Installation Instructions for a 295-6544 Air Conditioner Gp (Kit) for the 950H and the 962H Wheel Loaders{7320} Caterpillar


Installation Instructions for a 295-6544 Air Conditioner Gp (Kit) for the 950H and the 962H Wheel Loaders{7320}

Usage:

950H K5K
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

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.

------ WARNING! ------

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

  1. Remove the seat. Refer to the appropriate Disassembly and Assembly, RENR8881, "Seat-Remove ".

  1. Open the engine hood.



    Illustration 1g00830315

  1. Disconnect electrical connector (1) .



    Illustration 2g00830318

  1. Disconnect two heater lines (2). Place the lines away from the heater coil and the evaporator coil.



    Illustration 3g00830337

  1. Open access door (5) on the outside of the cab.



    Illustration 4g00830338

  1. Remove filter (6) .



    Illustration 5g00830339

  1. Remove two bolts (7) and the washers.



    Illustration 6g00991579

  1. Remove bolt (8) and the washer. Carefully remove the heater coil assembly (9) from the cab.



    Illustration 7g00840871

  1. Disconnect electrical connectors (10). Cut the wire ties which hold the wire assembly in place.



    Illustration 8g00840873

  1. Disconnect harness assembly (11) .



    Illustration 9g00840877

  1. Remove two bolts (12) and the washers. Remove cover (13) .



    Illustration 10g00991589

  1. Remove the eight screws (14) that hold the housing assembly together. Separate the housing assembly.

  1. Remove the old grommet from housing (14A) .



    Illustration 11g00840881

  1. Install the 189-4680 Evaporator Coil As (15) .

  1. Install the 177-6696 Grommet around the tubes for the evaporator coil assembly.



    Illustration 12g01320720

    Top view of heater

    (A) 110 mm (4.33 inch)

    (B) 15.9 mm (0.63 inch)

  1. Use existing hardware and install the 212-7042 Bracket (16) .

  1. 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).

  1. 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).



    Illustration 13g00991642

  1. Reconnect the housing assembly.



    Illustration 14g00840879

  1. Reinstall eight screws (14) which hold the housing assembly together.



    Illustration 15g00840877

  1. Reinstall cover (13). Reinstall two bolts (12) and the washers.



    Illustration 16g00840873

  1. Connect harness assembly (11) .



    Illustration 17g00840871

  1. Connect electrical connectors (10). Install wire ties which hold the wire assembly in place, as required.



    Illustration 18g00840861

  1. Carefully reinstall the heater coil and the evaporator coil assembly (9) in the cab. Reinstall bolt (8) and the washer.



    Illustration 19g00830339

  1. Reinstall two bolts (7) and the washers.



    Illustration 20g00830338

  1. Reinstall filter (6) from the outside of the cab.



    Illustration 21g00830337

  1. Close access door (5) .



    Illustration 22g00830318

  1. Reconnect two heater lines (2) .

Installation of the Air Conditioner Lines Group




    Illustration 23g01288135

    Top view of the heater

  1. Refer to Section A-A in Illustration 23. Remove the existing plate and install the following:

  1. 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) .

  1. 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.

  1. 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) .

  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.

  1. 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




    Illustration 24g01288184

    Front view of engine

    (A) Idler assembly

    (B) Belt

  1. Remove idler assembly (A) and belt (B) .



    Illustration 25g01288188

    Front view of engine

  1. Use the following hardware and install the 163-0872 Refrigerant Compressor Gp (1) :

  1. Install the two 192-1563 Idler Assemblies (2) .

  1. Install the 253-4531 Belt (3) .

Installation of the Condenser Core




    Illustration 26g01292709

    Rear view of the condenser core assembly

  1. Use the following hardware and install the 245-0766 Bracket (2) onto the 244-8839 Condenser Core Assembly (Refrigerant) (3) :

  1. Use the following hardware and install the 244-8839 Condenser Core Assembly (Refrigerant) (3) onto the radiator group:

  1. Use a 5C-7261 Nut (4) and install the 4E-1384 Conical Bumper (1) onto the radiator group.

  1. Latch the core.

  1. Adjust the 4E-1384 Conical Bumper (1) in order to touch the 245-0766 Bracket (2) .

  1. Unlatch the core.

  1. 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 27g03338859

Top and right side views of rear frame




    Illustration 28g01293593

    Section A-A from Illustration 27

    (A) 95 mm (3.74 inch)

    (B) 38.5 mm (1.52 inch)

  1. Use the following hardware and install the 186-6189 Air Conditioner Accumulator (6) :

    Note: When installing clips refer to Illustration 28.

Installation of the In-Line Refrigerant Dryer

  1. 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) :

  1. 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




    Illustration 29g03338867

    Right side view of rear frame

    (C) 37 mm (1.46 inch)

  1. 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.

  1. 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) .

  1. Use the following hardware and secure the 256-7205 Tube As (12) :

  1. Use a 9X-7383 O-Ring Seal (43) and connect the 246-7273 Hose As (9) onto the 256-7205 Tube As (12) .

  1. 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.

    • One 9X-7384 O-Ring Seal (44)

    • One 5P-3929 Refrigerant Coupling Assembly (22)




    Illustration 30g03338881

    View E-E

  1. 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).

  1. 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) .

  1. Use the following hardware and secure the 246-7272 Hose Assembly (8) to the machine:




    Illustration 31g03338890

    Top and right side views of the rear frame

  1. 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 32g01294983

    View B-B from Illustration 31

  1. 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.

  1. Use the following hardware and secure the 301-0356 Hose As (11) :

  1. 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) .

  1. 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.

  1. Use the following hardware and secure the 246-7274 Hose As (10) :

Installation of the Wiring Group for the Air Conditioner




    Illustration 33g01295872

    Partial top view of engine

  1. Use the following hardware and install the 191-7699 Bracket As (3) onto the compressor:

  1. Use the following hardware and install the 130-5300 Clip (5) :

  1. 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).

  1. Connect the power lead of 114-5333 Pressure Switch (2) to the engine harness wires "513 Orange" and "521 Yellow".

  1. Secure the power lead plug of the 114-5333 Pressure Switch (2) onto the 130-5300 Clip (5) .

  1. 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.

  1. Connect the power lead for the air compressor to the main engine harness.

  1. Mount the 156-6175 Clip (7) onto the engine.

  1. Connect the 218-4935 Arc Suppressor (4) to the engine harness wires "513 Orange" and "522 White".

  1. Use a 7K-1181 Cable Strap (1) and secure the 218-4935 Arc Suppressor (4) onto the 156-6175 Clip (7) .

Caterpillar Information System:

D3K, D4K and D5K Track-Type Tractors Electrohydraulic System Bank Valve
3500 Industrial Engines Exhaust Flange
963C Track-Type Loader Machine Systems Air Precleaner
2006/08/07 New Fuel Line is Now Used {1274}
C175-16 Locomotive Engine Cold Mode Operation
953D Track-Type Loader Power Train Piston Pump (Hydrostatic) - Remove - Left Side
657G Wheel Tractor-Scraper Auger Hydraulic System Oil Filter - Replace
C15 Petroleum Generator Set Engines Valve Mechanism
657G Wheel Tractor-Scraper Wheel Tractor Power Train Scavenge Pump and Mounting (Flywheel) - Assemble
657G Wheel Tractor-Scraper Wheel Tractor Power Train Scavenge Pump and Mounting (Flywheel) - Disassemble
657G Wheel Tractor-Scraper Machine Systems Brake Actuator - Install
657G Wheel Tractor-Scraper Machine Systems Brake Actuator - Remove
3176C Engines for Caterpillar Built Machines Digital Sensor Supply Circuit - Test
D7G Series 2 and D7G Series II Track-Type Tractors Leaving the Machine
3508B, 3512B, and 3516B High Displacement Generator Sets Air Shutoff - Test - Engines That Are Equipped with ADEM II or ADEM III Engine Control Modules
657G Wheel Tractor-Scraper Wheel Tractor Power Train Drive Shaft - Disassemble
Starting and Charging Systems Starter Solenoid (Starter One) Test Description
3176C Engines for Caterpillar Built Machines CID 0296 FMI 09 Unable to communicate with Transmission ECM
Starting and Charging Systems Start Relay (Starter Two) Test Description
Starting and Charging Systems Starter Solenoid Power Circuit (Starter Two) Test Description
3176C Engines for Caterpillar Built Machines CID 1599 FMI 05 Engine Fan Pull Solenoid open circuit
3176C Engines for Caterpillar Built Machines CID 1599 FMI 06 Engine Fan Pull Solenoid short to ground
3176C Engines for Caterpillar Built Machines CID 1600 FMI 06 Engine Fan Push Solenoid short to ground
3176C Engines for Caterpillar Built Machines CID 1600 FMI 05 Engine Fan Push Solenoid open circuit
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.