use four bolts (J) and the washers to install 112-2625 Baffle (15) to the top of the radiator shield.

13. Use two 4L-6454 Bolts (16) and two 5P-1075 Hard Washers (10) to install 110-6918 Support (17) to 112-2625 Baffle (15) .

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Illustration 107	g00758551
Rear view

14. Use one bolt (J) and the washer in order to install 7N-1277 Bracket (18) to 112-2625 Baffle (15) .

15. Use 7D-7233 Clip (19), 5S-7379 Bolt (20), and 8T-4896 Hard Washer (4) to secure the water line to 7N-1277 Bracket (18) .

16. Install the following components in order to secure the water line to condenser (1) : 5M-3062 Bolt (3), 8T-4896 Hard Washer (4) and 7D-7233 Clip (19) .

17. Use two 6V-8801 Nuts (21) and two 5P-1075 Hard Washers (10) to secure 108-8717 Bracket (22) to 112-2625 Baffle (15) .

18. Use two 8T-8917 Bolts (23) and two 8T-4223 Hard Washers (24) to secure 108-8717 Bracket (22) to 110-6898 Bracket (2) .

19. Install the hydraulic oil cooler (if equipped). Refer to Disassembly and Assembly, "Hydraulic Oil Cooler - Remove and Install" for your machine.

Install the Air Conditioner Hoses, the Accumulator, and the Dryer

Table 13

Required Parts for the Installation of the Lines
Item	Qty	Part Number	Description
1	1	111-7266	Hose As
2	2	9X-7381	O-Ring Seal
3	1	4D-7735	Clip
4	1	156-4676	Hose As
5	3	9X-7380	O-Ring Seal
6	4	9M-8406	Clip
7	1	5S-7379	Bolt
8	3	8T-4896	Hard Washer
9	2	3W-3808	Plate As
10	3	5P-1075	Hard Washer
11	5	4L-6454	Bolt
12	2	116-6202	Boot
13	2	103-6100	Quick Coupler
14	1	156-4679	Hose As
15	1	9X-7382	O-Ring Seal
16	4	5P-4116	Hard Washer
17	1	6V-1889	Clip
18	1	186-6189	Refrigerant Accumulator
19	1	136-7220	Bracket
20	1	128-5924	Clamp
21	1	8R-3393	Strap
22	2	8T-2561	Hard Washer
23	2	9X-7383	O-Ring Seal
24	1	3E-3535	In-Line Refrigerant Dryer
25	1	109-1633	Clip
26	1	109-1634	Clip
27	1	8T-2502	Bolt
28	1	9V-2500	Bracket
29	1	1B-4971	Spacer
30	1	7X-0274	Bolt
31	1	106-8704	Arc Suppressor
32	1	3S-2093	Cable Strap
33	2	9X-6772	Cable Strap
34	1	9G-9150	Clip
35	1	5M-3062	Bolt

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NOTICE
Secure all hoses per instructions. Lubricate all O-rings with R-134a refrigerant oil before installation. Keep all fittings and all O-rings protected during the installation in order to prevent the contamination of the air conditioning system.

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Illustration 108	g00758647
Top view

1. Attach 111-7266 Hose As (1) with one 9X-7381 O-Ring Seal (2) to the right side of the condenser.

2. Remove bolt (A) and the washer from the top of the radiator. Use 4D-7735 Clip (3) to secure 111-7266 Hose As (1) to the radiator.

3. Attach the other end of 111-7266 Hose As (1) with one 9X-7381 O-Ring Seal (2) to the compressor.

   Note: 111-7266 Hose As (1) attaches to the right port of the compressor.

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Illustration 109	g00758648
Left side view

4. Attach 156-4676 Hose As (4) with one 9X-7380 O-Ring Seal (5) to the left side of the condenser. Secure 156-4676 Hose As (4) to the bracket with the following components: 9M-8406 Clip (6), 5S-7379 Bolt (7) and 8T-4896 Hard Washer (8)

5. Remove nut (B) from the bracket. Use the following components to secure 156-4676 Hose As (4) to the bracket: 3W-3808 Plate As (9), 9M-8406 Clip (6), 5P-1075 Hard Washer (10) and 4L-6454 Bolt (11). Reinstall nut (B) to the bracket.

6. Attach 116-6202 Boot (12) and 103-6100 Quick Coupler (13) with 9X-7380 O-Ring Seal (5) to the end of 156-4676 Hose As (4) .

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Illustration 110	g00758649
Top view

7. Attach 156-4679 Hose As (14) with 9X-7382 O-Ring Seal (15) to the left side of the compressor. Route the hose toward the rear of the machine.

8. Remove bolt (C) and the washer from the right side of the aftercooler. Discard the washer. Install the following components to secure 156-4679 Hose As (14) to the aftercooler: 3W-3808 Plate As (9), 5P-4116 Hard Washer (16), 6V-1889 Clip (17) and 4L-6454 Bolt (11). Reinstall bolt (C) to the aftercooler.

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Illustration 111	g00758650
Left side view

9. Use the following components to secure 186-6189 Refrigerant Accumulator (18) to 136-7220 Bracket (19) : 128-5924 Clamp (20), 8R-3393 Strap (21), two 4L-6454 Bolts (11) and two 8T-2561 Hard Washers (22) .

10. Remove two bolts (D) and the washers from the right side of the aftercooler. Discard the washers. Use two 5P-4116 Hard Washers (16) to secure the bracket and the accumulator to the aftercooler. Reinstall two bolts (D) to the aftercooler.

11. Connect 156-4679 Hose As (14) with 9X-7383 O-Ring Seal (23) to the bottom of the accumulator.

12. Connect hose (E) with 9X-7383 O-Ring Seal (23) to the top of the accumulator.

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Illustration 112	g00758652
Left side view

13. Remove bolt (F) and the washers from the left side of the aftercooler. Discard the hardware. Use the following components to secure 3E-3535 In-Line Refrigerant Dryer (24) to the aftercooler: 109-1633 Clip (25), 109-1634 Clip (26), 8T-2502 Bolt (27), one 5P-1075 Hard Washers (10), 9V-2500 Bracket (28), 1B-4971 Spacer (29), 7X-0274 Bolt (30) and 5P-4116 Hard Washer (16) .

14. Connect 156-4676 Hose As (4) to the front of 3E-3535 In-Line Refrigerant Dryer (24).

15. Install 116-6202 Boot (12) and 103-6100 Quick Coupler (13) with 9X-7380 O-Ring Seal (5) to the end of hose (G). Connect hose (G) to the rear of 3E-3535 In-Line Refrigerant Dryer (24) .

16. Remove two bolts (H) and the washers from the top of the aftercooler. Use two 9M-8406 Clips (6) to secure hose (G) to the aftercooler. Reinstall bolts (H) to the aftercooler.

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Illustration 113	g00758653
Left side view

17. Locate the engine wiring harness. Connect the wiring harness to 106-8704 Arc Suppressor (31). Secure 106-8704 Arc Suppressor (31) to the clipon the left rear of the compressor with 3S-2093 Cable Strap (32). Secure the wiring from 106-8704 Arc Suppressor (31) with 9X-6772 Cable Strap (33) .

18. Connect the engine wiring harness to the pressure switch. Secure the wiring for the pressure switch to the clip with 9X-6772 Cable Strap (33). Secure the electrical connection to the bracket with 9G-9150 Clip (34), 5M-3062 Bolt (35), and 8T-4896 Hard Washer (8) .

19. Connect the engine wiring harness to the compressor clutch coil. Secure the connection to the clip near the front of the compressor.

Final Inspection, Charging, and Performance Checks

Table 14

Required Parts
Item	Qty	Part Number	Description
1	1	110-6393	Instruction Plate

1. Perform a visual inspection of all of the components. Make sure that all of the connections are secure. Make sure that all of the fasteners are tightened. Make sure that none of the hoses are kinked.

2. Evacuate the system for 60 minutes. Charge the air conditioning system. The correct charge is 1.6 kg (3.5 lb). Refer to the Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Service Manual, NEGD5056, "Air Conditioning Tools".

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Illustration 114	g00757738

3. Install cover (C) to the housing. Install four bolts (B) that secure cover (C). Install cover (A) and tighten two knobs.

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Illustration 115	g00758191

4. Stamp 110-6393 Instruction Plate (1) with 1.6 kg (3.5 lb). Attach plate (1) to the left side of the dash above the air vent. The plate should be visible through the cab door.

5. Install the hood. Refer to Disassembly and Assembly, "Hood and Dust Ejector - Remove" for your machine.