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A Replacement Procedure for the A/C Hose on Certain Motor Graders is Now Available{1808, 7320} Caterpillar


A Replacement Procedure for the A/C Hose on Certain Motor Graders is Now Available{1808, 7320}

Usage:

120M B9C
Motor Grader:
120M (S/N: B9C1-UP)
120M (S/N: B9N1-UP)
120M (S/N: B9W1-UP)
120M (S/N: D9W1-UP)
12M (S/N: B9F1-UP; B9R1-UP)
140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP; B9M1-UP)
160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

Introduction

ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines"

ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines"

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NOTICE

All Caterpillar air conditioning systems built since January 1, 1994 use only R134a refrigerant. Air conditioning systems built prior to January 1, 1994 require either R134a or R12. Use of incorrect refrigerant will cause air conditioning system failure. In order to identify the refrigerant type correctly, see identification plate on the refrigerant compressor. Machines that have been retrofitted to R134a refrigerant also have an identification plate on the refrigerant compressor.

This special instruction contains the procedure to update the A/C hose on the listed machines. Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

Note: If service work is required on an air conditioning system, the refrigerant must be recovered first before components are removed or installed.

Rework Procedure for the A/C Hose on the 120M and 12M Motor Graders

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Table 1
Required Parts for the 120M and 12M Motor Graders    
Callout     QTY     Part Number     Part Name    
1     1     355-5620     Hose As    
2     84 cm     7I-1024     Hose Guard    
4     1     203-2287     Clip    
5     1     8T-2602     Clip    
6     1     8T-2603     Clip    
7     1     122-0450     Grommet    
8     1     8T-4195     Bolt    
9     1     8T-4121     Hard Washer    
10     1     351-8678     Plate As    
    1     9X-7382     O-Ring Seal    
    1     9X-7383     O-Ring Seal    
    Show/hide table

    Illustration 1g02063034

  1. Remove 245-2780 Sheet As in order to access the air conditioning system.

  1. Remove the refrigerant from the air conditioning system before any service is completed.

    ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Refrigerant Recovery"

  1. Remove hose 286-9837 Hose As .

    ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Air Conditioner Lines - Remove and Install"

    Show/hide table

    Illustration 2g02057654

  1. Remove the existing 300-2120 Plate As .

    1. Retain the existing hardware.
    Show/hide table

    Illustration 3g02098499

    (10) 351-8678 Plate As

  1. Install plate (10) to the rubber blocks with the hardware that has been retained.

    Note: Torque 8T-4172 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

  1. Wrap hose guard (2) around new hose (1) .

    Note: The hose guard will cover hose (1) from the coupling at the accumulator to the clip with the grommet.

    Show/hide table

    Illustration 4g02098505

    (1) 355-5620 Hose As

    (2) 7I-1024 Hose Guard

    (3) 264-7977 Hose As

    (4) 203-2287 Clip

    (5) 8T-2602 Clip

    (6) 8T-2603 Clip

    (7) 122-0450 Grommet

    (8) 8T-4195 Bolt

    (9) 8T-4121 Hard Washer

    (10) 351-8678 Plate As

  1. Install hose (1). Refer to Illustration 4 for the proper routing.

    Note: New O-rings must be installed when the new hose is installed.

    ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Air Conditioner Lines - Remove and Install"

    Show/hide table

    Illustration 5g02057493

  1. Install clip (4) and route hose (1) through the clips that have been installed.

    Note: Torque 8T-4136 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

    Show/hide table

    Illustration 6g02097154

    (5) 8T-2602 Clip

    (6) 8T-2603 Clip

    (A) 10 degree angle

  1. Secure hose (1) at plate (10) with the hardware that is listed below. The clips should be at a 10 degree angle toward the engine. Make sure that there is sufficient length on either side of the clips. The hose should have 455 mm (18 inch) of length between the clip and the engine.

    Note: Torque 8T-4195 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

  1. Verify that all the connections are secure.

  1. Recharge the air conditioning system in order to complete the rework procedure.

    ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Refrigerant System - Charge"

  1. Reinstall the 245-2780 Sheet As in order to finish this rework. Make sure that the hose is inside the cutout of the 245-2780 Sheet As . Adjust the trim accordingly.

Rework Procedure for the A/C Hose on the 140M Motor Graders and the 140M AWD Motor Graders with the C7 Engine

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Table 2
Required Parts for the 140M Motor Graders and the 140M AWD Motor Graders with the C7 Engine    
Callout     QTY     Part Number     Part Name    
1     1     352-9744     Hose As    
2     86 cm     7I-1024     Hose Guard    
4     1     203-2287     Clip    
5     1     8T-1897     Clip    
6     1     8T-1898     Clip    
7     1     122-0450     Grommet    
8     1     8T-4195     Bolt    
9     1     8T-4121     Hard Washer    
10     1     351-8678     Plate As    
    1     9X-7382     O-Ring Seal    
    1     9X-7383     O-Ring Seal    
    Show/hide table

    Illustration 7g02063073

  1. Remove 349-6273 Plate As in order to access the air conditioning system.

  1. Remove the refrigerant from the air conditioning system before any service is completed.

    ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Refrigerant Recovery"

  1. Remove hose 296-7831 Hose As .

    ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Air Conditioner Lines - Remove and Install"

    Show/hide table

    Illustration 8g02058059

  1. Remove the existing 255-0686 Plate As .

    1. Retain the existing hardware.
    Show/hide table

    Illustration 9g02058594

    (10) 351-8678 Plate As

  1. Install plate (10) to the rubber blocks with the hardware that has been retained.

    Note: Torque 8T-4178 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

  1. Wrap hose guard (2) around new hose (1) .

    Note: The hose guard will cover hose (1) from the coupling at the accumulator to the clip with the grommet.

    Show/hide table

    Illustration 10g02058476

    (1) 352-9744 Hose As

    (2) 7I-1024 Hose Guard

    (3) 293-9352 Hose As

    (4) 203-2287 Clip

    (5) 8T-1897 Clip

    (6) 8T-1898 Clip

    (7) 122-0450 Grommet

    (8) 8T-4195 Bolt

    (9) 8T-4121 Hard Washer

    (10) 351-8678 Plate As

  1. Install hose (1). Refer to Illustration 10 for the proper routing.

    Note: New O-rings must be installed when the new hose is installed.

    ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Air Conditioner Lines - Remove and Install"

    Show/hide table

    Illustration 11g02057493

  1. Install clip (4) and route hose (1) through the clips that have been installed.

    Note: Torque 8T-4136 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

  1. Secure hose (1) at plate (10) with the hardware that is listed below:

    Note: Torque 8T-4195 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft)

  1. Verify that all the connections are secure.

  1. Recharge the air conditioning system in order to complete the rework procedure.

    ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Refrigerant System - Charge"

  1. Reinstall the 349-6273 Sheet As in order to finish this rework.

Rework Procedure for the A/C Hose on the 160M Motor Graders and the 140M AWD Motor Graders with the C9 Engine

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Table 3
Required Parts for the 160M Motor Graders and the 140M AWD Motor Graders with the C9 Engine    
Callout     QTY     Part Number     Part Name    
1     1     355-5619     Hose As    
2     84 cm     7I-1024     Hose Guard    
4     1     203-2287     Clip    
5     1     8T-1897     Clip    
6     1     8T-1898     Clip    
7     1     122-0450     Grommet    
8     1     8T-4195     Bolt    
9     1     8T-4121     Hard Washer    
10     1     351-8678     Plate As    
    1     9X-7382     O-Ring Seal    
    1     9X-7383     O-Ring Seal    
    Show/hide table

    Illustration 12g02063073

  1. Remove 349-6273 Plate As in order to access the air conditioning system.

  1. Remove the refrigerant from the air conditioning system before any service is completed.

    ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Refrigerant Recovery"

  1. Remove hose 296-7827 Hose As .

    ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Air Conditioner Lines - Remove and Install"

    Show/hide table

    Illustration 13g02058059

  1. Remove the existing 255-0686 Plate As .

    1. Retain the existing hardware.
    Show/hide table

    Illustration 14g02058594

    (10) 351-8678 Plate As

  1. Install plate (10) to the rubber blocks with the hardware that has been retained.

    Note: Torque 8T-4178 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

  1. Wrap hose guard (2) around new hose (1) .

    Note: The hose guard will cover hose (1) from the coupling at the accumulator to the clip with the grommet.

    Show/hide table

    Illustration 15g02058353

    (1) 355-5619 Hose As

    (2) 7I-1024 Hose Guard

    (3) 293-9352 Hose As

    (4) 203-2287 Clip

    (5) 8T-1897 Clip

    (6) 8T-1898 Clip

    (7) 122-0450 Grommet

    (8) 8T-4195 Bolt

    (9) 8T-4121 Hard Washer

    (10) 351-8678 Plate As

  1. Install hose (1). Refer to Illustration 15 for the proper routing.

    Note: New O-rings must be installed when the new hose is installed.

    ReferenceDisassembly and Assembly, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Air Conditioner Lines - Remove and Install"

    Show/hide table

    Illustration 16g02057493

  1. Install clip (4) and route hose (1) through the clips that have been installed.

    Note: Torque 8T-4136 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

    Show/hide table

    Illustration 17g02058060

    (1) 355-5619 Hose As

    (5) 8T-1897 Clip

    (6) 8T-1898 Clip

    (7) 122-0450 Grommet

    (8) 8T-4195 Bolt

    (9) 8T-4121 Hard Washer

    (10) 351-8678 Plate As

  1. Secure hose (1) at plate (10) with the hardware that is listed below:

    Note: Torque 8T-4195 Bolt to 55 ± 10 N·m (40.56580 ± 7.4 lb ft).

  1. Verify that all the connections are secure.

  1. Recharge the air conditioning system in order to complete the rework procedure.

    ReferenceTesting and Adjusting, SENR5664, "All Products Air Conditioning and Heating R-134a for All Caterpillar Machines", "Refrigerant System - Charge"

  1. Reinstall the 349-6273 Sheet As in order to finish this rework.

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