- Wheel Loader:
- 950H (S/N: K5K1-UP)
- 962H (S/N: K6K1-UP)
Introduction
This publication includes the general instructions for the installation of an air conditioner kit. The supplemental product support literature should be used with the Custom Parts Manual, SEBC1498, the appropriate Service Manual, and the appropriate Parts Manual that is available for each standard machine.
General Information
All refrigerant lines must be free of sharp bends. Also, do not use a refrigerant line that is kinked. Sharp bends will cause a restriction in the refrigerant flow. Restrictions in the refrigerant lines are identified by cold spots or frost on the line at the restriction. 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 ten 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.
Inspect the hoses yearly for leaks and hardness. Do a leak test on all the hoses and lines. Refer to the Service Manual, SENR5664, "Refrigerant Leakage-Test" section in Testing and Adjusting. Replace hoses if leaks or hardness are in the hoses. Replace hoses with a new hose that is sealed and free of contaminants.
The correct use of wrenches is important when connections are made. The type of wrench is also important. Use only wrenches that are made for use with tube type fittings. When a hose or a metal line is connected or disconnected, use a wrench on the fitting and on the nut. Also use a wrench on the hose connection.
When components and refrigerant lines are disconnected or removed refer to the Service Manual, SENR5664, "Refrigerant Recovery" section.
Install protective plugs or caps on all components and all hoses that are disconnected or removed.
O-rings and seats must be in good condition. Small cuts, scratches, or particles of dirt will cause a leak in the system. Put new refrigerant oil on all new O-ring seals at time of installation. Do not use any sealant on any air conditioner hose connection.
NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
Note: Put identification marks on all hoses and on all wires for installation purposes. Plug the hoses. This process will help to prevent fluid loss. This process will also help to keep contaminants from entering the system.
Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. |
Installation of the Evaporator Coil
- Remove the seat. Refer to the appropriate Disassembly and Assembly, RENR8881, "Seat-Remove ".
- Open the engine hood.
- Disconnect electrical connector (1) .
Illustration 1 | g00830315 |
- Disconnect two heater lines (2). Place the lines away from the heater coil and the evaporator coil.
Illustration 2 | g00830318 |
- Open access door (5) on the outside of the cab.
Illustration 3 | g00830337 |
- Remove filter (6) .
Illustration 4 | g00830338 |
- Remove two bolts (7) and the washers.
Illustration 5 | g00830339 |
- Remove bolt (8) and the washer. Carefully remove the heater coil assembly (9) from the cab.
Illustration 6 | g00991579 |
- Disconnect electrical connectors (10). Cut the wire ties which hold the wire assembly in place.
Illustration 7 | g00840871 |
- Disconnect harness assembly (11) .
Illustration 8 | g00840873 |
- Remove two bolts (12) and the washers. Remove cover (13) .
Illustration 9 | g00840877 |
- Remove the eight screws (14) that hold the housing assembly together. Separate the housing assembly.
Illustration 10 | g00991589 |
- Remove the old grommet from housing (14A) .
- Install the 189-4680 Evaporator Coil As (15) .
Illustration 11 | g00840881 |
- Install the 177-6696 Grommet around the tubes for the evaporator coil assembly.
- Use existing hardware and install the 212-7042 Bracket (16) .
Illustration 12 | g01320720 |
Top view of heater (A) 110 mm (4.33 inch) (B) 15.9 mm (0.63 inch) |
- Use the following hardware and install the 3E-5464 Thermostat Switch (11) for
the refrigerant:
Note: Tighten the 8T-6631 Screws (18) to 1.2 ± 0.2 N·m (10.62 ± 1.77 lb in).
- Insert the capillary tube of the 3E-5464 Thermostat Switch (11) into the 189-4680 Evaporator Coil As . The location is shown by Callout (A) and Callout (B). Insert the capillary tube to a depth of 340 mm (13.39 inch).
- Reconnect the housing assembly.
Illustration 13 | g00991642 |
- Reinstall eight screws (14) which hold the housing assembly together.
Illustration 14 | g00840879 |
- Reinstall cover (13). Reinstall two bolts (12) and the washers.
Illustration 15 | g00840877 |
- Connect harness assembly (11) .
Illustration 16 | g00840873 |
- Connect electrical connectors (10). Install wire ties which hold the wire assembly in place, as required.
Illustration 17 | g00840871 |
- Carefully reinstall the heater coil and the evaporator coil assembly (9) in the cab. Reinstall bolt (8) and the washer.
Illustration 18 | g00840861 |
- Reinstall two bolts (7) and the washers.
Illustration 19 | g00830339 |
- Reinstall filter (6) from the outside of the cab.
Illustration 20 | g00830338 |
- Close access door (5) .
Illustration 21 | g00830337 |
- Reconnect two heater lines (2) .
Illustration 22 | g00830318 |
Installation of the Air Conditioner Lines Group
- Refer to Section A-A in Illustration 23. Remove the existing plate and install the following:
Illustration 23 | g01288135 |
Top view of the heater |
- Use a 9X-7383 O-Ring Seal (15) and connect the 90 degree end of the 242-9372 Hose As (9) onto the 7K-3176 Coupling (3) .
- Use a 9X-7381 O-Ring Seal (13) and connect one end of the 242-9372 Hose As (9) onto the lower tube of the evaporator coil assembly.
- Use a 9X-7384 O-Ring Seal (16) and connect the 90 degree end of the 242-9371 Hose As (8) onto the 5P-3928 Coupling (1) .
- Use a 9X-7382 O-Ring Seal (14) and connect one end of the 242-9371 Hose As (8) onto the upper tube of the evaporator coil assembly.
- Use the following hardware and secure the 242-9371 Hose As (8) and the 242-9372 Hose As (9). Refer to Illustration 23.
Installation of the Refrigerant Compressor
- Remove idler assembly (A) and belt (B) .
Illustration 24 | g01288184 |
Front view of engine (A) Idler assembly (B) Belt |
- Use the following hardware and install the 163-0872 Refrigerant Compressor Gp (1) :
Illustration 25 | g01288188 |
Front view of engine |
- Install the two 192-1563 Idler Assemblies (2) .
- Install the 253-4531 Belt (3) .
Installation of the Condenser Core
- Use the following hardware and install the 245-0766 Bracket (2) onto the 244-8839 Condenser Core Assembly (Refrigerant) (3) :
Illustration 26 | g01292709 |
Rear view of the condenser core assembly |
- Use the following hardware and install the 244-8839 Condenser Core Assembly (Refrigerant) (3) onto the radiator group:
- Latch the core.
- Unlatch the core.
- Turn the 4E-1384 Conical Bumper (1) counterclockwise by a turn and a half and tighten the nut.
Installation of the Air Conditioner Accumulator
Illustration 27 | g03338859 |
Top and right side views of rear frame |
- Use the following hardware and install the 186-6189 Air Conditioner Accumulator (6) :
Note: When installing clips refer to Illustration 28.
Illustration 28 | g01293593 |
Section A-A from Illustration 27 (A) 95 mm (3.74 inch) (B) 38.5 mm (1.52 inch) |
Installation of the In-Line Refrigerant Dryer
- Refer to Illustration 28. Use the following hardware and mount the 242-2445 Clamp As (7) onto the 257-3226 Receiver-Dryer Assembly (Refrigerant) (14) :
- Use the following hardware and mount the 257-3226 Receiver-Dryer Assembly (Refrigerant) (14) and the 242-2445 Clamp As (7) onto the machine:
Installation of the Refrigerant Lines
- Use a 9X-7383 O-Ring Seal (43) and connect the male end of 246-7272 Hose Assembly (8) to
the bottom port of the 186-6189 Air Conditioner
Accumulator (6) .
Note: The other end of the 246-7272 Hose Assembly (8) will be connected later.
Illustration 29 | g03338867 |
Right side view of rear frame (C) 37 mm (1.46 inch) |
- Use a 9X-7383 O-Ring Seal (43) and connect the 256-7205 Tube As (12) to the top port of the 186-6189 Air Conditioner Accumulator (6) .
- Use the following hardware and secure the 256-7205 Tube As (12) :
- Use a 9X-7383 O-Ring Seal (43) and connect the 246-7273 Hose As (9) onto the 256-7205 Tube As (12) .
- Use the following parts and connect the 246-7273 Hose As (9) onto the
coupling for air conditioning that is on the cab wall:
Note: Refer to callout (1) in Illustration 23 for the location of the coupling for air conditioning that is on the cab wall.
- Use the following hardware and install the 202-8696 Air Conditioner Fitting (16) and
the 256-7206 Air Conditioner Fitting (13) onto the air conditioner compressor:
Note: Tighten the 8T-6466 Bolt (38) to 25 ± 7 N·m (221.27 ± 61.96 lb in).
Illustration 30 | g03338881 |
View E-E |
- Use a 9X-7382 O-Ring Seal (42) and connect the other end of the 246-7272 Hose Assembly (8) onto the 256-7206 Air Conditioner Fitting (13) .
- Use the following hardware and secure the 246-7272 Hose Assembly (8) to the machine:
- Use a 9X-7381 O-Ring Seal (41) and connect one end of the 301-0356 Hose As (11) onto the 202-8696 Air Conditioner Fitting (16) .
Illustration 31 | g03338890 |
Top and right side views of the rear frame |
- Route the 301-0356 Hose As (11) to the condenser group. Use a 9X-7381 O-Ring Seal (41) and connect the other end of the 301-0356 Hose As (11) onto the upper fitting of the condenser group.
Illustration 32 | g01294983 |
View B-B from Illustration 31 |
- Use the following hardware and secure the 301-0356 Hose As (11) :
- Use a 9X-7380 O-Ring Seal (40) and connect one end of the 246-7274 Hose As (10) onto the 257-3226 Receiver-Dryer Assembly (REFRIGERANT) (14) .
- Route the 246-7274 Hose As (10) to the condenser group. Use a 9X-7380 O-Ring Seal (40) and connect the other end of the 246-7274 Hose As (10) onto the lower fitting of the condenser group.
- Use the following hardware and secure the 246-7274 Hose As (10) :
Installation of the Wiring Group for the Air Conditioner
- Use the following hardware and install the 191-7699 Bracket As (3) onto the compressor:
Illustration 33 | g01295872 |
Partial top view of engine |
- Use the following hardware and install the 130-5300 Clip (5) :
- Use a 9X-7378 O-Ring Seal (12) and connect the 114-5333 Pressure Switch (2) onto the rear of the air conditioning compressor. Tighten to 8 ± 1.5 N·m (70.81 ± 13.28 lb in).
- Connect the power lead of 114-5333 Pressure Switch (2) to the engine harness wires "513 Orange" and "521 Yellow".
- Install a 132-5789 Clip (6) onto the compressor. Use a 7K-1181 Cable Strap (1) in order to secure the power lead for the air conditioning clutch.
- Connect the power lead for the air compressor to the main engine harness.
- Mount the 156-6175 Clip (7) onto the engine.
- Connect the 218-4935 Arc Suppressor (4) to the engine harness wires "513 Orange" and "522 White".