Aire Acondicionado

SENR5664-13
May 2006
Specifications
Systems Operation
Testing and Adjusting
Disassembly and
Assembly
All Products Air Conditioning and
Heating R-134a for All Caterpillar
Machines
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR5664-13 3
Table of Contents
Table of Contents System Capacities for Refrigerant (Mining

Excavators) ......................................................... 75
System Capacities for Refrigerant (Motor
Graders) .............................................................. 76
Specifications Section System Capacities for Refrigerant (Multi-Terrain
Loaders) .............................................................. 77
Refrigerant Compressor ....................................... 20
System Capacities for Refrigerant (Off-Highway
Trucks) ................................................................ 78
System Capacities for Refrigerant (Paving
Products) ............................................................. 79
System Capacities for Refrigerant (Skid Steer
Loaders) .............................................................. 81
System Capacities for Refrigerant (Small Wheel
Loaders) .............................................................. 82
System Capacities for Refrigerant
(Telehandlers) ..................................................... 83
System Capacities for Refrigerant (Track-Type
Loaders) .............................................................. 83
System Capacities for Refrigerant (Track-Type
Tractors) .............................................................. 84
System Capacities for Refrigerant (Underground
Articulated Truck) ................................................ 89
System Capacities for Refrigerant (Wheel
Dozers) ............................................................... 89
System Capacities for Refrigerant (Wheel
Tractor-Scrapers) ................................................ 90
Refrigerant Compressor ....................................... 52 Systems Operation Section
Refrigerant Compressor ....................................... 54 General Information .............................................. 92
System Capacities for Refrigerant (Agricultural Identifying the Air Conditioning System ................ 92
Tractors) .............................................................. 54 Refrigerant Expansion Valve System ................... 94
System Capacities for Refrigerant (Articulated Refrigerant Orifice Tube System ........................... 97
Trucks) ................................................................ 55 Refrigerant Compressor ....................................... 99
System Capacities for Refrigerant (Backhoe Refrigerant Condenser ....................................... 100
Loaders) .............................................................. 56 Evaporator Coil ................................................... 100
System Capacities for Refrigerant (Compact Wheel Heating and Air Conditioning Control System .... 101
Loaders) .............................................................. 59 Refrigerant Compressor Protection System ....... 103
System Capacities for Refrigerant (Compactors) .. 59 Heating System Schematic ................................. 104
System Capacities for Refrigerant (Excavators) ... 60 Preparation of Air Conditioner Units for Seasonal
System Capacities for Refrigerant (Excavators) ... 60 Use .................................................................... 104
System Capacities for Refrigerant (Excavators) ... 60 Cab Air Filters ..................................................... 105
System Capacities for Refrigerant (Excavators) ... 61 Glossary of Terms ............................................... 107
System Capacities for Refrigerant (Excavators) ... 62
System Capacities for Refrigerant (Excavators) ... 63 Testing and Adjusting Section
System Capacities for Refrigerant (Excavators) ... 64
System Capacities for Refrigerant (Excavators) ... 65 Troubleshooting
System Capacities for Refrigerant (Excavators) ... 66 Required Tools .................................................... 109
System Capacities for Refrigerant (Excavators) ... 68 Machine Preparation for Troubleshooting ............ 110
System Capacities for Refrigerant (Excavators) ... 68 General Troubleshooting Information .................. 111
System Capacities for Refrigerant (Excavators) ... 69 Visual Inspection .................................................. 112
System Capacities for Refrigerant (Forest Heating and Air Conditioning System
Products) ............................................................. 69 Troubleshooting ................................................. 113
System Capacities for Refrigerant (Integrated Troubleshooting Heating and Air Conditioning Control
Toolcarriers) ........................................................ 71 System .............................................................. 127
System Capacities for Refrigerant (Large Wheel
Loaders) .............................................................. 72 Testing and Adjusting
System Capacities for Refrigerant (Load Haul Refrigerant Recovery .......................................... 135
Dump) ................................................................. 73 Manifold Gauge Set (Refrigerant) - Install .......... 138
System Capacities for Refrigerant (Medium Wheel Refrigerant System - Evacuate ........................... 139
Loaders) .............................................................. 73 Refrigerant Leakage - Test ................................. 142
Refrigerant Compressor Oil - Check ................... 143
Refrigerant System - Charge .............................. 145
4 SENR5664-13
Table of Contents
Refrigerant Compressor - Test ............................ 151

Manifold Gauge Set (Refrigerant) - Remove ...... 155
Electronic Heat Control - Test (Type 1) ............... 158
Disassembly and Assembly Section

General Information ............................................ 166
Machine Preparation for Disassembly and
Assembly .......................................................... 167
Refrigerant Compressor - Remove and Install .. 168
Refrigerant Accumulator - Remove and Install ... 168
Refrigerant Expansion Valve - Remove and
Install ................................................................. 169
Receiver-Dryer - Remove and Install .................. 169
In-Line Refrigerant Dryer - Remove and Install .. 170
Refrigerant Orifice Tube - Remove and Install .... 171
Index Section
Index ................................................................... 173
SENR5664-13 5
Specifications Section
Specifications Section Part No.: 106-5122

S/N: GJB1-Up
i02512250
S/N: H2B1-Up
Refrigerant Compressor S/N: HAB1-Up

Part No.: 3E-1906
SMCS Code: 1802 S/N: JJB1-Up
S/N: 2021-Up Part No.: 3E-1906
Part No.: 217-4448 S/N: LJB1-Up
S/N: 4421-Up Part No.: 3E-1906
Part No.: 3E-1906 S/N: RBB1-Up
S/N: AKA1-Up Part No.: 106-5122
Part No.: 3E-1906 S/N: WCB1-Up
S/N: ASA1-Up Part No.: 3E-1906
Part No.: 3E-1906 S/N: WMB1-Up
S/N: BCA1-Up Part No.: 106-5122, 3E-1906
Part No.: 3E-1906 S/N: 4RC5589-Up
S/N: BDA1-Up Part No.: 3E-1906
Part No.: 3E-1906 S/N: 6FC5542-Up
S/N: BEA1-Up Part No.: 3E-1906
Part No.: 3E-1906 S/N: 7NC5527-Up
S/N: DDA1-Up Part No.: 3E-1906
S/N: H2A1-Up S/N: 8FC5612-Up
Part No.: 3E-1906 Part No.: 3E-1906

S/N: RTA1-Up S/N: 8RC5967-Up

S/N: 1AB1510-Up S/N: 9TC1-Up

S/N: 1FB571-Up S/N: ADC1-Up

S/N: 1JB1-Up S/N: AEC1-Up

S/N: 4AB5532-Up S/N: AFC1-Up

S/N: 5WB5586-Up S/N: BEC1-Up
Part No.: 106-5122 Part No.: 3E-1906

S/N: AAB1-Up S/N: BNC1-Up

S/N: AFB1-Up S/N: CCC1-Up

S/N: ASB1-Up S/N: DAC1-Up
Part No.: 3E-1906 S/N: H2C1-Up

S/N: BBB1-Up Part No.: 106-5122
Part No.: 3E-1906 S/N: HDC1-Up
S/N: BEB1-Up Part No.: 106-5122
Part No.: 106-5122 S/N: RFC1-Up
S/N: CEB1-Up
6 SENR5664-13

S/N: T4C1-Up S/N: BDE1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: TBC1-Up S/N: BLE1-Up
S/N: WAC1-Up S/N: BWE1-Up
S/N: 1DD6006-Up S/N: BZE1-Up
S/N: 1JD1-Up S/N: CYE1-Up
S/N: 1KD5600-Up S/N: DAE1-Up
S/N: 1YD5522-Up S/N: EAE1-Up
Part No.: 3E-1906 S/N: H2E1-Up
S/N: 2KD5618-Up
S/N: HAE1-Up
Part No.: 3E-1906
S/N: 2SD5549-Up Part No.: 106-5122
S/N: HKE1-Up
Part No.: 3E-1906
S/N: 3MD5594-Up Part No.: 3E-1906
S/N: WBE1-Up
Part No.: 3E-1906
S/N: 4KD5585-Up Part No.: 3E-1906
S/N: 1KF1040-Up
Part No.: 3E-1906
S/N: AFD1-Up Part No.: 3E-1906
S/N: 1SF1337-Up
Part No.: 3E-1906
S/N: AKD1-Up Part No.: 3E-1906
S/N: 3ZF5736-Up
Part No.: 3E-1906
S/N: BMD1-Up Part No.: 3E-1906
S/N: 4YF5575-Up
Part No.: 106-5122
S/N: CAD1-Up Part No.: 3E-1906
S/N: 5BF5690-Up
Part No.: 3E-1906
S/N: DAD1-Up Part No.: 3E-1906
S/N: 5HF5582-Up
S/N: H2D1-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: 6CF5565-Up
S/N: HCD1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 6ZF307-Up
S/N: WBD1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: 7ZF348-Up
S/N: AAE1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 8TF787-Up
S/N: ADE1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 9RF511-Up
S/N: AME1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: AAF1-Up
S/N: ASE1-Up
SENR5664-13 7

S/N: AEF1-Up S/N: 8ZG1-Up
Part No.: 3E-1906 Part No.: 106-5122, 3E-1906
S/N: AGF1-Up S/N: 9MG119-Up
S/N: APF1-Up S/N: 9WG1161-Up
S/N: ASF1-Up S/N: 9XG343-Up
S/N: AXF1-Up S/N: AFG1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: B3F1-Up S/N: AGG1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: B4F1-Up S/N: ASG1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: B5F1-Up S/N: BKG1-Up
S/N: H2F1-Up Part No.: 3E-1906
S/N: BWG1-Up
S/N: HAF1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: BXG1-Up
S/N: 2RG5622-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: BZG1-Up
S/N: 2TG5593-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CNG1-Up
S/N: 3XG5515-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: DAG1-Up
S/N: 3YG5772-Up
S/N: H2G1-Up
Part No.: 3E-1906
S/N: 4FG5573-Up S/N: HAG1-Up
Part No.: 3E-1906 S/N: RJG1-Up
S/N: 4GG5632-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: WBG1-Up
S/N: 4LG5598-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: WLG1-Up
S/N: 4YG1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: WRG1-Up
S/N: 5MG221-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: AAH1-Up
S/N: 6NG234-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: AGH1-Up
S/N: 6YG348-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: ALH1-Up
S/N: 86G1556-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: ASH1-Up
S/N: 8BG2191-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CEH1-Up
S/N: 8YG492-Up
8 SENR5664-13

S/N: HDH1-Up S/N: 8RJ4387-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: TGH1-Up S/N: 8WJ1-Up
S/N: WBH1-Up S/N: 8ZJ319-Up
S/N: 1FJ5542-Up S/N: 9EJ1-Up
S/N: 1XJ1-Up S/N: 9GJ945-Up
S/N: 2JJ100-Up S/N: 9KJ441-Up
S/N: 3AJ331-Up S/N: 9YJ1078-Up
S/N: 3BJ100-Up S/N: ABJ1-Up
S/N: 3XJ1-Up S/N: ACJ1-Up
S/N: 4EJ1-Up S/N: AEJ1-Up
S/N: 4ZJ597-Up S/N: ASJ1-Up
S/N: 5EJ1-Up S/N: BDJ1-Up
S/N: 5TJ1317 S/N: BGJ1-Up
S/N: 6XJ523-Up S/N: BMJ1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 6ZJ1-Up S/N: BRJ1-Up
Part No.: 3E-1906 S/N: BZJ1-Up
S/N: 7MJ340-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: DAJ1-Up
S/N: 7WJ1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: MTJ1-Up
S/N: 7XJ124-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1HK424-Up
S/N: 8AJ855-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2ZK1-Up
S/N: 8CJ1221-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 3HK1-Up
S/N: 8LJ884-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 3SK410-Up
S/N: 8PJ533-Up
Part No.: 3E-1906
S/N: 3XK1909-Up
SENR5664-13 9

S/N: 3YK1-Up S/N: 7ZK349-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4HK366-Up S/N: 8AK1-Up
S/N: 4MK1-Up S/N: 8CK206-Up
S/N: 4NK147-Up S/N: 8FK1-Up
S/N: 4SK22-Up S/N: 8HK144-Up
S/N: 5AK1-Up S/N: 8KK314-Up
S/N: 5KK336-Up S/N: 8LK1276-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5MK1651-Up S/N: 8SK369-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5MK1651-Up S/N: 8TK816-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5SK745-Up S/N: 9JK361-Up
S/N: 5WK1001-Up S/N: 9KK1359-Up
S/N: 6BK33-Up S/N: 9LK464-Up
S/N: 6CK354-Up S/N: 9MK350-Up
S/N: 6GK393-Up S/N: 9RK308-Up
S/N: 6KK1001-Up S/N: 9ZK143-Up
S/N: 6NK1-Up S/N: ABK1-Up
S/N: 6XK1-Up S/N: AWK1-Up
S/N: 6ZK64-Up S/N: BDK1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 7HK28-Up S/N: BMK1-Up
Part No.: 3E-1906 S/N: BZK1-Up
S/N: 7KK1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CFK1-Up
S/N: 7PK135-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: DAK1-Up
S/N: 7SK225-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: DMK1-Up
S/N: 7TK1-Up
10 SENR5664-13

S/N: GLK1-Up S/N: 6RL45-Up
S/N: JLK1-Up Part No.: 3E-1906
S/N: 6TL1-Up
Part No.: 3E-1906
S/N: 1AL1-Up Part No.: 3E-1906
S/N: 6WL1-Up
Part No.: 3E-1906
S/N: 1DL18-Up Part No.: 106-5122
S/N: 6XL170-Up
Part No.: 106-5122
S/N: 1JL1-Up Part No.: 3E-1906
S/N: 7ML1-Up
Part No.: 3E-1906
S/N: 1KL442-Up Part No.: 3E-1906
S/N: 7PL103-Up
Part No.: 3E-1906
S/N: 1SL510-Up Part No.: 106-5122
S/N: 7TL1-Up
Part No.: 3E-1906
S/N: 1YL320-Up Part No.: 3E-1906
S/N: 8AL1-Up
Part No.: 3E-1906
S/N: 2BL347-Up Part No.: 106-5122
S/N: 8BL1-Up
Part No.: 3E-1906
S/N: 2DL214-Up Part No.: 3E-1906
S/N: 8ML1-Up
Part No.: 3E-1906
S/N: 2EL332-Up Part No.: 3E-1906
S/N: 8NL78-Up
Part No.: 3E-1906
S/N: 2SL528-Up Part No.: 3E-1906
S/N: 8RL44-Up
Part No.: 3E-1906
S/N: 2TL346-Up Part No.: 3E-1906
S/N: 8SL1-Up
Part No.: 106-5122
S/N: 2XL1-Up Part No.: 106-5122
S/N: 9BL1-Up
Part No.: 3E-1906
S/N: 2ZL1-Up Part No.: 3E-1906
S/N: 9FL121-Up
Part No.: 106-5122
S/N: 3CL751-Up Part No.: 3E-1906
S/N: 9JL1-Up
Part No.: 3E-1906
S/N: 3LL678-Up Part No.: 3E-1909
S/N: 9KL99-Up
Part No.: 3E-1906
S/N: 3ML1-Up Part No.: 3E-1906
S/N: 9ML77-Up
Part No.: 3E-1906
S/N: 3RL35-Up Part No.: 3E-1906
S/N: 9RL1-Up
Part No.: 106-5122
S/N: 4CL165-Up Part No.: 3E-1906
S/N: 9WL87-Up
Part No.: 3E-1906
S/N: 4EL196-Up Part No.: 3E-1906
S/N: ACL1-Up
Part No.: 3E-1906
S/N: 5DL167-Up Part No.: 3E-1906
S/N: ASL1-Up
Part No.: 3E-1906
S/N: 6BL112-Up
SENR5664-13 11
Part No.: 106-5122 Part No.: 3E-1906

S/N: BNL1-Up S/N: 4YM270-Up
S/N: BZL1-Up Part No.: 3E-1906
S/N: 5FM1-Up
Part No.: 3E-1906
S/N: DCL1-Up Part No.: 3E-1906
S/N: 5HM1-Up
Part No.: 106-5122
S/N: JDL1-Up Part No.: 3E-1906
S/N: 5YM1-Up
Part No.: 3E-1906
S/N: 1AM1-Up Part No.: 3E-1906
S/N: 6KM213-Up
Part No.: 3E-1906
S/N: 1FM1-Up Part No.: 3E-1906
S/N: 6NM1-Up
Part No.: 3E-1906
S/N: 1JM46-Up Part No.: 3E-1906
S/N: 6RM1-Up
Part No.: 106-5122
S/N: 1KM1-Up Part No.: 3E-1906
S/N: 6WM1-Up
Part No.: 3E-1906
S/N: 1XM118-Up Part No.: 3E-1906
S/N: 7LM1-Up
Part No.: 106-5122
S/N: 1YM181-Up Part No.: 3E-1906
S/N: 7PM1-Up
Part No.: 3E-1906
S/N: 7XM1-Up
Part No.: 3E-1906
S/N: 2HM1-Up Part No.: 106-5122
S/N: 7YM1-Up
Part No.: 106-5122
S/N: 2LM348-Up Part No.: 3E-1906
S/N: 8GM299-Up
Part No.: 3E-1906
S/N: 2PM115-Up Part No.: 3E-1906
S/N: 8KM1-Up
Part No.: 106-5122
S/N: 2RM142-Up Part No.: 106-5122
S/N: 8SM142-Up
Part No.: 3E-1906
S/N: 2WM1-Up Part No.: 3E-1906
S/N: 8TM1-Up
Part No.: 3E-1906
S/N: 2ZM1-Up Part No.: 3E-1906
S/N: 8ZM1-Up
Part No.: 3E-1906
S/N: 3GM1-Up Part No.: 3E-1906
S/N: 9BM1-Up
Part No.: 3E-1906
S/N: 3ZM127-Up Part No.: 3E-1906
S/N: 9CM1-Up
Part No.: 3E-1906
S/N: 9DM1-Up
Part No.: 3E-1906
S/N: 4MM149-Up Part No.: 3E-1906
S/N: 9EM1-Up
Part No.: 3E-1906
S/N: 4RM1-Up Part No.: 3E-1906
S/N: 9HM1-Up
Part No.: 3E-1906
S/N: 4XM1-Up Part No.: 3E-1906
S/N: 9WM87-Up
12 SENR5664-13
Part No.: 106-5122 Part No.: 3E-1906

S/N: 9ZM1-Up S/N: 3ZN1-Up
S/N: AEM1-Up S/N: 4HN1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: AFM1-Up S/N: 4JN1-Up
S/N: AGM1-Up S/N: 4MN1-Up
S/N: ASM1-Up S/N: 4NN51-Up
S/N: BDM1-Up S/N: 4RN1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: BPM1-Up S/N: 4SN1-Up
S/N: BZM1-Up Part No.: 3E-1906
S/N: 4YN75-Up
Part No.: 3E-1906
S/N: CXM1-Up Part No.: 3E-1906
S/N: 5FN1-Up
Part No.: 3E-1906
S/N: DAM1-Up Part No.: 3E-1906
S/N: 5LN1-Up
Part No.: 106-5122
S/N: DLM1-Up Part No.: 3E-1906
S/N: 5NN75-Up
Part No.: 106-5122
S/N: LFM1-Up Part No.: 3E-1906
S/N: 5TN1-Up
Part No.: 3E-1906
S/N: 1DN1-Up Part No.: 3E-1906
S/N: 6DN1-Up
Part No.: 3E-1906
S/N: 1GN1-Up Part No.: 106-5122
S/N: 6FN238-Up
Part No.: 3E-1906
S/N: 1WN94-Up Part No.: 106-5122
S/N: 6GN1-Up
Part No.: 3E-1906
S/N: 2AN1-Up Part No.: 3E-1906
S/N: 6JN1-Up
Part No.: 3E-1906
S/N: 2EN1-Up Part No.: 3E-1906
S/N: 6KN51-Up
Part No.: 106-5122
S/N: 2RN1-Up Part No.: 3E-1906
S/N: 6MN75-Up
Part No.: 3E-1906
S/N: 2YN1-Up Part No.: 3E-1906
S/N: 6RN1-Up
Part No.: 106-5122
S/N: 2ZN1-Up Part No.: 3E-1906
S/N: 6YN1-Up
Part No.: 3E-1906
S/N: 2ZN1749-Up Part No.: 3E-1906
S/N: 7CN1-Up
Part No.: 3E-1906
S/N: 3DN1-Up Part No.: 3E-1906
S/N: 7EN303-Up
Part No.: 106-5122
S/N: 3WN1-Up
SENR5664-13 13

S/N: 7FN1-Up S/N: BYN1-Up
S/N: 7KN1-Up S/N: CEN1-Up
S/N: 7LN1-Up S/N: CNN1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 7PN75-Up S/N: KBN1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 7SN142-Up S/N: 9PP1-Up
S/N: 7ZN1-Up S/N: 9XP1-Up
S/N: 8FN1-Up S/N: AEP1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 8JN1-Up S/N: AKP1-Up
S/N: 8LN1-Up S/N: ALP1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 8MN1-Up S/N: BCP1-Up
S/N: 8WN1-Up S/N: BDP1-Up
S/N: 8XN1-Up S/N: BFP1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 9HN399-Up S/N: BPP1-Up
S/N: 9MN1-Up S/N: CFP1-Up
S/N: 9PN1-Up S/N: 2HR1-Up
S/N: 9TN1-Up S/N: 2JR1-Up
S/N: 9ZN1-Up S/N: 2KR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: AAN1-Up S/N: 2LR1-Up
S/N: AGN1-Up S/N: 2RR426-Up
S/N: ASN1-Up S/N: 2SR1-Up
S/N: BBN1-Up S/N: 2WR1-Up
S/N: BCN1-Up S/N: 2YR1-Up
S/N: BGN1-Up S/N: 2ZR1-Up
14 SENR5664-13
Part No.: 106-5122 Part No.: 3E-1906

S/N: 3CR1-Up S/N: 5MR1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 3DR1-Up S/N: 5NR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 3KR1-Up S/N: 5PR1-Up
S/N: 3NR307-Up S/N: 5RR1-Up
S/N: 3SR1-Up S/N: 5TR969-Up
S/N: 3YR1-Up S/N: 5WR1-Up
S/N: 3ZR1-Up S/N: 5YR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 4BR1-Up S/N: 6CR1-Up
S/N: 4ER1-Up S/N: 6DR1-Up
S/N: 4FR1-Up S/N: 6ER1-Up
S/N: 4JR1-Up S/N: 6FR1-Up
S/N: 4LR1-Up S/N: 6GR1-Up
S/N: 4NR1-Up S/N: 6HR1-Up
S/N: 4SR1-Up S/N: 6JR1-Up
S/N: 4TR1-Up S/N: 6KR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4WR1-Up S/N: 6LR1-Up
S/N: 4XR1-Up S/N: 6MR1-Up
S/N: 4YR1-Up S/N: 6TR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5BR1-Up S/N: 6XR1-Up
S/N: 5CR264-Up S/N: 7AR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5DR1-Up S/N: 7BR1-Up
S/N: 5LR1-Up S/N: 7DR1-Up
SENR5664-13 15

S/N: 7ER1-Up S/N: 9YR1-Up
S/N: 7FR1-Up S/N: ALR1-Up
S/N: 7GR1-Up S/N: ASR1-Up
S/N: 7HR1-Up S/N: BCR1-Up
S/N: 7JR1-Up S/N: BDR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 7LR1-Up S/N: BZR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 7SR1-Up S/N: CDR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 8CR1-Up S/N: CLR1-Up
S/N: 8GR1-461 S/N: CXR1-Up
S/N: 8JR1-Up S/N: DXR1-Up
Part No.: 3E-1906 S/N: TWR1-Up
S/N: 8MR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1AS1-346
S/N: 8NR1-243
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1DS1-Up
S/N: 8PR1-261
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1ES1-Up
S/N: 8RR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1GS1-143
S/N: 8SR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1HS1-Up
S/N: 8TR1-485
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1JS1-484
S/N: 8ZR1-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: 1KS1-Up
S/N: 9AR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1XS1-Up
S/N: 9GR1-412
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1YS1-Up
S/N: 9LR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1ZS1-Up
S/N: 9SR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2AS1-Up
S/N: 9TR1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: 2DS1-Up
S/N: 9XR1-Up
16 SENR5664-13
Part No.: 3E-1906 Part No.: 106-5122

S/N: 2ES1-Up S/N: 5AS1-Up
S/N: 2GS1-Up S/N: 5BS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 2JS1-Up S/N: 5CS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 2LS1-203 S/N: 5ES1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 2NS1-155 S/N: 5FS1-Up
S/N: 2PS1-Up S/N: 5KS1-Up
S/N: 2RS1-Up S/N: 5LS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 2YS1-Up S/N: 5MS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 3AS1-Up S/N: 5RS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 3BS1-Up S/N: 5SS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 3FS1-254 S/N: 6AS1-Up
S/N: 3ZS1-Up S/N: 6ES1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 4BS1-Up S/N: 6LS1-309
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4DS1-Up S/N: 6NS1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 4GS1-Up S/N: 6PS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4HS1-Up S/N: 6WS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 4JS1-Up S/N: 6YS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4NS1-Up S/N: 7BS1-Up
S/N: 4PS1-Up S/N: 7CS1-Up
S/N: 4RS1-Up S/N: 7FS1-Up
S/N: 4SS1-Up S/N: 7LS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 4YS1-Up S/N: 8AS1-Up
SENR5664-13 17

S/N: 8PS1-Up S/N: CKT1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 8RS1-Up S/N: CNT1-Up
S/N: 8SS1-Up S/N: DBT1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 9FS1-Up S/N: FDT1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 9GS1-Up S/N: GMT1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 9HS1-Up S/N: MRT1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 9JS1-269 S/N: 1CW1-Up
S/N: 9PS1-Up S/N: 1EW1-Up
S/N: 9RS1-Up S/N: 1GW1-Up
S/N: 9SS1-Up S/N: 1JW1-Up
S/N: 9WS1-Up S/N: 1SW1-214
S/N: 9XS1-Up S/N: 2KW1-Up
S/N: 9YS1-Up S/N: 2NW1-Up
S/N: ACS1-Up S/N: 2TW1-Up
S/N: CES1-Up S/N: 2XW1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: DPS1-Up S/N: 3AW1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: RLS1-Up S/N: 3JW1-Up
S/N: AET1-Up S/N: 3PW1-Up
S/N: AKT1-Up S/N: 3SW1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: AST1-Up S/N: 4PW1-Up
S/N: AXT1-Up S/N: 4WW1-Up
S/N: BLT1-Up S/N: 4XW1-103
S/N: BTT1-Up S/N: 5EW1-Up
18 SENR5664-13

S/N: 5FW1-Up S/N: 9NW1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5GW1-220 S/N: 9SW1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5MW1-Up S/N: 9WW1-Up
S/N: 5SW1-Up S/N: 9ZW1-Up
S/N: 5TW1-Up S/N: AAW1-Up
S/N: 5WW1-Up S/N: ANW1-Up
S/N: 63W4011-Up S/N: ARW1-Up
S/N: 64W195-Up S/N: AXW1-Up
S/N: 6AW1-Up S/N: BLW1-Up
S/N: 6EW1-Up S/N: DNW1-Up
Part No.: 3E-1906 S/N: TFW1-Up
S/N: 6HW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 01X6362-Up
S/N: 6LW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 02X371-Up
S/N: 6PW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 85X1651-Up
S/N: 6QW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 87X1700-Up
S/N: 6SW1-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: AAX1-Up
S/N: 6YW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: AMX1-Up
S/N: 7BW1-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: BDX1-Up
S/N: 8JW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CEX1-Up
S/N: 8XW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CFX1-Up
S/N: 9EW1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CNX1-Up
S/N: 9GW1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: LDX1-Up
S/N: 9MW1-Up
Part No.: 3E-1906
S/N: WGX1-Up
SENR5664-13 19

S/N: BDY1-Up S/N: 5KZ1-Up
S/N: BMY1-Up S/N: 5LZ1-Up
S/N: BTY1-Up S/N: 6AZ1-Up
S/N: 15Z1413-Up S/N: 6DZ1-Up
S/N: 16Z368-Up S/N: 6GZ1-Up
S/N: 17Z1614-Up S/N: 6SZ1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 1PZ1-Up S/N: 6YZ1-Up
S/N: 1YZ1-Up S/N: 79Z5611-Up
S/N: 1ZZ1-Up S/N: 7MZ1-Up
S/N: 21Z5346-Up S/N: 7PZ1-Up
S/N: 2CZ1-Up S/N: 7RZ1-283
S/N: 2FZ1-Up S/N: 80Z5518-Up
S/N: 2KZ1-Up S/N: 89Z271-Up
S/N: 2RZ1-Up S/N: 8XZ1-Up
S/N: 3AZ1-Up S/N: 90Z223-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 3DZ1-Up S/N: 91Z453-Up
S/N: 3KZ1-Up S/N: 92Z580-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 3PZ1-Up S/N: BCZ1-Up
S/N: 3RZ1-Up S/N: BKZ1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 3YZ1-Up S/N: BRZ1-Up
S/N: 4MZ1-Up S/N: CBZ1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5CZ1-Up S/N: CZZ1-Up
S/N: 5EZ253-Up S/N: DFZ1-Up
20 SENR5664-13
Part No.: 3E-1906 Cat 4C-2959 Air Conditioner Lubricant (250 mL

S/N: 86X1104-Up; 89X1-Up (8.45 Oz))
R-134a Refrigerant
DuPont ........................ SUVA TRANS A/C HFC134a
ICI ........................................................... KLEA 134a
Torque for Fittings
Torque for 7/8 inch threaded fitting .. 25 Nm (18 lb ft)
Note: The 7/8 inch threaded fitting is located on

the metal tube which has an internal diameter of
15.8 mm (.62 inch).
g00887217
Illustration 1 Torque for 3/4 inch threaded fitting ................ 17 Nm
(150 lb in)
(1) Installation torque for pressure switch
...................... 8.0 1.5 Nm (71.00 13.00 lb in) Note: The 3/4 inch threaded fitting is located on
(2) Pressure relief valve 12.7 mm (.50 inch).
Opening pressure of pressure relief M10 x 1.5 retaining bolt torque ................ 25 7 Nm
valve ................... 3800 300 kPa (551 44 psi) (18 5 lb ft)
Sealing pressure of pressure relief valve
.............................................. 2900 kPa (421 psi) Note: The retaining bolt is for the block fitting.
(3) Torque for oil plug ....... 10 2 Nm (89 18 lb in) Magnetic Clutch
Note: Oil plug (3) is under pressure when the system Clutch 24 DCV coil resistance (Green
is pressurized. wire) ................................................. 17.6 0.6 ohms
(4) Final installation torque .. 25 7 Nm (18 5 lb ft) Power connection ............................... DT Connector
(5) V-belt tension Minimum voltage for engagement ................ 16 DCV
New V-belt ...................... 535 22 N (120 5 lb)
Used V-belt ..................... 400 44 N (90 10 lb) Maximum Current ...................................... 1.42 amp
Note: Used belt tension is for a belt that has been i02528479
operated for at least 30 minutes at the rated speed.
Operate the air conditioner for 30 minutes. Then, Refrigerant Compressor
adjust the tension of the drive belt to 400 N (90 lb).
SMCS Code: 1802
Note: Use a Caterpillar 144-0235 Belt Tension
Gauge. Part No.: 163-0872
S/N: 1241-Up
Displacement per revolution .... 154.9 mL (5.20 fl oz) Part No.: 163-0872
S/N: 1251-Up
Recommended Compressor RPM ... 2500 200 rpm
Part No.: 163-0872
Refrigerant Oil S/N: 5251-Up
Oil capacity .................................... 300 mL (10 fl oz) Part No.: 163-0872

S/N: 5351-Up
Note: Refer to Systems Operation, Identifying the
Air Conditioning System. Part No.: 163-0872
S/N: 5451-Up
Poly Alkaline Glycol Oil (PAG)
SENR5664-13 21
Part No.: 163-0872 Part No.: 218-0324

S/N: 1261-Up S/N: CCC1-Up
Part No.: 218-0324 Part No.: 183-5106
S/N: AMA1-Up S/N: DBC1-Up
Part No.: 163-0872 Part No.: 183-5106
S/N: AYA1-Up S/N: MJC1-Up
Part No.: 163-0872 Part No.: 183-5106
S/N: BAA1-Up S/N: W1C1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: CCA1-Up S/N: A6D1-Up
Part No.: 183-5106 Part No.: 163-0872
S/N: DFA1-Up S/N: A7D1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: MYA1-Up S/N: AGD1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: N1A1-Up S/N: ALD1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: N4A1-Up S/N: ASD1-Up
S/N: TRA1-Up Part No.: 163-0872
S/N: AYD1-Up
Part No.: 218-0324
S/N: ALB1-Up Part No.: 163-0872
S/N: BAD1-Up
Part No.: 218-0324
S/N: APB1-Up Part No.: 183-5106
S/N: BBD1-Up
Part No.: 218-0324
S/N: AXB1-Up Part No.: 218-0324
S/N: BXD1-Up
Part No.: 163-0872
S/N: AYB1-Up Part No.: 163-0872
S/N: CLD1-Up
Part No.: 163-0872
S/N: BAB1-Up Part No.: 163-0872
S/N: CRD1-Up
Part No.: 183-5106
S/N: DBB1-Up Part No.: 183-5106
S/N: DBD1-Up
S/N: J8B1-Up
Part No.: 163-0872
Part No.: 218-0324 S/N: RCD1-Up
S/N: JMB1-Up
Part No.: 163-0872
Part No.: 163-0872 S/N: ASE1-Up
S/N: RTB1-Up
Part No.: 163-0872
Part No.: 183-5106 S/N: AXE1-Up
S/N: W1B1-Up
Part No.: 163-0872
Part No.: 163-0872 S/N: AYE1-Up
S/N: AXC1-Up
Part No.: 163-0872
Part No.: 163-0872 S/N: AGF1-Up
S/N: BAC1-Up
S/N: AWF1-Up
Part No.: 218-0324
S/N: BPC1-Up Part No.: 163-0872
S/N: BGF1-Up
Part No.: 163-0872
S/N: CBC1-Up
22 SENR5664-13
Part No.: 163-0872 Part No.: 218-0324

S/N: BKF1-Up S/N: A8J1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: CAF1-Up S/N: AKJ1-Up
Part No.: 183-5106 Part No.: 218-0324
S/N: CBF1-Up S/N: ANJ1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: A6G1-Up S/N: AXJ1-Up
Part No.: 163-0872 Part No.: 106-5122
S/N: A7G1-Up S/N: BZJ1-Up
Part No.: 218-0324 Part No.: 183-5106
S/N: AXG1-Up S/N: CBJ1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: AYG1-Up S/N: CDJ1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: BFG1-Up S/N: CFJ1-Up
Part No.: 183-5106 Part No.: 183-5106
S/N: CCG1-Up S/N: DFJ1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: CKG1-Up S/N: J5J1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: M1G1-Up S/N: J6J1-Up
Part No.: 163-0872 Part No.: 106-5122
S/N: M3G1-Up S/N: BZK1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: M5G1-Up S/N: CBK1-Up
Part No.: 218-0324 Part No.: 183-5106
S/N: MHG1-Up S/N: CCK1-Up
Part No.: 218-0324 Part No.: 163-0972
S/N: PEG1-Up S/N: K5K1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: AWH1-Up S/N: K6K1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: AYH1-Up S/N: ALL1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: BNH1-Up S/N: ARL1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: BTH1-Up S/N: AXL1-Up
Part No.: 183-5106 Part No.: 163-0872
S/N: CFH1-Up S/N: AYL1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: A6J1-Up S/N: BKL1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: A7J1-Up S/N: BRL1-Up
SENR5664-13 23
Part No.: 106-5122 Part No.: 218-0324

S/N: BZL1-Up S/N: 7HR1-Up
Part No.: 183-5106 Part No.: 141-9676
S/N: CBL1-Up S/N: AWR1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: FDL1-Up S/N: AXR1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: SDL1-Up S/N: BMR1-Up
Part No.: 183-5106 Part No.: 218-0324
S/N: AKM1-Up S/N: DER1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: APM1-Up S/N: 4SS1-Up
Part No.: 141-9676 Part No.: 218-0324
S/N: AXM1-Up S/N: 5WS1-Up
Part No.: 106-5122 Part No.: 218-0324
S/N: BZM1-Up S/N: 6XS1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: CFM1-Up S/N: 7KS1-Up
Part No.: 183-5106 Part No.: 218-0324
S/N: JKM1-Up S/N: 9GS1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: JSM1-Up S/N: AGS1-Up
Part No.: 183-5106 Part No.: 163-0872
S/N: KLM1-Up S/N: ANS1-Up
Part No.: 183-5106 Part No.: 163-0872
S/N: LKM1-Up S/N: ATS1-Up
S/N: WDM1-Up Part No.: 163-0872
S/N: AXS1-Up
Part No.: 218-0324
S/N: 9TN1-Up Part No.: 163-0872
S/N: AYS1-Up
Part No.: 163-0872
S/N: APN1-Up Part No.: 183-5106
S/N: CCS1-Up
Part No.: 163-0872
S/N: AXN1-Up Part No.: 163-0872
S/N: CLS1-Up
Part No.: 163-0872
S/N: JAN1-Up S/N: JMS1-Up
Part No.: 163-0872 S/N: RJS1-Up
S/N: PHN1-Up
Part No.: 218-0324
Part No.: 141-9676 S/N: ALT1-Up
S/N: AMP1-Up
Part No.: 163-0872
Part No.: 163-0872 S/N: ANT1-Up
S/N: AWP1-Up
Part No.: 218-0324
Part No.: 163-0872 S/N: AYT1-Up
S/N: AXP1-Up
Part No.: 163-0872
Part No.: 163-0872 S/N: CLT1-Up
S/N: CCP1-Up
Part No.: 218-0324
S/N: DET1-Up
24 SENR5664-13
Part No.: 218-0324 Part No.: 163-0872

S/N: 1JW1-Up S/N: B9Y1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: 2NW1-Up S/N: BLY1-Up
Part No.: 218-0324 S/N: BXY1-Up
S/N: 2SW1-Up
Part No.: 218-0324
Part No.: 141-9676, 163-0872, 218-0324 S/N: CDY1-Up
S/N: 2TW1-Up
Part No.: 218-0324
Part No.: 218-0324 S/N: CTY1-Up
S/N: 5YW1-Up
Part No.: 163-0872
Part No.: 218-0324 S/N: SJY1-Up
S/N: A4W1-Up
Part No.: 218-0324
Part No.: 218-0324 S/N: 4XZ1-Up
S/N: AWW1-Up
Part No.: 141-9676
S/N: AZW1-Up S/N: 6GZ1-Up
Part No.: 183-5106 Part No.: 141-9676
S/N: BTW1-Up S/N: 7MZ1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: DCW1-Up S/N: 9HZ1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: SAW1-Up S/N: 9PZ1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: AFX1-Up S/N: 9TZ1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: AKX1-Up S/N: ADZ1-Up
S/N: ASX1-Up Part No.: 163-0872
S/N: ALZ1-Up
Part No.: 163-0872
S/N: AXX1-Up Part No.: 163-0872
S/N: AMZ1-Up
Part No.: 218-0324
S/N: AZX1-Up Part No.: 163-0872
S/N: ANZ1-Up
Part No.: 183-5106
S/N: BBX1-Up Part No.: 163-0872
S/N: AWZ1-Up
Part No.: 183-5106
S/N: BWX1-Up Part No.: 218-0324
S/N: AZZ1-Up
Part No.: 163-0872
S/N: CSX1-Up S/N: KPZ1-Up
Part No.: 183-5106
S/N: ALY1-Up
Part No.: 163-0872
S/N: ANY1-Up
Part No.: 163-0872
S/N: AWY1-Up
Part No.: 163-0872
S/N: AXY1-Up
SENR5664-13 25
Maximum Current ...................................... 1.42 amp
i01934063
Refrigerant Compressor
SMCS Code: 1802
S/N: 4421-Up
Part No.: 198-4564
S/N: AGC1-Up
Part No.: 198-4564
S/N: 4XJ376-Up
Part No.: 198-4564
S/N: 7TJ1-Up
Part No.: 198-4564
S/N: 2TK79-Up
g01010215 Part No.: 198-4564

Illustration 2
S/N: 5RK1-Up
View of the 163-0872 Compressor
Part No.: 198-4564
(1) Torque for oil plug ....... 10 2 Nm (89 18 lb in) S/N: 6HK265-Up
Note: Oil plug (1) is under pressure when the system Part No.: 198-4564
is pressurized. S/N: 7EK231-Up
Part No.: 198-4564
(2) Final installation torque .. 25 7 Nm (18 5 lb ft)
S/N: 1HL102-Up
(3) Pressure relief valve Part No.: 198-4564
S/N: 5ZL1-Up
Opening pressure of the relief
valve ................................ 3500 kPa to 4100 kPa Part No.: 198-4564
(508 psi to 595 psi) S/N: 7LL1-Up
Sealing pressure of the relief valve ..... 2900 kPa
(420 psi) Part No.: 198-4564
S/N: 61M5358-Up
(4) Torque for pressure switch ............ 8.0 1.5 Nm
(71.00 13.00 lb in) Part No.: 198-4564
S/N: JSM1-Up
S/N: 3PR1-Up
Part No.: 198-4564
R-134a Refrigerant S/N: 4AR1-Up
DuPont ........................ SUVA TRANS A/C HFC134a Part No.: 198-4564

S/N: 5ER1-Up
ICI ........................................................... KLEA 134a
Part No.: 198-4564
Refrigerant Oil S/N: CBR1-Up
Part No.: 198-4564
Oil capacity .................................... 300 mL (10 fl oz) S/N: AFS1-Up
Cat 4C-2959 Air Conditioner Lubricant (PAG) Part No.: 198-4564
S/N: 93U3516-Up
Magnetic Clutch
Part No.: 198-4564
Clutch 24 DCV coil resistance ....... 17.6 0.6 ohms S/N: 96U9075-Up
Minimum voltage for engagement ................ 16 DCV

26 SENR5664-13
Part No.: 198-4564

S/N: 72V15940-Up
Part No.: 198-4564
S/N: 87V9732-Up
Part No.: 198-4564
S/N: 11W1351-Up
Part No.: 198-4564
S/N: 2BW1-Up
Part No.: 198-4564
S/N: 2YW1-Up
Part No.: 198-4564
S/N: APX1-Up
Part No.: 198-4564
S/N: AGY1-Up
Part No.: 198-4564
S/N: ATY1-Up
g00887111
Illustration 3
Part No.: 198-4564
S/N: 2PZ1-Up (1) Relief valve
Part No.: 198-4564 Opening pressure of relief valve .......... 3309 kPa
S/N: 3TZ83-Up (480 psi)
Part No.: 198-4564 Sealing pressure of relief valve .......... 2964 kPa
S/N: 4GZ1-Up (430 psi)
Part No.: 198-4564 (2) Final installation torque .. 25 7 Nm (18 5 lb ft)

S/N: 5AZ1-Up
(3) Oil capacity ............................... 310.0 14.5 mL
(10.50 0.50 fl oz)
(4) Torque for oil plug ....... 10 2 Nm (89 18 lb in)
Note: Oil plug (4) is pressurized.
(5) V-belt tension

New V-belt ...................... 712 22 N (160 5 lb)
Used V-belt ..................... 489 22 N (110 5 lb)
Note: Used belt tension is for a belt that has been

Operate the air conditioner for 30 minutes. Then,
adjust the tension of the drive belt to 489 22 N
(110 5 lb). The belt should not run below 400 N
(90 lb).

Gauge.
Torque for Fittings
Torque for 3/4 inch threaded fitting ................ 17 Nm

(150 lb in)
SENR5664-13 27
Note: The 3/4 inch fitting is located on the metal Part No.: 176-1895
tube which has an internal diameter of 12.7 mm S/N: CFB1-Up
(0.50 inch).
Part No.: 176-1895
Torque for 7/8 inch threaded fitting .. 25 Nm (18 lb ft) S/N: MAB1-Up
Part No.: 176-1895
Note: The 7/8 inch fitting is located on the metal
S/N: PAB1-Up
tube which has an internal diameter of 15.8 mm
(0.62 inch). Part No.: 176-1895
S/N: BBC1-Up
Torque for 3/8 inch retaining bolt ............. 25 7 Nm
(18 5 lb ft) Part No.: 176-1895
S/N: CJC1-Up
R-134a Refrigerant
Part No.: 176-1895
DuPont ........................ SUVA TRANS A/C HFC134a S/N: FBC1-Up
Part No.: 176-1895
ICI ........................................................... KLEA 134a S/N: GAC1-Up
Refrigerant Oil Part No.: 176-1895
S/N: MAC1-Up
Part No.: 176-1895
Cat 9U-7551 Air Conditioner Lubricant S/N: PAC1-Up
Part No.: 176-1895
Oil capacity ...... 310.0 14.5 mL (10.50 0.50 fl oz)
S/N: FED1-Up
Magnetic Clutch S/N: GAD1-Up
Clutch 24 DCV coil resistance ................ 12.5 ohms Part No.: 176-1895
S/N: AKE1-Up
Part No.: 176-1895
S/N: BDE1-Up
i01976060
Part No.: 176-1895
Refrigerant Compressor S/N: ANF1-Up
SMCS Code: 1802 Part No.: 176-1895

S/N: BEF1-Up
Part No.: 176-1895
S/N: BEA1-Up Part No.: 176-1895
S/N: BTG1-Up
Part No.: 176-1895
S/N: CBA1-Up Part No.: 176-1895
S/N: DBG1-Up
Part No.: 176-1895
S/N: DAA1-Up Part No.: 176-1895
S/N: JTG1-Up
Part No.: 176-1895
S/N: EGA1-Up Part No.: 176-1895
S/N: BPH1-Up
Part No.: 176-1895
S/N: FAA1-Up Part No.: 176-1895
S/N: DAH1-Up
Part No.: 176-1895
S/N: GLA1-Up Part No.: 176-1895
S/N: SAH1-Up
Part No.: 176-1895
S/N: GPA1-Up Part No.: 176-1895
S/N: BKJ1-Up
Part No.: 176-1895
S/N: ANB1-Up Part No.: 176-1895
S/N: AXK1-Up
Part No.: 176-1895
S/N: BGB1-Up
28 SENR5664-13
Part No.: 176-1895 Part No.: 176-1895

S/N: BFK1-Up S/N: CFT1-Up
Part No.: 176-1895 Part No.: 176-1895
S/N: BKK1-Up S/N: RAW1-Up
Part No.: 176-1895 Part No.: 176-1895
S/N: BBL1-Up S/N: BFX1-Up
Part No.: 176-1895 Part No.: 176-1895
S/N: EGL1-Up S/N: BMX1-Up
Part No.: 176-1895 Part No.: 176-1895
S/N: JPL1-Up S/N: BRX1-Up
S/N: KGL1-Up Part No.: 176-1895
S/N: SLX1-Up
Part No.: 176-1895
S/N: BKM1-Up Part No.: 176-1895
S/N: CBY1-Up
Part No.: 176-1895
S/N: BZM1-Up Part No.: 176-1895
S/N: MDY1-Up
Part No.: 176-1895
S/N: CAM1-Up Part No.: 176-1895
S/N: CLZ1-Up
Part No.: 176-1895
S/N: CLM1-Up
Part No.: 176-1895
S/N: BCN1-Up
Part No.: 176-1895
S/N: BFN1-Up
Part No.: 176-1895
S/N: BNN1-Up
Part No.: 176-1895
S/N: SBN1-Up
Part No.: 176-1895
S/N: BLP1-Up
Part No.: 176-1895
S/N: BGR1-Up
Part No.: 176-1895
S/N: BPR1-Up
g00792823
Part No.: 176-1895 Illustration 4
S/N: EMR1-Up
Refer to Specifications, Air Conditioner Lines for
Part No.: 176-1895 information concerning the torque of refrigerant lines.
S/N: MAR1-Up
(1) V-belt tension
Part No.: 176-1895
S/N: TBR1-Up New V-belt .................. 578 111 N (130 25 lb)
Used V-belt ................... 445 44 N (100 10 lb)
Part No.: 176-1895
S/N: AWS1-Up
Part No.: 176-1895 operated for at least 30 minutes at the rated speed.
S/N: FDS1-Up Operate the air conditioner for 30 minutes. Then,
Part No.: 176-1895
S/N: CBT1-Up
SENR5664-13 29
Note: Use a Caterpillar 144-0235 Belt Tension i01943954

Gauge in order to test the tension of the belt.
Displacement per revolution .... 188.0 mL (6.36 fl oz)
SMCS Code: 1802
Maximum allowable speed ........................ 6000 rpm
Part No.: 218-4994
S/N: CMB1-Up
R-134a Refrigerant
Part No.: 218-4994
DuPont ........................ SUVA TRANS A/C HFC134a S/N: CNC1-Up
ICI ........................................................... KLEA 134a Part No.: 218-4994

S/N: CED1-Up
Refrigerant Oil
Part No.: 218-4994
Oil capacity of compressor ...... 180.0 mL (6.10 fl oz) S/N: FDG1-Up
Part No.: 218-4994
Type of compressor oil .................. DENSO ND-OIL8 S/N: CMM1-Up
Cat 4C-2959 Air Conditioner Lubricant (PAG) Part No.: 218-4994
S/N: CNY1-Up
Magnetic Clutch
Part No.: 218-4994
Voltage of magnetic clutch ............................ 24 VDC S/N: 4YZ1-Up
Part No.: 218-4994
Power consumption of a saturated magnetic
clutch ................................................................ 40 W S/N: 5SZ1-Up
g01011770
Illustration 5
(1) Belt tension

New belt .......................... 534 22 N (120 5 lb)
Used belt ........................ 400 44 N (90 10 lb)

(90 10 lb).

Gauge.
Type of compressor ................................... TM-13HD
Displacement per revolution ......... 131 mL (4.4 fl oz)
Recommended Compressor RPM ......... 700 to 6000

30 SENR5664-13
R-134a Refrigerant i01714590
DuPont ........................ SUVA TRANS A/C HFC134a Refrigerant Compressor

ICI ........................................................... KLEA 134a SMCS Code: 1802
Part No.: 191-9028
Refrigerant Oil
S/N: DSA1-Up
Poly Alkaline Glycol (PAG) Part No.: 191-9028
S/N: NAD1-Up
Oil capacity of compressor ...... 150.0 mL (5.07 fl oz)
S/N: DCK1-Up
Magnetic Clutch
Part No.: 191-9028
Rated voltage of magnetic clutch .................. 12 VDC S/N: BTN1-Up
Part No.: 191-9028
Power consumption .............................. 45 W or less S/N: DGT1-Up
Part No.: 191-9028
S/N: BMW1-Up
Compressor
g00895618
Illustration 6
(1) Belt tension

New belt .......................... 800 22 N (180 5 lb)
Used belt ...................... 489 44 N (110 10 lb)

(110 10 lb).
Note: Use a Caterpillar 144-1102 Belt Tightener.
Type of compressor .................................... TM-08 B

SENR5664-13 31
Displacement per revolution ......... 82 mL (2.77 fl oz) Note: Use a Caterpillar 144-0235 Belt Tension
Gauge in order to adjust the tension of the belt.
Maximum allowable continuous RPM ............... 4000
Maximum continuous speed ...................... 7000 rpm
R-134a Refrigerant
Displacement per revolution ....... 100 mL (3.72 fl oz)
R-134a Refrigerant
ICI ........................................................... KLEA 134a
Refrigerant Oil
ICI ........................................................... KLEA 134a
Type of compressor oil ................................ ND-OIL8
Refrigerant Oil
Magnetic Clutch
Cat 4C-2959 Air Conditioner Lubricant
Rated voltage of magnetic clutch .................. 12 VDC
Power consumption .............................. 45 W or less
Magnetic Clutch
Effective pulley diameter ............ 125 mm (4.92 inch)
Voltage of magnetic clutch ............................ 24 VDC
i01725133
Effective pulley diameter ............ 145 mm (5.71 inch)
SMCS Code: 1802
Part No.: 105-9362
S/N: 2PM115-Up
g00886683
Illustration 7

information concerning the torque of refrigerant lines.
(1) V-belt tension

New V-belt .................. 578 111 N (130 25 lb)
Used V-belt ................... 445 44 N (100 10 lb)

32 SENR5664-13
i01727037 Note: Used belt tension is for a belt that has been
Refrigerant Compressor Operate the air conditioner for 30 minutes. Then,
SMCS Code: 1802
Part No.: 117-6353
S/N: GHA1-Up
Part No.: 117-6353 (2) Power connection ................. 2 pin DT connector
S/N: BBC1-Up
(3) Refer to Specifications, Air Conditioner Lines for
Part No.: 117-6353 information concerning the torque of refrigerant
S/N: HBC1-Up lines.
Part No.: 117-6353 Refer to Specifications, Relief Valve (Refrigerant)
S/N: KAJ1-Up for specified pressures.
Part No.: 117-6353
S/N: BCM1-Up Size of 1N-4635 V-Belt ...................................... 13A
Part No.: 117-6353 Model of compressor .................................. MSC90T

S/N: 2DW1-Up
Type of compression ........................................ Scroll
Part No.: 117-6353
S/N: 4RW1-Up Displacement per revolution .............. 90 mL (3 fl oz)
Part No.: 117-6353
R-134a Refrigerant
S/N: 5CW1-Up
Part No.: 117-6353 DuPont ........................ SUVA TRANS A/C HFC134a
S/N: 6KZ1-Up
ICI ........................................................... KLEA 134a
Part No.: 117-6353
S/N: 7DZ1-Up Refrigerant Oil
Cat 9U-7551 Air Conditioner Lubricant
Oil capacity of compressor ............. 130.0 10.0 mL

(4.50 .30 fl oz)
Magnetic Clutch

clutch ................................................................ 38 W
i01526357
SMCS Code: 1802
Illustration 8
g00887154 Part No.: 171-7495
S/N: GHA1-Up
(1) V-belt tension Part No.: 171-7495
New V-belt ...................... 535 22 N (120 5 lb) S/N: CFB1-Up
Used V-belt ..................... 400 44 N (90 10 lb) Part No.: 171-7495
S/N: BBC1-Up
SENR5664-13 33
Part No.: 171-7495 Maximum continuous speed ...................... 9000 rpm

S/N: HBC1-Up
Displacement per revolution ........ 90.0 cc (3.04 fl oz)
Part No.: 171-7495
S/N: PAD1-Up R-134a Refrigerant
Part No.: 171-7495
S/N: BNE1-Up
Part No.: 171-7495 ICI ........................................................... KLEA 134a
S/N: CKE1-Up
Refrigerant Oil
Part No.: 171-7495
S/N: KAJ1-Up Poly Alkaline Glycol Oil (PAG)
Part No.: 171-7495 Cat 4C-2959 Air Conditioner Lubricant
S/N: BCM1-Up
Part No.: 171-7495 Oil capacity of compressor ...... 140.0 mL (4.73 fl oz)
S/N: CFT1-Up
Magnetic Clutch

clutch ................................................................ 34 W
g00792850
Illustration 9

(1) V-belt tension

New V-belt .................. 578 111 N (130 25 lb)
Used V-belt ................... 445 44 N (100 10 lb)


34 SENR5664-13
i01712086 Note: Use a Caterpillar 144-0235 Belt Tightener.

Refrigerant Compressor Type of compressor ..................................... TM-08B
SMCS Code: 1802 Displacement per revolution ......... 82 mL (2.77 fl oz)
Part No.: 125-1782
S/N: KGA1-Up
Part No.: 125-1782 R-134a Refrigerant
S/N: AKG1-Up
Part No.: 125-1782
S/N: 9PR1-Up ICI ........................................................... KLEA 134a
Part No.: 125-1782 Refrigerant Oil
S/N: 3YS1-Up
Part No.: 125-1782 Type of compressor oil ................................ ND-OIL8
S/N: BAS1-Up
Oil capacity of compressor .. 150.0 mL (5.07 ounces)
Part No.: 125-1782
S/N: AEX1-Up Magnetic Clutch
Part No.: 125-1782 Rated voltage of magnetic clutch .................. 24 VDC

S/N: 9CZ1-Up
Power consumption .............................. 45 W or less
Compressor
Effective pulley diameter .............. 125 mm (4.9 inch)
g00881048
Illustration 10
(1) Belt tension

NewV-belt ....................... 535 22 N (120 5 lb)
Used V-belt ..................... 400 44 N (90 10 lb)

(90 10 lb).
SENR5664-13 35
i02413968 R-134a Refrigerant

Refrigerant Compressor DuPont ........................ SUVA TRANS A/C HFC134a
SMCS Code: 1802 ICI ........................................................... KLEA 134a
Part No.: 189-2746
Magnetic Clutch
S/N: KJA1-Up
Part No.: 189-2746 Voltage of Magnetic Clutch ........................... 24 VDC
S/N: PCA1-Up
Maximum RPM .......................................... 7000 rpm
Part No.: 189-2746
S/N: MCF1-Up
i01934402
Part No.: 189-2746
S/N: KCX1-Up Refrigerant Compressor
SMCS Code: 1802
Part No.: 154-0490
S/N: BBG1-Up
Part No.: 154-0490
S/N: 8GM299-Up
Part No.: 154-0490
S/N: 7EN303-Up
Part No.: 154-0490
S/N: 9HN399-Up
Part No.: 154-0490
S/N: 2JR1-Up
Part No.: 154-0490
S/N: 2RR426-Up
Part No.: 154-0490
S/N: 3LR1-Up
g00881921
Illustration 11 Part No.: 154-0490
S/N: 3NR307-Up
(1) V-belt tension
Part No.: 154-0490
New V-belt ...................... 535 22 N (120 5 lb) S/N: 4NR176-Up
Used V-belt ..................... 400 44 N (90 10 lb)
Part No.: 154-0490
Note: Used belt tension is for a belt that has been S/N: 5BR1639-Up
Part No.: 154-0490
S/N: 5CR264-Up
(90 10 lb). Part No.: 154-0490
S/N: 6CR2902-Up
Part No.: 154-0490
Displacement per revolution ....... 147 mL (4.97 fl oz) S/N: 6DR1-Up

S/N: 8GR1-Up
Oil capacity ................................... 210 mL (7.1 fl oz) Part No.: 154-0490
S/N: 8JR1008-Up
Air Conditioning System. Part No.: 154-0490
S/N: 8MR189-Up
36 SENR5664-13
Part No.: 154-0490 Part No.: 154-0490

S/N: 8NR244-Up S/N: 5GW221-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8PR262-Up S/N: 5EZ253-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8RR1-Up S/N: 7KZ1-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8SR418-Up S/N: 7RZ284-Up
Part No.: 154-0490
S/N: 8TR486-Up Compressor
Part No.: 154-0490
S/N: 9GR413-Up
Part No.: 154-0490
S/N: 1AS1-Up
Part No.: 154-0490
S/N: 1BS1-Up
Part No.: 154-0490
S/N: 1DS1-Up
Part No.: 154-0490
S/N: 1ES1-Up
Part No.: 154-0490
S/N: 1GS144-Up
Part No.: 154-0490
S/N: 1HS1-Up
Part No.: 154-0490
S/N: 1JS485-Up g00887095
Illustration 12
Part No.: 154-0490
S/N: 1KS1-Up (1) V-belt tension
Part No.: 154-0490 New V-belt ...................... 534 22 N (120 5 lb)

S/N: 2LS204-Up Used V-belt ..................... 400 44 N (90 10 lb)
Part No.: 154-0490 Note: Used belt tension is for a belt that has been
S/N: 2NS156-Up operated for at least 30 minutes at rated speed.
Part No.: 154-0490 adjust the tension of the drive belt to 400 44 N
S/N: 3FS255-Up (90 10 lb).
Part No.: 154-0490
S/N: 6LS310-Up Note: Use a 144-0235 Belt Tension Gauge.
Part No.: 154-0490 (2) Power connection ................ 2 pin DT connector

S/N: 9JS270-Up
(3) The port for charging on the low pressure side
Part No.: 154-0490 has a plastic cap.
S/N: 1SW215-Up
(4) Refer to Specifications, Refrigerant Relief Valve
Part No.: 154-0490 for specified pressures.
S/N: 3AW1-Up
Part No.: 154-0490 Type of compressor ................................... 10PA15C
S/N: 4XW104-Up
SENR5664-13 37
Maximum allowable continuous RPM ............... 6000 V-belt

R-134a Refrigerant Table 1
Product
DuPont ........................ SUVA TRANS A/C HFC134a V-belt
Model Identification
(A-ribbed)
Number
ICI ........................................................... KLEA 134a
311B 8GR462-UP 68-5590
Compressor Oil 311B 2LS204-UP 68-5590
312B 9GR413-UP 68-5590
312BL 8JR1008-UP 68-5590
Oil capacity of compressor ......... 180 mL (6 ounces)
312B 2NS156-UP 68-5590
Magnetic Clutch 312BL 3FS255-UP 68-5590
Type of magnetic clutch ...................................... L50 315B 1SW215-UP 8L-8646

315BL 3AW990-UP 8L-8646
Effective pulley diameter ..... 133.0 mm (5.20 inches)
315BL 7RZ284-UP 8L-8646
Rated voltage of magnetic clutch .................. 24 VDC 318B 3LR1-UP 8L-8646
Power consumption ................................. 14.4 Ohms 318BN 7KZ1-UP 8L-8646

320B 5BR1639-UP 8L-8646
Maximum current ......................................... 1.2 Amp
320B 8ES1639-UP 8L-8646
320B 4XW104-UP 8L-8646
320BL 9CS2902-UP 8L-8646
320BL 6CR2902-UP 8L-8646
320BL 5GW221-UP 8L-8646
320BLL 6LS310-UP 8L-8646
320BLL 9JS270-UP 8L-8646
320BN 4NR176-UP 8L-8646
322B 8MR189-UP 9L-1128
322B 3NR307-UP 9L-1128
322B 5CR264-UP 9L-1128
322BL 8NR244-UP 9L-1128
322BL 1AS347-UP 9L-1128
325B 8PR262-UP 5M-8135
325B 8GM299-UP 5M-8135
325B 7EN303-UP 5M-8135
325BL 8RR386-UP 5M-8135
325BL 1GS144-UP 5M-8135
330B 8SR418-UP 1N-4635
330B 9HN399-UP 1N-4635
330B 2RR426-UP 1N-4635
330BL 8TR486-UP 1N-4635
330BL 1JS485-UP 1N-4635
330B 5EZ253-UP 1N-4635
38 SENR5664-13
i02039238 Note: Used belt tension is for a belt that has been
Refrigerant Compressor Operate the air conditioner for 30 minutes. Then,
SMCS Code: 1802
Part No.: 231-6984
Gauge in order to test the tension of the belt.
S/N: CJC1-Up
S/N: CCD1-Up Displacement per revolution .... 188.0 mL (6.36 fl oz)
Part No.: 231-6984 Maximum allowable speed ........................ 6000 rpm

S/N: GAD1-Up
R-134a Refrigerant
Part No.: 231-6984
S/N: EAG1-Up DuPont ........................ SUVA TRANS A/C HFC134a
Part No.: 231-6984
S/N: BWH1-Up ICI ........................................................... KLEA 134a
Part No.: 231-6984 Refrigerant Oil

S/N: AXK1-Up
Part No.: 231-6984
S/N: KGL1-Up Type of compressor oil .................. DENSO ND-OIL8
Part No.: 231-6984
Cat 4C-2959 Air Conditioner Lubricant (PAG)
S/N: DBN1-Up
S/N: HKT1-Up Magnetic Clutch

clutch ................................................................ 40 W
i01976068
SMCS Code: 1802
Part No.: 178-5545
S/N: 1011-Up
S/N: 3011-Up
Part No.: 178-5545
S/N: 1021-Up
S/N: 2021-Up
g01048780
S/N: 3021-Up
Illustration 13
Part No.: 178-5545
Refer to Specifications, Air Conditioner Lines for S/N: 1031-Up
Part No.: 178-5545
(1) V-belt tension S/N: 1041-Up
New V-belt .................. 578 111 N (130 25 lb) Part No.: 178-5545
Used V-belt ................... 445 44 N (100 10 lb) S/N: BLA1-Up
Part No.: 178-5545
S/N: CYA1-Up
SENR5664-13 39
Part No.: 178-5545 Part No.: 178-5545

S/N: HAA1-Up S/N: G1L1-Up
Part No.: 178-5545 Part No.: 178-5545
S/N: MCA1-Up S/N: B3M1-Up
Part No.: 178-5545 Part No.: 178-5545
S/N: CRB1-Up S/N: BMM1-Up
Part No.: 178-5545 Part No.: 178-5545
S/N: JAB1-Up S/N: BTM1-Up
S/N: D3C1-Up Part No.: 178-5545
S/N: MKM1-Up
Part No.: 178-5545
S/N: S2C1-Up Part No.: 178-5545
S/N: S3M1-Up
Part No.: 178-5545
S/N: BTD1-Up Part No.: 178-5545
S/N: B4N1-Up
Part No.: 178-5545
S/N: JCD1-Up Part No.: 178-5545
S/N: Y4P1-Up
Part No.: 178-5545
S/N: JLD1-Up Part No.: 178-5545
S/N: C3R1-Up
Part No.: 178-5545
S/N: KDD1-Up Part No.: 178-5545
S/N: EMR1-Up
Part No.: 178-5545
S/N: BFE1-Up Part No.: 178-5545
S/N: LAR1-Up
Part No.: 178-5545
S/N: DTF1-Up Part No.: 178-5545
S/N: MAR1-Up
Part No.: 178-5545
S/N: GAG1-Up Part No.: 178-5545
S/N: BKT1-Up
Part No.: 178-5545
S/N: AMH1-Up Part No.: 178-5545
S/N: BKW1-Up
Part No.: 178-5545
S/N: BKH1-Up Part No.: 178-5545
S/N: BLX1-Up
Part No.: 178-5545
S/N: M2H1-Up Part No.: 178-5545
S/N: GKX1-Up
Part No.: 178-5545
S/N: RBH1-Up Part No.: 178-5545
S/N: DKY1-Up
Part No.: 178-5545
S/N: CSJ1-Up Part No.: 178-5545
S/N: CGZ1-Up
Part No.: 178-5545
S/N: B1K1-Up
Part No.: 178-5545
S/N: HEK1-Up
Part No.: 178-5545
S/N: JNK1-Up
Part No.: 178-5545
S/N: M2K1-Up
Part No.: 178-5545
S/N: B2L1-Up
40 SENR5664-13
Compressor S/N: CCC1-Up

Part No.: 161-3632
S/N: AGD1-Up
S/N: FEE1-Up
Part No.: 161-3632
S/N: BKF1-Up
Part No.: 161-3632
S/N: BTH1-Up
Part No.: 161-3632
S/N: CFJ1-Up
Part No.: 161-3632
S/N: ALL1-Up
Part No.: 161-3632
S/N: 5WS1-Up
Part No.: 161-3632
S/N: 6XS1-Up
g00880847
Illustration 14 Part No.: 161-3632
S/N: DET1-Up
Type of 146-0894 Belt ............................. (8K)-Poly
Part No.: 161-3632
Displacement per revolution .... 188.0 mL (6.36 fl oz) S/N: 2ZW1-Up
Part No.: 161-3632
Maximum allowable continuous RPM ............... 6000 S/N: 6MW1-Up
R-134a Refrigerant Part No.: 161-3632
S/N: 8KW1-Up
Part No.: 161-3632
ICI ........................................................... KLEA 134a S/N: 8RW1-Up

S/N: 9CW1-Up
Oil capacity of compressor ...... 180.0 mL (6.10 fl oz) Part No.: 161-3632
S/N: AKX1-Up
Type of compressor oil ..................... Denso ND-OIL8
Part No.: 161-3632
Caterpillar 4C-2959 Air Conditioner Lubricant (PAG) S/N: BKX1-Up
Magnetic Clutch Part No.: 161-3632

S/N: BLY1-Up
Part No.: 161-3632
S/N: 4XZ1-Up
Resistance ............................................... 14.4 Ohms
i01934419
SMCS Code: 1802
Part No.: 161-3632
S/N: AMA1-Up
SENR5664-13 41
Compressor Rated voltage of magnetic clutch .................. 24 VDC
Power consumption ................................. 14.4 Ohms
i01723517
SMCS Code: 1802
Part No.: 113-3499
S/N: AMA1-Up
Part No.: 113-3499
Illustration 15
g00887192 S/N: AGD1-Up
(1) Belt tension Part No.: 113-3499

S/N: ALD1-Up
New belt .......................... 800 22 N (180 5 lb)
Used belt ...................... 489 44 N (110 10 lb) Part No.: 113-3499
S/N: BTH1-Up
Note: Used belt tension is for a belt that has been Part No.: 113-3499
operated for at least 30 minutes at the rated speed. S/N: 8WJ77-Up
adjust the tension of the drive belt to 489 44 N Part No.: 113-3499
(110 10 lb). S/N: AKJ1-Up
Note: Use a Caterpillar 144-1102 Belt Tightener. Part No.: 113-3499

S/N: CDJ1-Up
Type of 146-0894 Belt ............................. (8K)-Poly
Part No.: 113-3499
S/N: CFJ1-Up
(2) Power connection ................ 2 pin DT connector
Part No.: 113-3499
(3) The port for charging on the low pressure side S/N: 6NK1-Up
has a plastic cap.
Part No.: 113-3499
(4) Refer to Specifications, Refrigerant Relief Valve S/N: 6XK89-Up
for specified pressures.
Part No.: 113-3499
Type of compressor ................................... 10PA15C S/N: 8HK144-Up
Part No.: 113-3499
Displacement per revolution .... 155.3 mL (5.25 fl oz) S/N: 2ZL1-Up
Maximum allowable continuous RPM ............... 6000 Part No.: 113-3499
S/N: 3ML1-Up
R-134a Refrigerant
Part No.: 113-3499
DuPont ........................ SUVA TRANS A/C HFC134a S/N: 6RL1-Up
ICI ........................................................... KLEA 134a Part No.: 113-3499

S/N: 9FL121-Up
S/N: 9WL87-Up
Part No.: 113-3499
Oil capacity of compressor .. 180.0 mL (6.10 ounces) S/N: ALL1-Up
Magnetic Clutch Part No.: 113-3499

S/N: 1JM46-Up
Type of magnetic clutch ...................................... L50
Part No.: 113-3499
S/N: 5WS1-Up
42 SENR5664-13
Part No.: 113-3499 (4) Refer to Specifications, Refrigerant Relief Valve

S/N: 6XS1-Up for specified pressures.
Part No.: 133-3499 Displacement per revolution .... 155.3 mL (5.25 fl oz)
S/N: ALT1-Up
Part No.: 113-3499
S/N: 6MW1-Up
R-134a Refrigerant
Part No.: 113-3499
S/N: 8KW1-Up DuPont ........................ SUVA TRANS A/C HFC134a
Part No.: 113-3499 ICI ........................................................... KLEA 134a

S/N: 8RW1-Up
Compressor Oil
Part No.: 113-3499
S/N: 9CW1-Up Type of compressor oil ................................ ND-OIL8
Part No.: 113-3499
S/N: AKX1-Up Oil capacity of compressor ......... 180 mL (6 ounces)
Part No.: 113-3499 Magnetic Clutch

S/N: 4XZ1-Up
Effective pulley diameter ................. 152 mm (6 inch)
i02334021
SMCS Code: 1802
Part No.: 245-7779
S/N: 1011-Up
Part No.: 245-7779
S/N: 3011-Up
Part No.: 245-7779
S/N: 5111-Up
Part No.: 245-7779
S/N: 5211-Up
g00887095 Part No.: 245-7779

Illustration 16
S/N: 5411-Up
(1) V-belt tension Part No.: 245-7779
S/N: 5511-Up
New V-belt ...................... 534 22 N (120 5 lb)
Used V-belt ..................... 400 44 N (90 10 lb) Part No.: 245-7779
S/N: 1021-Up
operated for at least 30 minutes at rated speed. Part No.: 245-7779
Operate the air conditioner for 30 minutes. Then, S/N: 2021-Up
(90 10 lb). Part No.: 245-7779
S/N: 3021-Up
Note: Use a 144-0235 Belt Tension Gauge. Part No.: 245-7779
S/N: 5221-Up
(2) Power connection ................. 2 pin DT connector
Part No.: 245-7779
(3) The port for charging on the low pressure side S/N: 5321-Up
has a plastic cap.
SENR5664-13 43
Part No.: 245-7779 S/N: PJW1-Up

S/N: 5521-Up
Part No.: 245-7779
Part No.: 245-7779 S/N: WAW1-Up
S/N: 1031-Up
S/N: CPX1-Up
Part No.: 245-7779
S/N: 1041-Up S/N: BWY1-Up
S/N: EDA1-Up S/N: MCY1-Up
S/N: MMA1-Up S/N: SRY1-Up
S/N: TBA1-Up S/N: MNZ1-Up
S/N: XJA1-Up
Compressor
S/N: KGB1-Up
S/N: ELC1-Up
S/N: FPC1-Up
S/N: GWC1-Up
S/N: KBC1-Up
S/N: ESD1-Up
S/N: SBE1-Up
S/N: T2E1-Up
S/N: WDE1-Up
S/N: T2F1-Up
S/N: TDG1-Up
S/N: GPH1-Up
Part No.: 245-7779 g00880847
Illustration 17
S/N: TAJ1-Up
S/N: KKK1-Up Type of 146-0894 Belt ............................. (8K)-Poly
S/N: EAM1-Up Displacement per revolution .... 188.0 mL (6.36 fl oz)

S/N: JCM1-Up Maximum allowable continuous RPM ............... 6000
S/N: MEM1-Up
R-134a Refrigerant
S/N: FEN1-Up
S/N: PAN1-Up
ICI ........................................................... KLEA 134a
S/N: DHP1-Up
S/N: GJR1-Up Refrigerant Oil
S/N: M2R1-Up Oil capacity of compressor ...... 200.0 mL (6.76 fl oz)

S/N: PAR1-Up Type of compressor oil ..................... Denso ND-OIL8
S/N: D3S1-Up
Caterpillar 4C-2959 Air Conditioner Lubricant (PAG)
S/N: LYS1-Up
Magnetic Clutch
S/N: MCS1-Up
S/N: GLT1-Up
Resistance ............................................... 14.4 Ohms
44 SENR5664-13
Effective pulley diameter ..... 140.0 mm (5.50 inches) (2) Final installation torque .. 25 7 Nm (18 5 lb ft)
(3) V-belt tension

i01727090
New V-belt ...................... 535 22 N (120 5 lb)
Refrigerant Compressor Used V-belt ..................... 400 44 N (90 10 lb)
SMCS Code: 1802 Note: Used belt tension is for a belt that has been
Part No.: 114-9484 operated for at least 30 minutes at the rated speed.
S/N: 8RD1-Up Operate the air conditioner for 30 minutes. Then,
Part No.: 114-9484
S/N: 9DF1-Up Note: Use a Caterpillar 144-0235 Belt Tension
Gauge.
Part No.: 114-9484
S/N: ABF1-Up Displacement per revolution .... 154.9 mL (5.20 fl oz)
Part No.: 114-9484 Recommended Compressor RPM ... 2500 200 rpm
S/N: 3BK1-Up
Part No.: 114-9484 Torque for Fittings
S/N: 5DK1-Up
Part No.: 114-9484
S/N: ADK1-Up Note: The 7/8 inch threaded fitting is located on
Part No.: 114-9484 15.8 mm (.62 inch).
S/N: 7DM1-Up
Torque for 3/4 inch threaded fitting ................ 17 Nm
Part No.: 114-9484
(150 lb in)
S/N: 6NN1-Up
Part No.: 114-9484 Note: The 3/4 inch threaded fitting is located on
S/N: 8DN1-Up the metal tube which has an internal diameter of
12.7 mm (.50 inch).
Part No.: 114-9484
S/N: AEN1-Up M10 x 1.5 retaining bolt torque ................ 25 7 Nm
(18 5 lb ft)
Part No.: 114-9484
S/N: 1DR201-Up Note: The retaining bolt is for the block fitting.
Part No.: 114-9484
S/N: 4DZ1-Up Refrigerant Oil
Oil capacity ...................................... 270 mL (9 fl oz)

Air Conditioning System.
Cat 4C-2959 Air Conditioner Lubricant (250 mL

(8.45 Oz))
R-134a Refrigerant
Illustration 18
g00887199 ICI ........................................................... KLEA 134a
(1) Torque for oil plug ....... 10 2 Nm (89 18 lb in) Magnetic Clutch
Note: Oil plug (1) is under pressure when the system Clutch 12 DCV coil resistance (Black
is pressurized. wire) ................................................ 3.5 0.15 ohms
SENR5664-13 45
Minimum voltage for engagement ............... 7.5 DCV (4) Final installation torque .. 25 7 Nm (18 5 lb ft)
Maximum Current ...................................... 3.58 amp (5) V-belt tension

New V-belt ...................... 535 22 N (120 5 lb)
i01727244 Used V-belt ..................... 400 44 N (90 10 lb)
Refrigerant Compressor Note: Used belt tension is for a belt that has been
SMCS Code: 1802 Operate the air conditioner for 30 minutes. Then,
Part No.: 3E-1907 adjust the tension of the drive belt to 400 N (90 lb).
S/N: 8SG5327-Up
Part No.: 3E-1907 Gauge.
S/N: 5YJ1546-Up
Part No.: 3E-1907
S/N: 6MJ650-Up Recommended Compressor RPM ... 2500 200 rpm
Part No.: 3E-1907
Torque for Fittings
S/N: 7EJ2812-Up
Part No.: 3E-1907 Torque for 7/8 inch threaded fitting .. 25 Nm (18 lb ft)
S/N: 3KK1136-Up
Part No.: 3E-1907 the metal tube which has an internal diameter of
S/N: 8ZK1769-Up 15.8 mm (.62 inch).
Part No.: 3E-1907 Torque for 3/4 inch threaded fitting ................ 17 Nm
S/N: 9TK1-Up (150 lb in)
Part No.: 3E-1907
S/N: 4GR1-Up
12.7 mm (.50 inch).
M10 x 1.5 retaining bolt torque ................ 25 7 Nm

(18 5 lb ft)
Note: The retaining bolt is for the block fitting.
Refrigerant Oil
Oil capacity .................................... 300 mL (10 fl oz)

Illustration 19
g00887217 Poly Alkaline Glycol Oil (PAG)
(1) Installation torque for pressure switch Cat 4C-2959 Air Conditioner Lubricant (250 mL
...................... 8.0 1.5 Nm (71.00 13.00 lb in) (8.45 Oz))
(2) Pressure relief valve R-134a Refrigerant
Opening pressure of pressure relief DuPont ........................ SUVA TRANS A/C HFC134a
valve ................... 3800 300 kPa (551 44 psi)
Closing pressure of pressure relief ICI ........................................................... KLEA 134a
valve ..................................... 2900 kPa (421 psi)
Magnetic Clutch
Clutch 12 DCV coil resistance (Black
Note: Oil plug (3) is under pressure when the system wire) ................................................ 3.5 0.15 ohms
is pressurized.
Minimum voltage for engagement ............... 7.5 DCV
46 SENR5664-13
Maximum Current ...................................... 3.58 amp Part No.: 3E-1908

S/N: FDH1-Up
i01727253 Part No.: 3E-1908
S/N: FGH1-Up
Part No.: 3E-1908
SMCS Code: 1802 S/N: JMH1-Up
S/N: EAA1-Up S/N: 2ZJ375-1964
S/N: FEA1-Up S/N: 5YJ1546-Up
S/N: GCA1-Up S/N: 6MJ650-Up
S/N: BNB1-Up S/N: 7EJ2812-Up
S/N: WGB1-Up S/N: 3KK1136-Up
S/N: BKC1-Up S/N: 8ZK1796-Up
S/N: BMC1-Up S/N: 9TK1-Up
S/N: CFC1-Up S/N: BNK1-Up
S/N: FDC1-Up S/N: 2YL1-Up
S/N: BLD1-Up S/N: 5BL386-Up
S/N: HYD1-Up S/N: 6KL1-Up
S/N: BPE1-Up S/N: 6SL172-Up
S/N: 1KF1040-Up S/N: 6YL141-Up
S/N: 6XF1-Up S/N: 7XL107-Up
S/N: CFF1-Up S/N: 7YL64-Up
S/N: 8SG5327-Up S/N: 8DL35-Up
S/N: BRG1-Up S/N: 8EL57-Up
S/N: RKG1-Up S/N: 9CL78-Up
S/N: CNH1-Up S/N: 9EL48-Up
SENR5664-13 47

S/N: BLL1-Up S/N: 1WR1-Up
S/N: BML1-Up S/N: 1XR1-Up
S/N: 4ZN1-Up S/N: 1YR1-Up
S/N: 5YN1-Up S/N: 1ZR1-Up
S/N: 6XN1-Up S/N: 2AR1-Up
S/N: 7WN1-Up S/N: 2BR1-Up
S/N: 8RN1-Up S/N: 2CR1-Up
S/N: 8TN1-Up S/N: 2DR1-Up
S/N: 9JN1-Up S/N: 4GR1-Up
S/N: 9KN1-Up S/N: 5AR1-Up
S/N: BLN1-Up S/N: BKR1-Up
S/N: BPN1-Up S/N: BYR1-Up
S/N: CFN1-Up S/N: 4KS1-Up
S/N: BGP1-Up S/N: 4LS1-Up
S/N: FDP1-Up S/N: 4MS1-Up
S/N: 1CR1-Up S/N: 4TS1-Up
S/N: 1ER1-Up S/N: 5GS1-Up
S/N: 1FR1-Up S/N: 5HS1-Up
S/N: 1MR1-Up S/N: 5JS1-Up
S/N: 1NR1-Up S/N: 6BS1-Up
S/N: 1PR1-Up S/N: 6CS1-Up
S/N: 1RR1-Up S/N: 6DS1-Up
S/N: 1TR1-Up S/N: 6GS1-Up
48 SENR5664-13
Part No.: 3E-1908 Opening pressure of pressure relief valve

S/N: 6HS1-Up ............................ 3800 300 kPa (551 44 psi)
Sealing pressure of pressure relief
Part No.: 3E-1908 valve ..................................... 2900 kPa (421 psi)
S/N: 6JS1-Up
Part No.: 3E-1908
S/N: 6KS1-Up
Note: Oil plug (3) is under pressure when the system
Part No.: 3E-1908 is pressurized.
S/N: 6ZS1-Up
Part No.: 3E-1908
S/N: 7PS1-Up (5) V-belt tension
Part No.: 3E-1908 New V-belt ...................... 535 22 N (120 5 lb)
S/N: 8BS1-Up Used V-belt ..................... 400 44 N (90 10 lb)
Part No.: 3E-1908 Note: Used belt tension is for a belt that has been
S/N: 8CS1-Up operated for at least 30 minutes at the rated speed.
Part No.: 3E-1908 Operate the air conditioner for 30 minutes. Then,
S/N: 8ZS1-Up adjust the tension of the drive belt to 400 N (90 lb).
Part No.: 3E-1908 Note: Use a Caterpillar 144-0235 Belt Tension

S/N: 9TS1-Up Gauge.
Part No.: 3E-1908 Displacement per revolution .... 154.9 mL (5.20 fl oz)
S/N: BNS1-Up
Part No.: 3E-1908
S/N: BMT1-Up Torque for Fittings
Part No.: 3E-1908
S/N: 1FW1-Up Torque for 7/8 inch threaded fitting .. 25 Nm (18 lb ft)
Part No.: 3E-1908 Note: The 7/8 inch threaded fitting is located on
S/N: FDW1-Up the metal tube which has an internal diameter of
15.8 mm (0.62 inch).
Part No.: 3E-1908
S/N: TLX1-Up Torque for 3/4 inch threaded fitting ................ 17 Nm
(150 lb in)
Part No.: 3E-1908
S/N: BRY1-Up
12.7 mm (.50 inch).

(18 5 lb ft)
Refrigerant Oil

g00887217
Illustration 20
(1) Installation torque for pressure
switch ...................... 8.0 1.5 Nm (71 13 lb in) Cat 4C-2959 Air Conditioner Lubricant (250 mL
(8.45 Oz))
(2) Pressure relief valve
SENR5664-13 49
R-134a Refrigerant New belt ...................... 578 111 N (130 25 lb)

Used belt ...................... 445 44 N (100 10 lb)
ICI ........................................................... KLEA 134a operated for at least 30 minutes at the rated speed.
Magnetic Clutch adjust the tension of the drive belt to 445 44 N
(100 10 lb).
wire) ................................................ 3.5 0.15 ohms Note: Use a Caterpillar 144-0235 Belt Tension
Gauge.
Type of connector ............................... DT Connector
Minimum voltage for engagement of clutch .. 7.5 DCV
Recommended compressor RPM .... 2500 200 rpm
Maximum allowable RPM ................................. 4000
i01935556
Refrigerant Oil
Refrigerant Compressor Oil capacity ...................................... 180 mL (6 fl oz)
SMCS Code: 1802
Part No.: 222-2276 Air Conditioning System.
S/N: 4CS130-Up
Part No.: 222-2276
S/N: 4HZ1-Up R-134a Refrigerant
ICI ........................................................... KLEA 134a
Magnetic Clutch
Clutch 24 DCV coil resistance ............... 13.4 ohms
Maximum current ....................................... 1.79 amp
g01007514
Illustration 21

Opening pressure of the relief
valve ................................ 3500 kPa to 4100 kPa
(508 psi to 595 psi)
Sealing pressure of the relief valve ..... 2000 kPa
(290 psi)
(3) Belt tension

50 SENR5664-13
i02528525 Refrigerant Oil

Refrigerant Compressor Oil capacity .................................... 300 mL (10 fl oz)
SMCS Code: 1802 Note: Refer to Systems Operation, Identifying the
Part No.: 151-5270
S/N: 7DM1-Up

(8.45 Oz))
R-134a Refrigerant
ICI ........................................................... KLEA 134a
Magnetic Clutch

wire) ................................................ 3.5 0.15 ohms
i01727258
g00754247
Illustration 22
(1) Torque for oil plug ....... 10 2 Nm (89 18 lb in) SMCS Code: 1802
Note: Oil plug (1) is under pressure when the system Part No.: 134-3997
is pressurized. S/N: 7NC5527-Up
(2) Final installation torque .. 25 7 Nm (18 5 lb ft) Part No.: 134-3997

S/N: 8FC5612-Up
Part No.: 134-3997
Opening pressure of the relief S/N: 8RC5967-Up
valve ................... 3800 300 kPa (550 44 psi)
Sealing pressure of the relief valve ..... 2900 kPa Part No.: 134-3997
(420 psi) S/N: 9HC5521-Up
Part No.: 134-3997
Belt tension S/N: 9TC1-Up
New belt .......................... 800 22 N (180 5 lb) Part No.: 134-3997
Used belt ...................... 489 44 N (110 10 lb) S/N: 1DD6006-Up
Note: Used belt tension is for a belt that has been Part No.: 134-3997
operated for at least 30 minutes at the rated speed. S/N: 1KF1040-Up
adjust the tension of the drive belt to 489 44 N Part No.: 134-3997
(110 10 lb). S/N: 1SF1337-Up
Part No.: 3E-1909
S/N: 6NG234-Up
S/N: 8BG2191-Up
SENR5664-13 51
Part No.: 134-3997 Part No.: 3E-1909

S/N: 1XJ1-Up S/N: 2XL1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 3BJ100-Up S/N: 3CL751-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 5TJ1317-Up S/N: 4CL165-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 5XJ1-Up S/N: 4EL196-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 6XJ523-Up S/N: 5DL167-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 7XJ124-Up S/N: 6XL170-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 8CJ1221-Up S/N: 7PL103-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 8PJ533-Up S/N: 1KM1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 8RJ4387-Up S/N: 1YM181-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 9GJ945-Up S/N: 2LM348-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 9YJ1078-Up S/N: 2RM142-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 3SK410-Up S/N: 7YM1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 4HK366-Up S/N: 8SM142-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 4NK147-Up S/N: 1GN1-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 4SK22-Up S/N: 4RN1-Up
S/N: 5SK745-Up S/N: 6FN238-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 7PK135-Up S/N: 6KN51-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 7TK1-Up S/N: 6MN75-Up
Part No.: 3E-1909 Part No.: 134-3997
S/N: 8AK1-Up S/N: 7PN75-Up
S/N: 8TK816-Up S/N: 7SN142-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 9JK361-Up S/N: 8JN1-Up
Part No.: 3E-1909 Part No.: 134-3997
S/N: 1JL1-Up S/N: 2KR1-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 1SL510-Up S/N: 2SR1-Up
52 SENR5664-13
Part No.: 134-3997 Torque for Fittings

S/N: 8ZR1-Up
Part No.: 134-3997
S/N: 63W4011-Up Note: The 7/8 inch threaded fitting is located on
Part No.: 134-3997
15.8 mm (.62 inch).
S/N: 64W195-Up
Part No.: 134-3997 Torque for 3/4 inch threaded fitting ................ 17 Nm
S/N: 21Z5346-Up (150 lb in)

12.7 mm (.50 inch).

(18 5 lb ft)
Refrigerant Oil

g00887217 Air Conditioning System.
Illustration 23
(1) Installation torque for pressure switch Poly Alkaline Glycol Oil (PAG)
...................... 8.0 1.5 Nm (71.00 13.00 lb in)
(2) Pressure relief valve (8.45 Oz))
Opening pressure of relief valve R-134a Refrigerant

............................ 3800 300 kPa (551 44 psi)
Sealing pressure of pressure relief valve DuPont ........................ SUVA TRANS A/C HFC134a
.............................................. 2900 kPa (421 psi)
ICI ........................................................... KLEA 134a
Magnetic Clutch
Note: Oil plug (3) is under pressure when the system
is pressurized. Clutch 24 DCV coil resistance (Green
wire) ................................................ 17.6 0.6 ohms
(5) V-belt tension
New V-belt ...................... 535 22 N (120 5 lb)
Used V-belt ..................... 400 44 N (90 10 lb)
Used belt tension is for a belt that has been operated

for at least 30 minutes at the rated speed. Operate
the air conditioner for 30 minutes. Then, adjust the
tension of the drive belt to 400 N (90 lb).

Gauge.

SENR5664-13 53
i02509605 4C-2959 Air Conditioner Oil

Refrigerant Compressor Capacity ............................... 180 cc (6.1 fluid oz)
SMCS Code: 1802 Rotation ...................... CW rotation or CCW rotation
Part No.: 217-4448 Recommended RPM at rated engine

S/N: FDB1-Up speed ............................................. 2500 200 RPM
Specifications for the Clutch

Voltage .......................................................... 24 VDC
Breakaway torque ........................... 59 Nm (43 lb ft)
Minimum voltage for clutch engagement ...... 16 VDC
Coil resistance at 20 C ........................... 13.4 Ohms
Maximum current at 20 C ......................... 1.79 amp
Belt type ............................................................ PV-8
g01128447
Illustration 24
(1) Relief valve

Installation Torque ............. 13 Nm (115.06 lb in)
Opening pressure of relief
valve ............. 3450 to 3920 kPa (500 to 568 psi)
(2) Bolt
Installation Torque ......... 25 7 Nm (18 5 lb ft)
Specifications for the Compressor

Bore ......................................... 32 mm (1.2598 inch)
Stroke ................................... 26.7 mm (1.0512 inch)
Displacement per revolution .. 214.7 cc (13.1010 in3)
Number of cylinders .............................................. 10
Maximum allowable RPM ................................. 4000
Refrigerant ..................................................... R134A
Oil
54 SENR5664-13
i01721298 Note: Use a Caterpillar 138-2514 Belt Tightener.

Refrigerant Compressor Displacement per revolution .... 154.9 mL (5.20 fl oz)
SMCS Code: 1802 Recommended Compressor RPM ... 2500 200 rpm
Part No.: 178-9570
Refrigerant Oil
S/N: SLA1-Up
Part No.: 178-9570 Oil capacity .................................... 300 mL (10 fl oz)
S/N: SLB1-Up
Part No.: 178-9570 Air Conditioning System.
S/N: SLC1-Up
Part No.: 178-9570
S/N: SLD1-Up Cat 4C-2959 Air Conditioner Lubricant (250 mL
Part No.: 178-9570 (8.45 Oz))
S/N: SLE1-Up
R-134a Refrigerant
Part No.: 178-9570
S/N: SLG1-Up DuPont ........................ SUVA TRANS A/C HFC134a
S/N: SLH1-Up ICI ........................................................... KLEA 134a
Magnetic Clutch
Clutch 24 DCV coil resistance ....... 17.6 0.6 ohms
i02512413
System Capacities for

Refrigerant (Agricultural
Tractors)
SMCS Code: 1809
Reference: For the proper procedure to handle

refrigerant, refer to Testing and Adjusting, Refrigerant
System - Charge.
g00884295
Illustration 25
(1) Torque for oil plug ....... 10 2 Nm (89 18 lb in) DV87 Refrigerant Capacities
Note: Oil plug (1) is under pressure when the system DV87
is pressurized. 9AM1-Up ......................................... 2 kg (4.4 lb)
Belt tension
Challenger 35 Refrigerant
New belt .......................... 800 22 N (180 5 lb)
Used belt ...................... 489 44 N (110 10 lb)
Capacities
Challenger 35
operated for at least 30 minutes at the rated speed. 8DN1-Up .......................................... 2.3 kg (5 lb)
Operate the air conditioner for 30 minutes. Then, 8RD1-Up .......................................... 2.3 kg (5 lb)
adjust the tension of the drive belt to 489 44 N AKD1-Up ......................................... 2.3 kg (5 lb)
(110 10 lb). 9DF1-Up .......................................... 2.3 kg (5 lb)
SENR5664-13 55
Challenger 45 Refrigerant Challenger 85 Refrigerant

Capacities Capacities
Challenger 45 Challenger 85C
4DZ1-Up .......................................... 2.3 kg (5 lb) 9TK1-Up ....................................... 1.9 kg (4.2 lb)
1DR201-Up ...................................... 2.3 kg (5 lb)
ABF1-Up .......................................... 2.3 kg (5 lb) Challenger 85D
3BK1-Up .......................................... 2.3 kg (5 lb)
4GR1-Up ...................................... 1.9 kg (4.2 lb)
Challenger 55 Refrigerant Challenger 85E
Capacities 6JS1-Up ........................................ 1.9 kg (4.2 lb)
Challenger 55
Challenger 95E Refrigerant
7DM1-200 ........................................ 2.3 kg (5 lb)
7DM201-Up ..................................... 2.3 kg (5 lb) Capacities
AEN1-Up ......................................... 2.3 kg (5 lb)
6NN1-Up .......................................... 2.3 kg (5 lb) Challenger 95E
5DK1-Up .......................................... 2.3 kg (5 lb)
6KS1-Up ....................................... 1.9 kg (4.2 lb)
Challenger 65 Refrigerant
i02501323
Capacities
Challenger 65C
Refrigerant (Articulated
2ZJ1-374 ...................................... 1.9 kg (4.2 lb)
2ZJ375-1964 ................................ 1.9 kg (4.2 lb)
Trucks)
SMCS Code: 1809
Challenger 65D
2ZJ1965-2299 .............................. 1.9 kg (4.2 lb) D20 Refrigerant Capacities
2ZJ2300-Up .................................. 2.1 kg (4.6 lb)
D20D
Challenger 65E
9MG119-Up ........................................ 2.0 kg (4.5 lb)
6GS1-Up ....................................... 1.9 kg (4.2 lb)
D25 Refrigerant Capacities
Challenger 70C Refrigerant
Capacities D25D
Challenger 70C 1HK424-Up ......................................... 2.0 kg (4.5 lb)
2YL1-Up ....................................... 1.9 kg (4.2 lb) D30 Refrigerant Capacities

Challenger 75 Refrigerant D30D
Capacities
3AJ331-Up .......................................... 2.0 kg (4.5 lb)
Challenger 75C
4KK374-Up ................................... 1.9 kg (4.2 lb)
Challenger 75D D40D

5AR1-Up ....................................... 1.9 kg (4.2 lb) 2JJ100-Up .......................................... 2.0 kg (4.5 lb)
Challenger 75E
6HS1-Up ....................................... 1.9 kg (4.2 lb)
56 SENR5664-13
D250 Refrigerant Capacities D400E Series II
D250D 8PS1-Up ............................................. 2.0 kg (4.5 lb)
6NG234-Up ......................................... 2.0 kg (4.5 lb) D400E Series II Ejector
D250E 8PS1-Up ............................................. 2.0 kg (4.5 lb)
5TN1-Up ............................................. 1.8 kg (4.0 lb) 725 Refrigerant Capacities

D250E Series II 725
4PS1-Up ............................................. 2.0 kg (4.5 lb) AFX1-Up ............................................. 2.0 kg (4.5 lb)
D300 Refrigerant Capacities 730 Refrigerant Capacities

D300D 730
5MG221-Up ........................................ 2.0 kg (4.5 lb) AGF1-Up ............................................. 2.0 kg (4.5 lb)
D300E 735 Refrigerant Capacities

7FN1-Up ............................................. 1.8 kg (4.0 lb)
735
D300E Series II AWR1-Up ............................................ 2.0 kg (4.5 lb)
5KS1-Up ............................................. 2.0 kg (4.5 lb)
740 Refrigerant Capacities
D350 Refrigerant Capacities 740
D350D AXM1-Up ............................................ 2.0 kg (4.5 lb)
9RF511-Up ......................................... 2.0 kg (4.5 lb)
740 Ejector
D350E AZZ1-Up ............................................. 2.0 kg (4.5 lb)
9LR1-Up ............................................. 1.8 kg (4.0 lb)
i02503130
D350E Series II System Capacities for

2XW1-Up ............................................ 2.0 kg (4.5 lb) Refrigerant (Backhoe Loaders)
SMCS Code: 1809
D400D 416 Refrigerant Capacities
8TF787-Up .......................................... 2.0 kg (4.5 lb) 416B
D400D 8SG5327-Up ....................................... 2.1 kg (4.6 lb)
4EJ1-Up .............................................. 2.0 kg (4.5 lb) 8ZK1769-Up ....................................... 2.1 kg (4.6 lb)
D400E 416C
2YR1-Up ............................................. 1.8 kg (4.0 lb) 4ZN1-Up ............................................. 1.8 kg (4.0 lb)
SENR5664-13 57
5YN1-Up ............................................. 1.8 kg (4.0 lb) 424 Refrigerant Capacities

1BR1-Up ............................................. 1.8 kg (4.0 lb) 424D
1KR1-Up ............................................. 1.8 kg (4.0 lb) BGP1-Up ............................................ 1.4 kg (3.0 lb)
1LR1-Up ............................................. 1.8 kg (4.0 lb) BKR1-Up ............................................. 1.4 kg (3.0 lb)
1WR1-Up ............................................ 1.8 kg (4.0 lb) CJZ1-Up ............................................. 1.4 kg (3.0 lb)
1XR1-Up ............................................. 1.8 kg (4.0 lb) RXA1-Up ............................................. 1.4 kg (3.0 lb)
416D 426 Refrigerant Capacities

CXP1-Up ............................................. 1.4 kg (3.0 lb)
426B
B2D1-Up ............................................. 1.4 kg (3.0 lb)
5YJ1546-Up ........................................ 2.1 kg (4.6 lb)
BFP1-Up ............................................. 1.4 kg (3.0 lb)
6KL1769-Up ........................................ 2.1 kg (4.6 lb)
BKG1-Up ............................................ 1.4 kg (3.0 lb)
426C
BGJ1-Up ............................................. 1.4 kg (3.0 lb)
6XN1-Up ............................................. 1.8 kg (4.0 lb)
416E
7WN1-Up ............................................ 1.8 kg (4.0 lb)
SHA1-Up ........................................... 3.2 kg (7.06 lb)
1CR1-Up ............................................. 1.8 kg (4.0 lb)
CST1-Up ........................................... 3.2 kg (7.06 lb)
1ER1-Up ............................................. 1.8 kg (4.0 lb)
420 Refrigerant Capacities 1MR1-Up ............................................ 1.8 kg (4.0 lb)
420D 1NR1-Up ............................................. 1.8 kg (4.0 lb)
FDP1-Up ............................................. 1.4 kg (3.0 lb) 1YR1-Up ............................................. 1.8 kg (4.0 lb)
BKC1-Up ............................................. 1.4 kg (3.0 lb) 1ZR1-Up ............................................. 1.8 kg (4.0 lb)
BMC1-Up ............................................ 1.4 kg (3.0 lb)

MBH1-Up ............................................ 1.4 kg (3.0 lb)
428B
BLN1-Up ............................................. 1.4 kg (3.0 lb)
7EJ2812-Up ........................................ 2.1 kg (4.6 lb)
420E
428C
HLS1-Up ........................................... 3.2 kg (7.06 lb)
8RN1-Up ............................................. 1.8 kg (4.0 lb)
KMW1-Up ......................................... 3.2 kg (7.06 lb)
1HR1-Up ............................................. 1.8 kg (4.0 lb)
THP1-Up ........................................... 3.2 kg (7.06 lb)
1SR1-Up ............................................. 1.8 kg (4.0 lb)
422 Refrigerant Capacities 2CR1-Up ............................................. 1.8 kg (4.0 lb)
422E 428D
HBE1-Up ........................................... 3.2 kg (7.06 lb) BLL1-Up .............................................. 1.4 kg (3.0 lb)
BMT1-Up ............................................ 1.4 kg (3.0 lb)

58 SENR5664-13
BNS1-Up ............................................. 1.4 kg (3.0 lb) 436C

BNB1-Up ............................................. 1.4 kg (3.0 lb) 8TN1-Up ............................................. 1.8 kg (4.0 lb)
BXC1-Up ............................................. 1.4 kg (3.0 lb) 9JN1-Up .............................................. 1.8 kg (4.0 lb)
DSX1-Up ............................................. 1.4 kg (3.0 lb) 1FR1-Up ............................................. 1.8 kg (4.0 lb)
MBM1-Up ............................................ 1.4 kg (3.0 lb) 1GR1-Up ............................................. 1.8 kg (4.0 lb)
428E 1PR1-Up ............................................. 1.8 kg (4.0 lb)
SNL1-Up ........................................... 3.2 kg (7.06 lb) 1RR1-Up ............................................. 1.8 kg (4.0 lb)
2AR1-Up ............................................. 1.8 kg (4.0 lb)

2BR1-Up ............................................. 1.8 kg (4.0 lb)
430D
BML1-Up ............................................. 1.4 kg (3.0 lb)
BNK1-Up ............................................. 1.4 kg (3.0 lb) 438B

3KK1136-Up ....................................... 2.1 kg (4.6 lb)
430E
BYC1-Up ........................................... 3.2 kg (7.06 lb) 438C
DDT1-Up ........................................... 3.2 kg (7.06 lb) 1JR1-Up .............................................. 1.8 kg (4.0 lb)
EAT1-Up ........................................... 3.2 kg (7.06 lb) 9KN1-Up ............................................. 1.8 kg (4.0 lb)
1TR1-Up ............................................. 1.8 kg (4.0 lb)

2DR1-Up ............................................. 1.8 kg (4.0 lb)
432D
438D
BLD1-Up ............................................. 1.4 kg (3.0 lb)
BPN1-Up ............................................. 1.4 kg (3.0 lb)
TDR1-Up ............................................. 1.4 kg (3.0 lb)
BPE1-Up ............................................. 1.4 kg (3.0 lb)
WEP1-Up ............................................ 1.4 kg (3.0 lb)
432E
BXE1-Up ........................................... 3.2 kg (7.06 lb) 442D

BRY1-Up ............................................. 1.4 kg (3.0 lb)
BRG1-Up ............................................ 1.4 kg (3.0 lb)
434E
SMJ1-Up ............................................. 1.4 kg (3.0 lb)
FSH1-Up ........................................... 3.2 kg (7.06 lb)
TBD1-Up ............................................. 1.4 kg (3.0 lb)
442E
436B
GKZ1-Up ........................................... 3.2 kg (7.06 lb)
6MJ650-Up ......................................... 2.1 kg (4.6 lb)
7FL1-Up .............................................. 2.1 kg (4.6 lb)

SENR5664-13 59
444 Refrigerant Capacities i02503700
444E
Refrigerant (Compactors)
LBE1-Up ........................................... 3.2 kg (7.06 lb)
SMCS Code: 1809
446 Refrigerant Capacities Reference: For the proper procedure to handle
446B System - Charge.
5BL386-Up ........................................ 2.2 kg (4.85 lb)
Soil Compactors
6XF386-Up ....................................... 2.2 kg (4.85 lb)
446D
815B
DBL386-Up ....................................... 1.6 kg (3.53 lb) 17Z1614-Up .................................. 1.4 kg (3.1 lb)
i02504183 815F
System Capacities for BKL1-Up ....................................... 1.9 kg (4.2 lb)

Refrigerant (Compact Wheel 1GN1-Up ...................................... 2.1 kg (4.6 lb)
Loaders) 2BS1-Up ....................................... 1.9 kg (4.2 lb)
SMCS Code: 1809 815F II

BYN1-Up ...................................... 1.9 kg (4.2 lb)
904B
825B
B4L1-Up ............................................ 0.7 kg (1.54 lb)
43N1-Up ....................................... 1.9 kg (4.2 lb)
825C
906 86X1104-Up .................................. 2.1 kg (4.6 lb)
6ZS1-Up ........................................... 1.7 kg (3.75 lb) 89X1-Up ....................................... 1.4 kg (3.1 lb)
MER1-Up .......................................... 1.7 kg (3.75 lb) 825G

6RN1-Up ....................................... 2.5 kg (5.5 lb)
825G II
908
AXB1-Up ....................................... 2.5 kg (5.5 lb)
8BS1-Up ........................................... 1.6 kg (3.53 lb)
825H
TAR1-Up ........................................... 1.7 kg (3.75 lb) AZW1-Up ...................................... 2.5 kg (5.5 lb)
Landfill Compactors
816B
15Z1413-Up .................................. 2.5 kg (5.5 lb)
816F
60 SENR5664-13
5FN1-Up ....................................... 2.1 kg (4.6 lb) 304 CR Refrigerant Capacities

BMR1-Up ...................................... 1.6 kg (3.5 lb)
304 CR
816F II
NAD1-UP ...................................... 0.6 kg (1.3 lb)
BZR1-Up ....................................... 1.6 kg (3.5 lb)
305 CR Refrigerant Capacities
305 CR
826B
DSA1-UP ...................................... 0.6 kg (1.3 lb)
58U1-Up ....................................... 1.9 kg (4.2 lb) DGT1-UP ...................................... 0.8 kg (1.8 lb)
826C
313B Refrigerant Capacities
87X1700-Up .................................... 2.3 kg (5 lb)
313B CR
826G
BAS1-UP ......................................... 0.9 kg (2 lb)
7LN1-534 ...................................... 2.5 kg (5.5 lb)
7LN535-Up ................................... 1.6 kg (3.5 lb) 321B Refrigerant Capacities
826G II 321B LCR
AYH1-Up ....................................... 1.5 kg (3.3 lb) KGA1-UP ......................................... 0.9 kg (2 lb)
826H i02528643
AWF1-Up ...................................... 1.5 kg (3.3 lb) System Capacities for

836 Refrigerant Capacities Refrigerant (Excavators)
836 SMCS Code: 1809
3RL35-Up ........................................ 3 kg (6.6 lb) Reference: For the proper procedure to handle
7FR1-Up .......................................... 3 kg (6.6 lb) System - Charge.
836G
BRL1-Up ....................................... 1.5 kg (3.3 lb)
307B
7MZ1-Up ....................................... 1.5 kg (3.3 lb)
4RW1-UP ........................................ 0.9 kg (2 lb)
836H 7DZ1-UP .......................................... 0.9 kg (2 lb)
BXD1-Up ...................................... 1.5 kg (3.3 lb) 307B SB

AFB1-UP ...................................... 1.9 kg (4.2 lb)
i02545968 5CW1-UP ........................................ 0.9 kg (2 lb)
6KZ1-UP .......................................... 0.9 kg (2 lb)
Refrigerant (Excavators) i02499097
SMCS Code: 1809 System Capacities for

Reference: For the proper procedure to handle Refrigerant (Excavators)
System - Charge. SMCS Code: 1809

System - Charge.
SENR5664-13 61
307C Refrigerant Capacities 320B Refrigerant Capacities

307C 320B
BNE1-UP ......................................... 0.9 kg (2 lb) 5BR1-1638 ................................... 1.0 kg (2.2 lb)
BCM1-UP ........................................ 0.9 kg (2 lb) 8ES1-1638 .................................... 1.0 kg (2.2 lb)
9CS1-2901 ................................... 1.0 kg (2.2 lb)
4XW1-103 ..................................... 1.0 kg (2.2 lb)
311C Refrigerant Capacities
311C 320B L
6CR1-2901 ................................... 1.0 kg (2.2 lb)
CKE1-UP ......................................... 0.9 kg (2 lb)
PAD1-UP ......................................... 0.9 kg (2 lb) 5GW1-220 .................................... 1.0 kg (2.2 lb)
320B LL
6LS1-309 ......................................... 0.9 kg (2 lb)
320C L 9JS1-269 ......................................... 0.9 kg (2 lb)
HBC1-UP ......................................... 0.9 kg (2 lb) 320B N

4NR1-175 ..................................... 1.0 kg (2.2 lb)
i02518519
System Capacities for 322B Refrigerant Capacities

Refrigerant (Excavators) 322B
SMCS Code: 1809 8MR1-188 ..................................... 1.0 kg (2.2 lb)
Reference: For the proper procedure to handle 322B L

System - Charge. 8NR1-243 ..................................... 1.0 kg (2.2 lb)
1AS1-346 ...................................... 1.0 kg (2.2 lb)
311B
325B
8GR1-461 ..................................... 1.0 kg (2.2 lb)
2LS1-203 ...................................... 1.0 kg (2.2 lb) 8PR1-261 ..................................... 1.0 kg (2.2 lb)
325B L
8RR1-385 ..................................... 1.0 kg (2.2 lb)
312B 1GS1-143 ..................................... 1.0 kg (2.2 lb)
9GR1-412 ..................................... 1.0 kg (2.2 lb)
2NS1-155 ..................................... 1.0 kg (2.2 lb) 330B Refrigerant Capacities
312B L 330B
8JR1-1007 .................................... 1.0 kg (2.2 lb) 8SR1-417 ..................................... 1.0 kg (2.2 lb)
3FS1-254 ...................................... 1.0 kg (2.2 lb)
330B L
315B Refrigerant Capacities 8TR1-485 ...................................... 1.0 kg (2.2 lb)
1JS1-484 ...................................... 1.0 kg (2.2 lb)
315B
1SW1-214 ..................................... 1.0 kg (2.2 lb)
7RZ1-283 ...................................... 1.0 kg (2.2 lb)
315B L
3AW1-989 ..................................... 1.0 kg (2.2 lb)
62 SENR5664-13
i02518748 320B LL
System Capacities for 6LS310-UP ................................... 1.4 kg (3.1 lb)
9JS270-UP ................................... 1.4 kg (3.1 lb)
Refrigerant (Excavators)
SMCS Code: 1809 322B Refrigerant Capacities
Reference: For the proper procedure to handle 322B
System - Charge. 8MR189-UP .................................. 1.1 kg (2.4 lb)
322B L
8NR244-UP .................................. 1.1 kg (2.4 lb)
311B
8GR462-Up .................................. 1.1 kg (2.4 lb) 325B Refrigerant Capacities
2LS204-Up ................................... 1.1 kg (2.4 lb)
325B
312B Refrigerant Capacities 8PR262-UP .................................. 1.1 kg (2.4 lb)
312B 325B L
9GR413-Up .................................. 1.1 kg (2.4 lb) 8RR386-UP .................................. 1.1 kg (2.4 lb)
2NS156-Up ................................... 1.1 kg (2.4 lb)
312B L
8JR1008-UP ................................. 1.1 kg (2.4 lb) 330B
3FS255-Up ................................... 1.1 kg (2.4 lb) 8SR418-UP .................................. 1.2 kg (2.6 lb)
315B Refrigerant Capacities 330B L
315B 8TR486-UP ................................... 1.2 kg (2.6 lb)
1SW215-UP .................................. 1.1 kg (2.4 lb) 345B Refrigerant Capacities

315B L 345B
3LR1-UP ....................................... 1.1 kg (2.4 lb) 6XS1-UP ....................................... 1.1 kg (2.4 lb)
7RZ284-UP ................................... 1.4 kg (3.1 lb) 2ZW1-UP ...................................... 1.1 kg (2.4 lb)
3AW990-UP .................................. 1.1 kg (2.4 lb)
345B L
315B LN
5WS1-UP ...................................... 1.1 kg (2.4 lb)
7KZ1-UP ....................................... 1.1 kg (2.4 lb) 3MW1-UP ..................................... 1.1 kg (2.4 lb)
320B Refrigerant Capacities 365B Refrigerant Capacities

320B 365B L
4XW104-UP .................................. 1.1 kg (2.4 lb) AGD1-UP ...................................... 1.5 kg (3.3 lb)
5BR1639-UP ................................ 1.1 kg (2.4 lb)
365B LU
320B L
CJF1-UP ....................................... 1.4 kg (3.1 lb)
6CR2902-UP ................................ 1.1 kg (2.4 lb)
5GW221-UP ................................. 1.1 kg (2.4 lb)
320B N
385B
4NR176-UP .................................. 1.1 kg (2.4 lb)
SENR5664-13 63
BKF1-UP ...................................... 1.4 kg (3.1 lb) 7JR1-Up ....................................... 1.7 kg (3.7 lb)
2AS1-Up ....................................... 1.7 kg (3.7 lb)
385B L 9WS1-Up ...................................... 1.7 kg (3.7 lb)
6LW1-Up ....................................... 1.7 kg (3.7 lb)
BLY1-UP ....................................... 1.4 kg (3.1 lb)
320B LN
i02500379
3YZ1-Up ....................................... 1.7 kg (3.7 lb)
System Capacities for 320B S
5MS1-Up ...................................... 1.7 kg (3.7 lb)
SMCS Code: 1809
refrigerant, refer to Testing and Adjusting, Refrigerant 322B
System - Charge.
1YS1-Up ....................................... 1.7 kg (3.7 lb)
312B Refrigerant Capacities 322B L
312B 2ES1-Up ....................................... 1.7 kg (3.7 lb)
6SW1-Up ...................................... 1.0 kg (2.2 lb)
322B LN
9NW1-Up ...................................... 1.0 kg (2.2 lb)
1ZS1-Up ....................................... 1.7 kg (3.7 lb)
312B L
9FS1-Up ....................................... 1.0 kg (2.2 lb) 325B Refrigerant Capacities
2KW1-Up ...................................... 1.0 kg (2.2 lb)
325B L
315B Refrigerant Capacities 2JR1-Up ....................................... 1.7 kg (3.7 lb)
6DN1-Up ....................................... 1.7 kg (3.7 lb)
315B L 8FN1-Up ....................................... 1.7 kg (3.7 lb)
4DS1-Up ....................................... 1.7 kg (3.7 lb)
5SW1-Up ...................................... 1.5 kg (3.3 lb)
5BS1-Up ....................................... 1.7 kg (3.7 lb)
317B Refrigerant Capacities M325B Refrigerant Capacities

317B
M325B L
9WW1-Up ..................................... 1.5 kg (3.3 lb)
BGN1-Up ...................................... 1.7 kg (3.7 lb)
317B N
6DZ1-Up ....................................... 1.5 kg (3.3 lb)
330B
318B Refrigerant Capacities AME1-Up ...................................... 1.7 kg (3.7 lb)
4RS1-Up ....................................... 1.7 kg (3.7 lb)
318B L
ADC1-Up ...................................... 1.5 kg (3.3 lb) 330B L
3YR1-Up ....................................... 1.7 kg (3.7 lb)
318B LN
6DR1-Up ....................................... 1.7 kg (3.7 lb)
AEJ1-Up ....................................... 1.5 kg (3.3 lb) 5LS1-Up ....................................... 1.7 kg (3.7 lb)
330B LN
5LR1-Up ....................................... 1.7 kg (3.7 lb)
320B
1XS1-Up ....................................... 1.7 kg (3.7 lb) 345B Refrigerant Capacities
320B L 345B
64 SENR5664-13
BFG1-Up ...................................... 2.2 kg (4.8 lb) SDL1-Up ....................................... 1.9 kg (4.2 lb)
2NW1-Up ...................................... 2.2 kg (4.8 lb)
345B L
4SS1-Up ....................................... 2.2 kg (4.8 lb) 385B
7KS1-Up ....................................... 2.2 kg (4.8 lb)
MYA1-Up ...................................... 2.2 kg (4.8 lb)
9GS1-Up ....................................... 2.2 kg (4.8 lb) RCD1-Up ...................................... 2.2 kg (4.8 lb)
2SW1-Up ...................................... 2.2 kg (4.8 lb)
CLS1-Up ....................................... 2.2 kg (4.8 lb)
345B MH 385B L
APB1-Up ....................................... 2.2 kg (4.8 lb)
FDL1-Up ....................................... 2.2 kg (4.8 lb)
ANS1-Up ...................................... 2.2 kg (4.8 lb)
345B Series II Refrigerant
Capacities 5090B Refrigerant Capacities
345B Series II 5090B
ALB1-Up ....................................... 2.2 kg (4.8 lb) CLD1-Up ....................................... 2.2 kg (4.8 lb)
CCC1-Up ...................................... 2.2 kg (4.8 lb) SJY1-Up ....................................... 2.2 kg (4.8 lb)
FEE1-Up ....................................... 2.2 kg (4.8 lb)
ANJ1-Up ....................................... 2.2 kg (4.8 lb)
i02500666
CDJ1-Up ....................................... 2.2 kg (4.8 lb)
AGS1-Up ......................................
DET1-Up .......................................
2.2 kg (4.8 lb)
2.2 kg (4.8 lb)
DCW1-Up ..................................... 2.2 kg (4.8 lb) Refrigerant (Excavators)
345B Series II MH SMCS Code: 1809
CFM1-Up ...................................... 2.2 kg (4.8 lb) Reference: For the proper procedure to handle
W345B Series II Refrigerant System - Charge.
Capacities
W345B Series II
312C
CDY1-Up ...................................... 2.2 kg (4.8 lb)
BNN1-Up .................................... 0.80 kg (1.8 lb)
365B Refrigerant Capacities 312C L
365B L CBT1-Up ..................................... 0.80 kg (1.8 lb)
9PZ1-Up ....................................... 1.9 kg (4.2 lb)
9TZ1-Up ....................................... 1.9 kg (4.2 lb) 322C Refrigerant Capacities
365B MH 322C
CTY1-Up ....................................... 1.9 kg (4.2 lb) BPH1-Up .................................... 1.30 kg (2.9 lb)
CAM1-Up .................................... 1.30 kg (2.9 lb)
CBY1-Up .................................... 1.30 kg (2.9 lb)
365B Series II Refrigerant SLX1-Up ..................................... 1.30 kg (2.9 lb)
Capacities
322C L
365B Series II
BKJ1-Up ................................... 1.40 kg (3.09 lb)
JMB1-Up ....................................... 1.9 kg (4.2 lb) HEK1-Up .................................. 1.05 kg (2.32 lb)
DER1-Up ...................................... 1.9 kg (4.2 lb)
322C FM
365B Series II MH
M2H1-Up ....................................... 1.30 kg (3 lb)
SENR5664-13 65
C3R1-Up ........................................ 1.30 kg (3 lb) 312C High Ambient Cooling

LAR1-Up ........................................ 1.30 kg (3 lb)
BNN1-UP .................................... 0.95 kg (2.1 lb)
325C Refrigerant Capacities 312C L
325C CBA1-UP .................................... 0.95 kg (2.1 lb)
BWH1-UP ........................................ 1 kg (2.2 lb)
M2K1-Up .................................... 1.30 kg (2.9 lb)
G1L1-Up ..................................... 1.30 kg (2.9 lb) 312C High Ambient Cooling
S3M1-Up .................................... 1.30 kg (2.9 lb)
CBT1-UP ......................................... 1 kg (2.2 lb)
325C L
BFE1-Up ................................... 1.05 kg (2.32 lb) 315C Refrigerant Capacities
325C MH 315C
S2C1-Up ..................................... 1.30 kg (2.9 lb) CFB1-UP ...................................... 0.9 kg (2.0 lb)
AKE1-UP ......................................... 1 kg (2.2 lb)
CFT1-UP ......................................... 1 kg (2.2 lb)
315C L
330C
CJC1-UP ......................................... 1 kg (2.2 lb)
B1K1-Up ..................................... 1.30 kg (2.9 lb) ANF1-UP ...................................... 0.9 kg (2.0 lb)
B3M1-Up .................................... 1.30 kg (2.9 lb)
B4N1-Up ..................................... 1.30 kg (2.9 lb)
330C L
318C
DKY1-Up .................................. 1.05 kg (2.32 lb)
FAA1-UP ....................................... 0.8 kg (1.8 lb)
330C FM GPA1-UP ......................................... 1 kg (2.2 lb)
BTG1-UP ...................................... 0.8 kg (1.8 lb)
B2L1-Up ................................... 1.05 kg (2.32 lb) DAH1-UP ...................................... 0.8 kg (1.8 lb)
AWS1-UP ..................................... 0.8 kg (1.8 lb)
330C MH MDY1-UP ........................................ 1 kg (2.2 lb)
D3C1-Up ..................................... 1.30 kg (2.9 lb)
TK1051 Refrigerant Capacities 319C LN
TK1051 KGL1-UP ...................................... 0.8 kg (1.8 lb)
9HZ1-Up ..................................... 1.30 kg (2.9 lb)
i02518751 320C
System Capacities for MAB1-UP ......................................... 1 kg (2.2 lb)
Refrigerant (Excavators) AMC1-UP ........................................ 1 kg (2.2 lb)
FBC1-UP ......................................... 1 kg (2.2 lb)
BEF1-UP ......................................... 1 kg (2.2 lb)
SMCS Code: 1809
DBG1-UP ...................................... 0.9 kg (2.0 lb)
BCN1-UP ......................................... 1 kg (2.2 lb)
RAW1-UP ........................................ 1 kg (2.2 lb)
System - Charge.
320C L
312C Refrigerant Capacities GLA1-UP ...................................... 0.9 kg (2.0 lb)

ANB1-UP ......................................... 1 kg (2.2 lb)
312C PAB1-UP ......................................... 1 kg (2.2 lb)
BBC1-UP ......................................... 1 kg (2.2 lb)
DBN1-UP ......................................... 1 kg (2.2 lb) GAC1-UP ......................................... 1 kg (2.2 lb)
FDS1-UP ......................................... 1 kg (2.2 lb) BDE1-UP ......................................... 1 kg (2.2 lb)
EAG1-UP ...................................... 0.9 kg (2.0 lb)
66 SENR5664-13
SBN1-UP ......................................... 1 kg (2.2 lb) BLA1-UP ....................................... 0.9 kg (2.0 lb)

JLD1-UP .......................................... 1 kg (2.2 lb)
320C LN DTF1-UP ......................................... 1 kg (2.2 lb)
AMH1-UP ..................................... 0.9 kg (2.0 lb)
BEA1-UP ......................................... 1 kg (2.2 lb) BKH1-UP ...................................... 0.9 kg (2.0 lb)
JTG1-UP ....................................... 0.9 kg (2.0 lb) BKW1-UP ..................................... 0.9 kg (2.0 lb)
AXK1-UP ...................................... 0.9 kg (2.0 lb)
325C L
320C LRR
CRB1-UP ...................................... 0.9 kg (2.0 lb)
GAD1-UP ...................................... 0.9 kg (2.0 lb) JLC1-UP .......................................... 1 kg (2.2 lb)
BTD1-UP ...................................... 0.9 kg (2.0 lb)
320C S BMM1-UP ..................................... 0.9 kg (2.0 lb)
BBL1-UP ....................................... 0.9 kg (2.0 lb) BKT1-UP ...................................... 0.9 kg (2.0 lb)
BLX1-UP ....................................... 0.9 kg (2.0 lb)
EGL1-UP ...................................... 0.9 kg (2.0 lb)
BMZ1-UP ...................................... 0.9 kg (2.0 lb)
325C LN
320C U CSJ1-UP ....................................... 0.9 kg (2.0 lb)
MAC1-UP ..................................... 0.9 kg (2.0 lb)
CLM1-UP ......................................... 1 kg (2.2 lb) 330C Refrigerant Capacities
320C LU 330C
PAC1-UP ......................................... 1 kg (2.2 lb) MCA1-UP ........................................ 1 kg (2.2 lb)
CLZ1-UP .......................................... 1 kg (2.2 lb) JAB1-UP .......................................... 1 kg (2.2 lb)
JCD1-UP ......................................... 1 kg (2.2 lb)
320C MH
330C L
EGA1-UP ...................................... 0.9 kg (2.0 lb)
JPL1-UP ....................................... 0.9 kg (2.0 lb) KDD1-UP ......................................... 1 kg (2.2 lb)
JNK1-UP .......................................... 1 kg (2.2 lb)
320C FM CAP1-UP ......................................... 1 kg (2.2 lb)
GKX1-UP ......................................... 1 kg (2.2 lb)
BGB1-UP ...................................... 1.4 kg (3.1 lb)
BKK1-UP ...................................... 1.4 kg (3.1 lb) 330C LN
TBR1-UP ...................................... 1.4 kg (3.1 lb)
SAH1-UP ...................................... 1.4 kg (3.1 lb) CGZ1-UP ......................................... 1 kg (2.2 lb)
322C Refrigerant Capacities 330C MH

MKM1-UP ........................................ 1 kg (2.2 lb)
322C
DAA1-UP ......................................... 1 kg (2.2 lb) i02527368
BLP1-UP ....................................... 0.9 kg (2.0 lb)
322C L
FED1-UP ......................................... 1 kg (2.2 lb)
BKM1-UP ...................................... 0.9 kg (2.0 lb) SMCS Code: 1809
BGR1-UP ......................................... 1 kg (2.2 lb)
MAR1-UP ........................................ 1 kg (2.2 lb) Reference: For the proper procedure to handle
322C LN System - Charge.
BFK1-UP ......................................... 1 kg (2.2 lb)

EMR1-UP ........................................ 1 kg (2.2 lb)
320D Refrigerant Capacities
320D
CXY 1-UP ..................................... 0.8 kg (1.8 lb)
325C
320D L
SENR5664-13 67
DHK 1-UP ..................................... 0.8 kg (1.8 lb) PKE 1-UP ..................................... 0.8 kg (1.8 lb)
325D MH
320D RR Refrigerant Capacities
C4H 1-UP ..................................... 1.0 kg (2.2 lb)
320D LRR RJK 1-UP ......................................... 1.3 kg (3 lb)
LWR 1-UP ..................................... 1.1 kg (2.4 lb)
FXK 1-UP ..................................... 0.9 kg (2.0 lb)
EBY 1-UP ..................................... 0.9 kg (2.0 lb)
325D FM
320D RR C7K 1-UP ........................................ 1.3 kg (3 lb)
C8L 1-UP ......................................... 1.3 kg (3 lb)
GKL 1-UP ..................................... 0.9 kg (2.0 lb)
323D Refrigerant Capacities 328D Refrigerant Capacities

323D L 328D LCR
GTN 1-UP ..................................... 0.8 kg (1.8 lb)
SDC 1-UP ..................................... 0.9 kg (2.0 lb)
PBM 1-UP ..................................... 0.9 kg (2.0 lb) MKR 1-UP .................................... 0.8 kg (1.8 lb)
323D LN 330D Refrigerant Capacities

CYD 1-UP ..................................... 0.9 kg (2.0 lb) 330D
323D S B6H 1-UP ..................................... 0.9 kg (2.0 lb)
THJ 1-UP ...................................... 0.9 kg (2.0 lb)
DKW 1-UP .................................... 0.9 kg (2.0 lb) JLP 1-UP ...................................... 0.9 kg (2.0 lb)
MEY 1-UP ..................................... 0.9 kg (2.0 lb)
330D L
324D L
GBC 1-UP ..................................... 0.9 kg (2.0 lb)
LAB 1-UP ...................................... 0.8 kg (1.8 lb) NBD 1-UP ..................................... 0.9 kg (2.0 lb)
T2D 1-UP ...................................... 0.8 kg (1.8 lb) ERN 1-UP ..................................... 0.9 kg (2.0 lb)
JJG 1-UP ...................................... 0.8 kg (1.8 lb) MWP 1-UP .................................... 0.9 kg (2.0 lb)
SYM 1-UP ..................................... 0.8 kg (1.8 lb) HAS 1-UP ..................................... 0.9 kg (2.0 lb)
DFP 1-UP ..................................... 0.8 kg (1.8 lb) RAS 1-UP ..................................... 0.9 kg (2.0 lb)
CJX 1-UP ...................................... 0.8 kg (1.8 lb) T2Y 1-UP ...................................... 0.9 kg (2.0 lb)
EDX 1-UP ..................................... 0.9 kg (2.0 lb)
324D LN
330D LN
EJC 1-UP ...................................... 0.8 kg (1.8 lb)
GGE 1-UP .................................... 0.9 kg (2.0 lb)
324D FM
330D FM
JKR 1-UP .................................... 1.3 kg (2.87 lb)
JLS 1-UP .................................... 1.3 kg (2.87 lb) E4K 1-UP ......................................... 1.3 kg (3 lb)
H3K 1-UP ........................................ 1.3 kg (3 lb)
L2K 1-UP ......................................... 1.3 kg (3 lb)
330D MH
325D L
C5K 1-UP ..................................... 1.1 kg (2.4 lb)
GPB 1-UP ..................................... 0.8 kg (1.8 lb) LEM 1-UP ........................................ 1.3 kg (3 lb)
KDG 1-UP ..................................... 0.8 kg (1.8 lb)
MCL 1-UP ..................................... 0.8 kg (1.8 lb)
PAL 1-UP ...................................... 0.8 kg (1.8 lb)
AZP 1-UP ..................................... 0.8 kg (1.8 lb)
A3R 1-UP ..................................... 0.8 kg (1.8 lb)
GBR 1-UP ..................................... 0.8 kg (1.8 lb)
SCR 1-UP ..................................... 0.8 kg (1.8 lb)
T2S 1-UP ...................................... 0.8 kg (1.8 lb)
CYW 1-UP .................................. 1.3 kg (2.87 lb)
325D LN
68 SENR5664-13
i02499083 JCM1-UP ...................................... 1.1 kg (2.4 lb)

MNZ1-UP ...................................... 1.1 kg (2.4 lb)
Refrigerant (Excavators) 385C L
EDA1-UP ...................................... 1.1 kg (2.4 lb)
SMCS Code: 1809
KGB1-UP ...................................... 1.1 kg (2.4 lb)
SBE1-UP ...................................... 1.1 kg (2.4 lb)
Reference: For the proper procedure to handle T2E1-UP ....................................... 1.1 kg (2.4 lb)
KKK1-UP ...................................... 1.1 kg (2.4 lb)
System - Charge.
385C MH
WAW1-UP .................................... 1.1 kg (2.4 lb)
345C
385C FS
BWY1-UP ..................................... 0.9 kg (2.0 lb)
MMA1-UP ..................................... 1.1 kg (2.4 lb)
345C L T2F1-UP ....................................... 1.1 kg (2.4 lb)
EAM1-UP ...................................... 1.1 kg (2.4 lb)
TBA1-UP ...................................... 0.9 kg (2.0 lb) GLT1-UP ....................................... 1.1 kg (2.4 lb)
FPC1-UP ...................................... 0.9 kg (2.0 lb)
ESD1-UP ...................................... 0.9 kg (2.0 lb)
i02502384
WDE1-UP ..................................... 0.9 kg (2.0 lb)
TDG1-UP ......................................
GPH1-UP ......................................
0.9 kg (2.0 lb)
0.9 kg (2.0 lb)
TAJ1-UP ....................................... 0.9 kg (2.0 lb) Refrigerant (Excavators)
GCL1-UP ...................................... 0.9 kg (2.0 lb)
DHP1-UP ...................................... 0.9 kg (2.0 lb) SMCS Code: 1809
GJR1-UP ...................................... 0.9 kg (2.0 lb)
ELS1-UP ....................................... 0.9 kg (2.0 lb) Reference: For the proper procedure to handle
LYS1-UP ....................................... 0.9 kg (2.0 lb) refrigerant, refer to Testing and Adjusting, Refrigerant
PJW1-UP ...................................... 0.9 kg (2.0 lb) System - Charge.
345C MH M312 Refrigerant Capacities

M2R1-UP ...................................... 1.1 kg (2.4 lb)
D3S1-UP ...................................... 1.1 kg (2.4 lb) M312
6TL1-UP ....................................... 1.3 kg (2.9 lb)
365C L
M315 Refrigerant Capacities
ELC1-UP ...................................... 1.1 kg (2.4 lb) M315
FEN1-UP ...................................... 1.1 kg (2.4 lb) 7ML1-UP ...................................... 1.3 kg (2.9 lb)
MEM1-UP ..................................... 1.1 kg (2.4 lb)
MCS1-UP ..................................... 1.1 kg (2.4 lb)
MCY1-UP ..................................... 1.1 kg (2.4 lb) M318 Refrigerant Capacities
365C MH M318
GWC1-UP ..................................... 1.1 kg (2.4 lb) 8AL1-UP ....................................... 1.3 kg (2.9 lb)
6ES1-UP ....................................... 1.3 kg (2.9 lb)
365C FS 8SS1-UP ....................................... 1.3 kg (2.9 lb)
PAR1-UP ...................................... 1.1 kg (2.4 lb)

M320 Refrigerant Capacities
385C Refrigerant Capacities M320
385C 6WL1-UP ...................................... 1.3 kg (2.9 lb)

9PS1-UP ....................................... 1.3 kg (2.9 lb)
KBC1-UP ...................................... 1.1 kg (2.4 lb)
SENR5664-13 69
i02502622 i02504907
System Capacities for System Capacities for

Refrigerant (Excavators) Refrigerant (Forest Products)
SMCS Code: 1809 SMCS Code: 1809
Reference: For the proper procedure to handle Reference: For the proper procedure to handle
refrigerant, refer to Testing and Adjusting, Refrigerant refrigerant, refer to Testing and Adjusting, Refrigerant
System - Charge. System - Charge.
M313C Refrigerant Capacities Wheel Skidders

M313C 515 Refrigerant Capacities
BDR1-UP .................................... 2.2 kg (4.85 lb)
H2A1-UP .................................... 2.2 kg (4.85 lb) 4LR1-Up ............................................. 1.6 kg (3.5 lb)

M315C Refrigerant Capacities
525
M315C
1DN1-Up ....................................... 1.6 kg (3.5 lb)
BDM1-UP ................................... 2.2 kg (4.85 lb)
H2B1-UP .................................... 2.2 kg (4.85 lb) 525B
M316C Refrigerant Capacities 3KZ1-Up ....................................... 1.6 kg (3.5 lb)
M316C 525C
BDX1-UP .................................... 2.2 kg (4.85 lb) 5251-Up ........................................ 1.6 kg (3.5 lb)
H2C1-UP .................................... 2.2 kg (4.85 lb)
M318C Refrigerant Capacities 535B
M318C AAE1-Up ....................................... 1.6 kg (3.5 lb)
BCZ1-UP .................................... 2.2 kg (4.85 lb) 535C
H2D1-UP .................................... 2.2 kg (4.85 lb)
5351-Up ........................................ 1.6 kg (3.5 lb)
M318C MH
BEB1-UP .................................... 2.5 kg (5.50 lb) 545 Refrigerant Capacities
H2F1-UP ..................................... 2.5 kg (5.50 lb)
545
M322C Refrigerant Capacities 2FZ1-Up ....................................... 1.6 kg (3.5 lb)
M322C 545C
BDK1-UP .................................... 2.2 kg (4.85 lb) 5451-Up ........................................ 1.6 kg (3.5 lb)
H2E1-UP .................................... 2.2 kg (4.85 lb)
M322C MH
Track Skidders
BDY1-UP .................................... 2.5 kg (5.50 lb) 517 Refrigerant Capacities
H2G1-UP .................................... 2.5 kg (5.50 lb)
5WW1-Up ........................................... 1.6 kg (3.5 lb)
M325C Refrigerant Capacities 6PW1-Up ............................................ 1.6 kg (3.5 lb)
M325C MH
XJA1-UP ..................................... 2.5 kg (5.50 lb)
PAN1-UP .................................... 2.5 kg (5.50 lb) 4NS1-Up ............................................. 1.6 kg (3.5 lb)
70 SENR5664-13
2RS1-Up ............................................. 1.6 kg (3.5 lb) 580 Refrigerant Capacities

3DS1-Up ............................................. 1.6 kg (3.5 lb) 580
7CN1-Up ....................................... 1.2 kg (2.6 lb)
Knuckleboom Loaders
580B
CLT1-Up ................................... 1.40 kg (3.09 lb)
1PZ1-Up ........................................... 1.5 kg (3.25 lb)
Wheel Feller Bunchers
Forwarders
TK370 Refrigerant Capacities
WBD1-Up .......................................... 1.1 kg (2.42 lb)
1AM1-Up ........................................... 1.2 kg (2.60 lb)
TGH1-Up ........................................ 1.10 kg (2.42 lb)
WBG1-Up ......................................... 1.1 kg (2.42 lb)
KBN1-Up ......................................... 1.14 kg (2.51 lb)
WBE1-Up .......................................... 1.1 kg (2.42 lb)
574
WBH1-Up .......................................... 1.1 kg (2.42 lb)
1FM1-Up ..................................... 1.2 kg (2.60 lb)
574B
CZZ1-Up ................................... 1.14 kg (2.51 lb) CDR1-Up .......................................... 1.1 kg (2.42 lb)
RLS1-Up ................................... 1.14 kg (2.51 lb)
Wheel Harvesters ASJ1-Up ........................................... 1.1 kg (2.42 lb)
HA Series Refrigerant Capacities
550
HA770
7ZN1-Up ..................................... 1.2 kg (2.60 lb)
HAB1-Up .................................... 1.1 kg (2.42 lb)
550B
HA771
SAW1-Up .................................. 1.40 kg (3.09 lb)
HAF1-Up ..................................... 1.1 kg (2.42 lb)
560B Refrigerant Capacities HA870
TRA1-Up ......................................... 1.40 kg (3.09 lb) HAE1-Up .................................... 1.1 kg (2.42 lb)
570 Refrigerant Capacities HA871

HAG1-Up .................................... 1.1 kg (2.42 lb)
570
4XR1-Up ..................................... 1.2 kg (2.60 lb) Track Feller Bunchers
570B
CKG1-Up .................................. 1.40 kg (3.09 lb)
5111-Up ............................................. 1.7 kg (3.75 lb)
SENR5664-13 71
521 Refrigerant Capacities 1190 Refrigerant Capacities

5211-Up ............................................ 1.7 kg (3.75 lb) BZK1-Up ......................................... 1.70 kg (3.75 lb)
522 Refrigerant Capacities 1190T Refrigerant Capacities

5221-Up ............................................ 1.7 kg (3.75 lb) BZL1-Up ......................................... 1.70 kg (3.75 lb)

5321-Up ............................................ 1.7 kg (3.75 lb) BZM1-Up .......................................... 1.3 kg (2.87 lb)

5411-Up ............................................ 1.7 kg (3.75 lb) B3F1-Up ........................................... 1.3 kg (2.87 lb)

5511-Up ............................................ 1.7 kg (3.75 lb) B4F1-Up ........................................... 1.3 kg (2.87 lb)

5521-Up ............................................ 1.7 kg (3.75 lb) B5F1-Up ........................................... 1.3 kg (2.87 lb)
TK711 Refrigerant Capacities i02502143
1011-Up .......................................... 1.70 kg (3.75 lb) System Capacities for

Refrigerant (Integrated
Toolcarriers)
1021-Up .......................................... 1.70 kg (3.75 lb)
SMCS Code: 1809
1031-Up .......................................... 1.70 kg (3.75 lb) refrigerant, refer to Testing and Adjusting, Refrigerant
System - Charge.
Small Integrated Toolcarriers
1041-Up .......................................... 1.70 kg (3.75 lb)
IT12F Refrigerant Capacities
1KF1040-Up ....................................... 1.6 kg (3.5 lb)
2021-Up .......................................... 1.70 kg (3.75 lb)
IT14 Refrigerant Capacities
IT14F
3011-Up .......................................... 1.70 kg (3.75 lb)
4EL196-Up ................................... 1.6 kg (3.5 lb)
TK752 Refrigerant Capacities IT14G
3021-Up .......................................... 1.70 kg (3.75 lb) 1WN94-UP ................................... 1.2 kg (2.7 lb)
8ZM1-Up ....................................... 1.2 kg (2.7 lb)
IT18F Refrigerant Capacities
9HZ1-Up ......................................... 1.70 kg (3.75 lb)
6ZF307-Up .......................................... 2.0 kg (4.5 lb)
5EJ1-Up .............................................. 2.0 kg (4.5 lb)
BZJ1-Up .......................................... 1.70 kg (3.75 lb)
72 SENR5664-13
IT24F Refrigerant Capacities i02504816
4NN51-Up ........................................... 2.0 kg (4.5 lb) System Capacities for

Refrigerant (Large Wheel
6KN51-Up ........................................... 2.0 kg (4.5 lb)
Loaders)
SMCS Code: 1809
IT28F
1JL1-Up ........................................ 2.5 kg (5.5 lb) refrigerant, refer to Testing and Adjusting, Refrigerant
3CL751-Up ................................... 2.5 kg (5.5 lb) System - Charge.
IT28G 988 Refrigerant Capacities

8CR1-Up ....................................... 1.2 kg (2.7 lb)
988F
9AR1-Up ....................................... 1.2 kg (2.7 lb)
DBT1-Up ....................................... 1.3 kg (2.9 lb) 8YG492-Up ................................... 2.7 kg (6.0 lb)
WAC1-Up ...................................... 1.3 kg (2.9 lb)
EWF1-Up ...................................... 1.3 kg (2.9 lb) 988F II
2ZR1-Up ....................................... 2.8 kg (6.0 lb)
Medium Integrated Toolcarriers
988G
2TW1-Up ...................................... 2.6 kg (5.7 lb)
IT38F
BNH1-Up ...................................... 2.6 kg (5.7 lb)
6FN238-Up ................................... 2.0 kg (4.4 lb)
988H
5DR1-Up ....................................... 2.0 kg (4.4 lb)
BXY1-Up ....................................... 2.6 kg (5.7 lb)
IT38G
7BS1-Up ....................................... 1.5 kg (3.3 lb) 990 Refrigerant Capacities
1CW1-Up ...................................... 1.5 kg (3.3 lb)
990
IT38G II 7HK28-Up ..................................... 3.8 kg (8.4 lb)
CSX1-Up ...................................... 1.5 kg (3.3 lb)
JAN1-Up ....................................... 1.5 kg (3.3 lb) 990 II
4FR1-372 ...................................... 3.8 kg (8.4 lb)
IT38H
4FR373-Up ................................... 4.1 kg (9.0 lb)
MCJ1-Up ...................................... 1.5 kg (3.3 lb)
BCR1-Up ...................................... 2.7 kg (6.0 lb)
990H
IT62G
BWX1-Up ...................................... 2.7 kg (6.0 lb)
6PS1-Up ....................................... 2.3 kg (5.0 lb)
AKP1-Up ....................................... 2.0 kg (4.4 lb) 992 Refrigerant Capacities
IT62G II 992D
AYA1-Up ....................................... 1.7 kg (3.7 lb) 7MJ340-Up ................................... 2.7 kg (6.0 lb)
IT62H 992G
M5G1-Up ...................................... 2.0 kg (4.4 lb) AZX1-Up ....................................... 2.3 kg (5.1 lb)
7HR1-Up ....................................... 4.1 kg (9.0 lb)
SENR5664-13 73
ADZ1-Up ....................................... 4.1 kg (9.0 lb) R1700 Refrigerant Capacities

994 Refrigerant Capacities R1700
994 4LZ1-Up .............................................. 2.0 kg (4.4 lb)
9YF83-Up ........................................ 3 kg (6.6 lb) R1700G

994D 8XZ1-Up ............................................. 2.0 kg (4.4 lb)
3TZ83-Up ..................................... 2.7 kg (6.0 lb)
R2900 Refrigerant Capacities
994F
4421-Up ........................................ 3.2 kg (7.0 lb) R2900
5TW1-Up ............................................ 2.0 kg (4.4 lb)
i02517702
BAR1-Up ............................................. 2.0 kg (4.4 lb)
Refrigerant (Load Haul Dump) R2900G
SMCS Code: 1809 GLK1-Up ............................................. 2.3 kg (5.0 lb)
Reference: For the proper procedure to handle JLK1-Up ............................................ 4.8 kg (10.6 lb)
System - Charge.
i02504003
Note: The following refrigerant capacities are for

underground machines.
Refrigerant (Medium Wheel
R1300 Refrigerant Capacities Loaders)
R1300 SMCS Code: 1809
6QW1-Up ............................................ 2.0 kg (4.4 lb) Reference: For the proper procedure to handle
System - Charge.
R1300G
LJB1-Up .............................................. 1.9 kg (4.2 lb) 936F Refrigerant Capacities
R1300G Series II 8AJ855-Up .......................................... 2.4 kg (5.3 lb)
RSL1-Up ........................................... 1.18 kg (2.6 lb) 9MK350-Up ......................................... 2.4 kg (5.3 lb)
4TK1-Up ............................................. 1.8 kg (4.0 lb)

R1600 Refrigerant Capacities
R1600
938F
9EW1-Up ............................................ 2.0 kg (4.4 lb)
1KM1-Up ......................................... 1.8 kg (4 lb)
9XP1-Up ............................................. 2.0 kg (4.4 lb) 2RM142-Up ..................................... 1.8 kg (4 lb)
8SM142-Up ..................................... 1.8 kg (4 lb)
R1600G 7SN142-Up ...................................... 1.8 kg (4 lb)
9PP1-Up ............................................. 2.0 kg (4.4 lb) 938G

4YS1-Up .......................................... 1.8 kg (4 lb)
6WS1-Up ...................................... 1.5 kg (3.3 lb)
8RS1-Up ....................................... 1.5 kg (3.3 lb)
9HS1-Up ....................................... 1.5 kg (3.3 lb)
74 SENR5664-13
938G II 6XL170-Up ............................................. 2 kg (4.4 lb)

CRD1-Up ...................................... 1.5 kg (3.3 lb) 1YM181-Up ............................................ 2 kg (4.4 lb)
PHN1-Up ...................................... 1.5 kg (3.3 lb)
RTB1-Up ....................................... 1.5 kg (3.3 lb)
B9Y1-Up ....................................... 1.5 kg (3.3 lb) 962 Refrigerant Capacities
938H 962G
MJC1-Up ...................................... 1.5 kg (3.3 lb) 4PW1-Up ......................................... 2.3 kg (5 lb)

LKM1-Up ...................................... 1.5 kg (3.3 lb) 5RS1-Up .......................................... 2 kg (4.4 lb)
JKM1-Up ....................................... 1.5 kg (3.3 lb) 5AS1-Up .......................................... 2 kg (4.4 lb)
KLM1-Up ...................................... 1.5 kg (3.3 lb) 3BS1-Up .......................................... 2 kg (4.4 lb)
6EW1-Up ......................................... 2.3 kg (5 lb)
7BW1-Up ......................................... 2.3 kg (5 lb)
950 Refrigerant Capacities 6HW1-Up ......................................... 2.3 kg (5 lb)
BDP1-Up ......................................... 2.3 kg (5 lb)
950F
962G II
6YG348-Up ...................................... 2 kg (4.4 lb)
7ZF348-Up ...................................... 2 kg (4.4 lb) AYE1-Up ..................................... 1.7 kg (3.75 lb)
BAB1-Up ..................................... 1.7 kg (3.75 lb)
950F II AXS1-Up ..................................... 1.7 kg (3.75 lb)
AYG1-Up .................................... 1.7 kg (3.75 lb)
4DJ2240-Up .................................... 2 kg (4.4 lb)
AXY1-Up ..................................... 1.7 kg (3.75 lb)
5SK745-Up ...................................... 2 kg (4.4 lb)
8TK816-Up ...................................... 2 kg (4.4 lb) BAD1-Up .................................... 1.7 kg (3.75 lb)
BAC1-Up .................................... 1.7 kg (3.75 lb)
2LM348-Up ...................................... 2 kg (4.4 lb)
950G 962H
K6K1-Up ....................................... 1.9 kg (4.2 lb)
2JS1-Up ........................................... 2.3 kg (5 lb)
8JW1-Up .......................................... 2.3 kg (5 lb) N4A1-Up ....................................... 1.9 kg (4.2 lb)
M3G1-Up ...................................... 1.9 kg (4.2 lb)
5MW1-Up ........................................ 2.3 kg (5 lb)
J6J1-Up ........................................ 1.9 kg (4.2 lb)
3JW1-Up .......................................... 2.3 kg (5 lb)
8DS1-Up .......................................... 2 kg (4.4 lb)
6NS1-Up .......................................... 2 kg (4.4 lb) 966 Refrigerant Capacities
4BS1-Up .......................................... 2 kg (4.4 lb)
5FW1-Up ......................................... 2.3 kg (5 lb) 966F
950G II 3XJ1-Up ........................................ 2.1 kg (4.6 lb)

4YG1-Up ....................................... 2.1 kg (4.6 lb)
AYD1-Up ..................................... 1.7 kg (3.75 lb)
AXX1-Up ..................................... 1.7 kg (3.75 lb) 966F II
BAA1-Up ..................................... 1.7 kg (3.75 lb)
AYB1-Up ..................................... 1.7 kg (3.75 lb) 8BG2191-Up .................................... 2 kg (4.4 lb)
AYL1-Up ..................................... 1.7 kg (3.75 lb) 9YJ1078-Up ..................................... 2 kg (4.4 lb)
AYS1-Up ..................................... 1.7 kg (3.75 lb) 1SL510-Up ...................................... 2 kg (4.4 lb)
AXR1-Up .................................... 1.7 kg (3.75 lb)
966G
950H
3SW1-Up .................................... 2.4 kg (5.25 lb)
K5K1-Up ....................................... 1.9 kg (4.2 lb) 9RS1-Up .......................................... 2.3 kg (5 lb)
N1A1-Up ....................................... 1.9 kg (4.2 lb) 3ZS1-Up ..................................... 2.4 kg (5.25 lb)
M1G1-Up ...................................... 1.9 kg (4.2 lb) 3PW1-Up ......................................... 2.3 kg (5 lb)
J5J1-Up ........................................ 1.9 kg (4.2 lb) AAH1-Up ...................................... 2.1 kg (4.6 lb)
8XW1-Up ......................................... 2.3 kg (5 lb)
960F Refrigerant Capacities 966G II
9ZJ167-Up ............................................. 2 kg (4.4 lb) AWY1-Up ...................................... 1.9 kg (4.2 lb)
AXJ1-Up ....................................... 1.9 kg (4.2 lb)
4CL165-Up ............................................ 2 kg (4.4 lb) ANT1-Up ....................................... 2.1 kg (4.6 lb)
ANZ1-Up ....................................... 2.1 kg (4.6 lb)
SENR5664-13 75
AWZ1-Up ...................................... 1.9 kg (4.2 lb) AYT1-Up ....................................... 1.9 kg (4.2 lb)
AXL1-Up ....................................... 1.9 kg (4.2 lb) AWH1-Up ...................................... 1.9 kg (4.2 lb)
AXG1-Up ...................................... 1.9 kg (4.2 lb)
966H
980H
A6D1-Up ....................................... 1.9 kg (4.2 lb)
A6G1-Up ....................................... 1.9 kg (4.2 lb) JMS1-Up ....................................... 1.9 kg (4.2 lb)
A6J1-Up ........................................ 1.9 kg (4.2 lb) MHG1-Up ..................................... 1.9 kg (4.2 lb)
A8J1-Up ........................................ 1.9 kg (4.2 lb)
970F Refrigerant Capacities
i02504277
7SK225-Up ............................................ 2 kg (4.5 lb)
9JK361-Up ............................................. 2 kg (4.5 lb)
Refrigerant (Mining
7PL103-Up ............................................. 2 kg (4.5 lb) Excavators)
972 Refrigerant Capacities SMCS Code: 1809
972G Reference: For the proper procedure to handle

1EW1-Up ......................................... 2.3 kg (5 lb) System - Charge.
6AW1-Up ......................................... 2.3 kg (5 lb)
9GW1-Up ......................................... 2.3 kg (5 lb) 5110 Refrigerant Capacities
7LS1-Up ....................................... 2.4 kg (5.3 lb)
4WW1-Up ..................................... 2.4 kg (5.3 lb) 5110B
AAW1-Up ...................................... 2.1 kg (4.6 lb)
AAA1-Up .......................................... 2.7 kg (6 lb)
972G II AAT1-Up .......................................... 2.7 kg (6 lb)
AAK1-Up .......................................... 2.7 kg (6 lb)
AXC1-Up ...................................... 1.9 kg (4.2 lb)
AXN1-Up ...................................... 1.9 kg (4.2 lb)
ANY1-Up ...................................... 2.1 kg (4.6 lb) 5130 Refrigerant Capacities
AWP1-Up ...................................... 2.1 kg (4.6 lb)
AXE1-Up ....................................... 1.9 kg (4.2 lb) 5130
AXP1-Up ....................................... 1.9 kg (4.2 lb)
5ZL1-Up ........................................... 3 kg (6.6 lb)
7TJ1-Up ........................................... 3 kg (6.6 lb)
972H
A7D1-Up ....................................... 1.9 kg (4.2 lb) 5130B
A7G1-Up ....................................... 1.9 kg (4.2 lb)
4CS130-Up ............................... 3.75 kg (8.25 lb)
A7J1-Up ........................................ 1.9 kg (4.2 lb)

5230
980F
7LL1-85 ........................................... 3 kg (6.6 lb)
8CJ1221-Up .................................... 2.3 kg (5 lb)
7LL86-Up .................................. 3.75 kg (8.25 lb)
3HK1-Up .......................................... 2.3 kg (5 lb)
5230B
980F II
4HZ1-Up ................................... 3.75 kg (8.25 lb)
8JN1-Up .......................................... 2.3 kg (5 lb)
4RN1-Up .......................................... 2.3 kg (5 lb)
5XJ1-Up ........................................... 2.3 kg (5 lb)
980G
9CM1-Up ...................................... 2.5 kg (5.5 lb)
2KR1-Up ....................................... 2.5 kg (5.5 lb)
2SR1-Up ....................................... 2.5 kg (5.5 lb)
980G II
76 SENR5664-13
i02502767 4ER1-Up ....................................... 1.9 kg (4.2 lb)

2GS1-Up ....................................... 1.9 kg (4.2 lb)
System Capacities for 1251-Up ........................................ 2.1 kg (4.6 lb)
Refrigerant (Motor Graders) AMZ1-Up ...................................... 2.1 kg (4.6 lb)
CBK1-Up ...................................... 2.1 kg (4.6 lb)
SMCS Code: 1809
12H ES
Reference: For the proper procedure to handle 2LR1-Up ....................................... 1.6 kg (3.5 lb)
System - Charge.
12H NA
120 Refrigerant Capacities 4XM1-3131 ................................... 1.6 kg (3.5 lb)

4XM3132-Up ................................ 1.6 kg (3.5 lb)
120G 8MN1-Up ...................................... 1.6 kg (3.5 lb)
2WR1-Up ...................................... 1.6 kg (3.5 lb)
87V9732-Up ................................. 1.9 kg (4.2 lb)
11W1351-Up ................................. 1.9 kg (4.2 lb)
61M15358-Up ............................... 2.4 kg (5.3 lb)
140G
120H
72V15940-Up ............................... 2.4 kg (5.3 lb)
2AN1-Up ....................................... 1.6 kg (3.5 lb)
5FM1-Up ....................................... 1.9 kg (4.2 lb)
140H
1241-Up ........................................ 2.1 kg (4.6 lb)
ALZ1-Up ....................................... 2.1 kg (4.6 lb) 5HM1-Up ...................................... 1.9 kg (4.2 lb)
CAF1-Up ....................................... 2.1 kg (4.6 lb) 3AS1-Up ....................................... 1.6 kg (3.5 lb)
APM1-Up ...................................... 2.1 kg (4.6 lb)
120H ES CCA1-Up ...................................... 2.1 kg (4.6 lb)
1261-Up ........................................ 2.1 kg (4.6 lb)
9YR1-Up ....................................... 1.6 kg (3.5 lb)
6NM1-Up ...................................... 1.6 kg (3.5 lb) 140H ES
120H NA 8KM1-Up ...................................... 1.6 kg (3.5 lb)
4MK1-Up ...................................... 1.6 kg (3.5 lb)
140H NA
6YN1-Up ....................................... 1.6 kg (3.5 lb)
2ZK1-7566 .................................... 1.6 kg (3.5 lb)
130 Refrigerant Capacities 2ZK7567-Up ................................. 1.6 kg (3.5 lb)
9TN1-Up ....................................... 1.6 kg (3.5 lb)
130G 9ZN1-Up ....................................... 1.6 kg (3.5 lb)
74V2604-Up ................................. 1.9 kg (4.2 lb) 143 Refrigerant Capacities

135 Refrigerant Capacities 143H
135H APN1-Up ...................................... 2.1 kg (4.6 lb)
8ZG1-Up ....................................... 1.6 kg (3.5 lb) 143H NA

8WN1-Up ...................................... 1.9 kg (4.2 lb)
7PM1-Up ...................................... 1.9 kg (4.2 lb) 1AL1-Up .......................................... 2 kg (4.5 lb)
AMX1-Up ...................................... 2.1 kg (4.6 lb)
CBC1-Up ...................................... 2.1 kg (4.6 lb) 160 Refrigerant Capacities
135H NA 160G
3YK1-Up ....................................... 1.6 kg (3.5 lb) 4JD186-Up ...................................... 2.3 kg (5 lb)
BDJ1-Up ....................................... 1.6 kg (3.5 lb)
160H
12 Refrigerant Capacities 2FM186-Up ................................... 1.9 kg (4.2 lb)
ASD1-Up ...................................... 2.1 kg (4.6 lb)
12H
SENR5664-13 77
CCP1-Up ...................................... 2.1 kg (4.6 lb) i02504893
160H ES System Capacities for

6WM1-Up ..................................... 1.6 kg (3.5 lb)
Refrigerant (Multi-Terrain
Loaders)
160H NA
SMCS Code: 1809
9EJ1-1264 .................................... 1.6 kg (3.5 lb)
9EJ1265-Up .................................. 1.6 kg (3.5 lb)
3GM1-Up ...................................... 1.6 kg (3.5 lb) 247 Refrigerant Capacities
163 Refrigerant Capacities 247B
163H MTL1-Up ....................................... 0.81 kg (1.786 lb)
ARL1-Up ....................................... 2.1 kg (4.6 lb) 257 Refrigerant Capacities

163H NA
257
5AK1-Up .......................................... 2 kg (4.5 lb)
CMM3400-Up ............................... 0.68 kg (1.500 lb)
257B
14G
SLK1-Up ....................................... 0.81 kg (1.786 lb)
96U9075-Up ................................. 1.9 kg (4.2 lb)
14H
7WJ1-2242 ................................... 1.6 kg (3.5 lb) 267B
7WJ2243-Up ................................. 1.6 kg (3.5 lb)
ASE1-Up ....................................... 2.1 kg (4.6 lb) CYC1-Up ...................................... 0.81 kg (1.786 lb)

16G 277
93U3516-Up ................................. 1.9 kg (4.2 lb)
CNC3400-Up ................................ 0.68 kg (1.500 lb)
16H
277B
6ZJ1-982 ...................................... 1.6 kg (3.5 lb)
6ZJ983-Up .................................... 1.6 kg (3.5 lb) MDH1-Up ...................................... 0.81 kg (1.786 lb)
ATS1-Up ....................................... 2.1 kg (4.6 lb)
287
24H
7KK1-Up ....................................... 2.6 kg (5.7 lb) CNY3400-Up ................................ 0.68 kg (1.500 lb)
287B
ZSA1-Up ....................................... 0.81 kg (1.786 lb)
78 SENR5664-13
i02501714 772 Refrigerant Capacities

System Capacities for 772B
Refrigerant (Off-Highway 64W195-Up .................................. 1.9 kg (4.2 lb)
Trucks)
SMCS Code: 1809
773 Refrigerant capacities
773B
refrigerant, refer to Testing and Adjusting, Refrigerant 63W4011-Up ................................. 1.9 kg (4.2 lb)
System - Charge.
773D
Note: Refrigerant capacities for models 69D and 73D
are for underground machines. 7ER1-Up ....................................... 1.8 kg (4.0 lb)
7CS1-Up ....................................... 1.8 kg (4.0 lb)
69 Refrigerant Capacities 773E
69D BDA1-Up ...................................... 2.5 kg (5.5 lb)
9XS1-Up .......................................... 1.8 kg (4 lb)
9SS1-Up ....................................... 1.3 kg (2.9 lb) 775 Refrigerant Capacities
775B
7XJ124-Up .................................... 1.9 kg (4.2 lb)
73D
775D
9YS1-Up .......................................... 1.8 kg (4 lb)
1GW1-Up ...................................... 1.3 kg (2.9 lb) 6KR1-Up ....................................... 1.8 kg (4.0 lb)
8AS1-Up ....................................... 1.8 kg (4.0 lb)
775E
768C BEC1-Up ...................................... 1.8 kg (4.0 lb)
02X371-Up ................................... 1.9 kg (4.2 lb)
776C
769C 2TK79-Up ..................................... 1.9 kg (4.2 lb)
01X6362-Up ................................. 1.9 kg (4.2 lb)
776D
769D 5ER1-Up ....................................... 1.8 kg (4.0 lb)
5TR1-969 ...................................... 1.8 kg (4.0 lb) AFS1-Up ....................................... 1.8 kg (4.0 lb)
5TR970-Up ................................... 1.8 kg (4.0 lb)
BBB1-Up ....................................... 2.5 kg (5.5 lb) 777 Refrigerant Capacities
5SS1-Up ....................................... 1.8 kg (4.0 lb)
777C
771 Refrigerant Capacities 4XJ367-Up .................................... 1.9 kg (4.2 lb)
771C 777D
3BJ100-Up .................................... 1.9 kg (4.2 lb) 3PR1-Up ....................................... 1.8 kg (4.0 lb)
AGC1-Up ...................................... 1.8 kg (4.0 lb)
771D AGY1-Up ...................................... 1.8 kg (4.0 lb)
6JR1-Up ....................................... 1.8 kg (4.0 lb) 2YW1-Up ...................................... 1.8 kg (4.0 lb)
BCA1-Up ...................................... 2.5 kg (5.5 lb)
6YS1-Up ....................................... 1.8 kg (4.0 lb)
SENR5664-13 79
784 Refrigerant Capacities i02517304
784B System Capacities for

5RK1-Up ....................................... 2.1 kg (4.6 lb)
Refrigerant (Paving Products)
SMCS Code: 1809
784C
2PZ1-Up ....................................... 2.1 kg (4.6 lb) RR-250 Refrigerant Capacities
785 Refrigerant Capacities RR-250B
785B 3RR1-Up ........................................... 1.7 kg (3.75 lb)
6HK265-Up ................................... 2.1 kg (4.6 lb)
SS-250 Refrigerant Capacities
785C
SS-250B
5AZ1-Up .......................................... 3 kg (6.6 lb)
APX1-Up .......................................... 3 kg (6.6 lb) 5GR1-Up ........................................... 1.7 kg (3.75 lb)
789 Refrigerant Capacities RM-350 Refrigerant Capacities

789B
RM-350B
7EK231-Up ................................... 2.1 kg (4.6 lb)
7FS1-Up ............................................. 1.8 kg (4.0 lb)
789C
AXW1-Up ............................................ 1.0 kg (2.2 lb)
2BW1-Up ......................................... 3 kg (6.6 lb)
CB-434 Refrigerant Capacities
CB-434D
793B
1HL102-Up ................................... 2.1 kg (4.6 lb) CNH1-Up ............................................ 1.2 kg (2.7 lb)
793C CB-534 Refrigerant Capacities

4AR1-Up ....................................... 2.1 kg (4.6 lb)
ATY1-243 ...................................... 2.1 kg (4.6 lb) CB-534D
ATY244-Up ...................................... 3 kg (6.6 lb)
CBR1-Up ......................................... 3 kg (6.6 lb) FGH1-Up ............................................ 1.2 kg (2.7 lb)
4GZ1-Up ....................................... 2.1 kg (4.6 lb)
GCA1-Up ............................................ 1.2 kg (2.7 lb)
793D
CB-534D XW
FDB1-Up .......................................... 2.7 kg (6 lb)
EAA1-Up ............................................. 1.2 kg (2.7 lb)
FEA1-Up ............................................. 1.2 kg (2.7 lb)
797
5YW1-Up ......................................... 2 kg (4.5 lb)
CP/CS-423 Refrigerant Capacities
797B CP-423E
JSM1-Up .......................................... 2.7 kg (6 lb) BWG1-Up ........................................... 1.3 kg (2.9 lb)
CS-423E
CFX1-Up ............................................. 1.3 kg (2.9 lb)
DCL1-Up ............................................. 1.3 kg (2.9 lb)

80 SENR5664-13
AGH1-Up ............................................ 1.3 kg (2.9 lb) CS-533E

ASH1-Up ............................................. 1.3 kg (2.9 lb) DAK1-Up ............................................. 1.3 kg (2.9 lb)
EAE1-Up ............................................. 1.3 kg (2.9 lb) ASL1-Up ............................................. 1.3 kg (2.9 lb)
BZE1-Up ............................................. 1.3 kg (2.9 lb)

CP/CS-433 Refrigerant Capacities
CP-433E CP/CS-563 Refrigerant Capacities
CFK1-Up ............................................. 1.3 kg (2.9 lb) CP-563D
CYE1-Up ............................................. 1.3 kg (2.9 lb) 5LZ1-Up .............................................. 1.3 kg (2.9 lb)
BTY1-Up ............................................. 1.3 kg (2.9 lb) 9ZW1-Up ............................................ 1.3 kg (2.9 lb)
ASN1-Up ............................................. 1.3 kg (2.9 lb) CP-563E

CS-433E CNT1-Up ............................................. 1.3 kg (2.9 lb)
CFP1-Up ............................................. 1.3 kg (2.9 lb) BWE1-Up ............................................ 1.3 kg (2.9 lb)
DAC1-Up ............................................ 1.3 kg (2.9 lb) CS-563D

BTT1-Up ............................................. 1.3 kg (2.9 lb) 2RZ1-Up ............................................. 1.3 kg (2.9 lb)
ASR1-Up ............................................. 1.3 kg (2.9 lb) 9MW1-Up ............................................ 1.3 kg (2.9 lb)
CS-531 Refrigerant Capacities 1SZ1-Up ............................................. 1.3 kg (2.9 lb)
CS-531D CS-563E
3AZ1-Up ............................................. 1.3 kg (2.9 lb) CNG1-Up ............................................ 1.3 kg (2.9 lb)
4MZ1-Up ............................................. 1.3 kg (2.9 lb) ASA1-Up ............................................. 1.3 kg (2.9 lb)
AGH1-Up ............................................ 1.3 kg (2.9 lb) CS-573 Refrigerant Capacities

CP/CS-533 Refrigerant Capacities CS-573E
CP-533D CNN1-Up ............................................ 1.3 kg (2.9 lb)
6AZ1-Up ............................................. 1.3 kg (2.9 lb) CEB1-Up ............................................. 1.3 kg (2.9 lb)
AFC1-Up ............................................. 1.3 kg (2.9 lb) CS-583 Refrigerant Capacities

DAM1-Up ............................................ 1.3 kg (2.9 lb)
CS-583D
ASM1-Up ............................................ 1.3 kg (2.9 lb)
2CZ1-Up ............................................. 1.3 kg (2.9 lb)
BZG1-Up ............................................. 1.3 kg (2.9 lb)
CS-583E
CS-533D
CNX1-Up ............................................ 1.3 kg (2.9 lb)
5CZ1-Up ............................................. 1.3 kg (2.9 lb)
DAJ1-Up ............................................. 1.3 kg (2.9 lb)
AET1-Up ............................................. 1.3 kg (2.9 lb)
SENR5664-13 81
CP-633 Refrigerant Capacities 242 Refrigerant Capacities

CP-633E 242
DAF1-Up ............................................. 1.3 kg (2.9 lb) CMB1-Up ...................................... 0.68 kg (1.500 lb)
CP/CS-663 Refrigerant Capacities 242B

BXM1-Up ...................................... 0.81 kg (1.786 lb)
CP-663E
ASF1-Up ............................................. 1.3 kg (2.9 lb) 246 Refrigerant Capacities
CS-663E 246
AEF1-Up ............................................. 1.3 kg (2.9 lb) 5SZ1-Up ....................................... 0.68 kg (1.500 lb)
DAG1-Up ............................................ 1.3 kg (2.9 lb) 246B

ASB1-Up ............................................. 1.3 kg (2.9 lb) PAT1-Up ........................................ 0.81 kg (1.786 lb)
CS-683 Refrigerant Capacities 248 Refrigerant Capacities

CS-683E 248B
DAD1-Up ............................................ 1.3 kg (2.9 lb) SCL1-Up ....................................... 0.81 kg (1.786 lb)
ASG1-Up ............................................ 1.3 kg (2.9 lb)
i02504737
252
System Capacities for FDG1-Up ...................................... 0.68 kg (1.500 lb)
Refrigerant (Skid Steer
Loaders) 252B
SMCS Code: 1809 SCP1-Up ....................................... 0.81 kg (1.786 lb)

216 262
4NZ3400-Up ................................. 0.68 kg (1.500 lb) CED1-Up ...................................... 0.68 kg (1.500 lb)

PDT1-Up ....................................... 0.81 kg (1.786 lb)
226B
MJH1-Up ....................................... 0.81 kg (1.786 lb) 268 Refrigerant Capacities

LBA1-Up ....................................... 0.81 kg (1.786 lb)
236
4YZ1-Up ....................................... 0.68 kg (1.500 lb)
236B
HEN1-Up ...................................... 0.81 kg (1.786 lb)
82 SENR5664-13
i02504269 RBB1-Up ........................................... 1.3 kg (2.87 lb)

System Capacities for WMB1-Up ......................................... 1.3 kg (2.87 lb)
Refrigerant (Small Wheel
6YW1-Up .......................................... 1.3 kg (2.87 lb)
Loaders)
3DZ1-Up ........................................... 1.3 kg (2.87 lb)
SMCS Code: 1809
924GZ
DFZ1-Up ........................................... 1.3 kg (2.87 lb)
910F
RTA1-Up ........................................... 1.3 kg (2.87 lb)
1SF1337-Up ..................................... 1.6 kg (3.53 lb)
WGX1-Up ......................................... 1.3 kg (2.87 lb)
910G AAB1-Up ........................................... 1.3 kg (2.87 lb)
AKR1-Up ........................................... 1.3 kg (2.87 lb)
928F
914G 8AK1-Up ........................................... 2.5 kg (5.51 lb)
9WM87-Up ........................................ 1.3 kg (2.87 lb)
2XL1-Up ............................................ 2.5 kg (5.51 lb)
7ZM1-Up ........................................... 1.3 kg (2.87 lb)
7YM1-Up ........................................... 2.5 kg (5.51 lb)
PDF1-Up ........................................... 1.3 kg (2.87 lb)
928G
918 Refrigerant Capacities 6XR1-Up ........................................... 1.3 kg (2.87 lb)
918F 7SR1-Up ........................................... 1.3 kg (2.87 lb)
3TJ363-Up ........................................ 2.0 kg (4.41 lb) DJD1-Up ........................................... 1.3 kg (2.87 lb)
5DL167-Up ....................................... 2.0 kg (4.41 lb) WLG1-Up .......................................... 1.3 kg (2.87 lb)

924F 930G
4YN75-Up ......................................... 2.0 kg (4.41 lb) TWR1-Up .......................................... 1.3 kg (2.87 lb)
5NN75-Up ......................................... 2.0 kg (4.41 lb) TFW1-Up .......................................... 1.3 kg (2.87 lb)
6MN75-Up ........................................ 2.0 kg (4.41 lb)
7PN75-Up ......................................... 2.0 kg (4.41 lb)
924G
9SW1-Up .......................................... 1.3 kg (2.87 lb)
3PZ1-Up ........................................... 1.3 kg (2.87 lb)
AAN1-Up ........................................... 1.3 kg (2.87 lb)
DDA1-Up .......................................... 1.3 kg (2.87 lb)

SENR5664-13 83
i02504921 TH360 Refrigerant Capacities

System Capacities for TH360B
Refrigerant (Telehandlers)
SLE1-Up ........................................... 0.8 kg (1.76 lb)
SMCS Code: 1809
TH460 Refrigerant Capacities
TH460B
TH210
SLF1-Up ........................................... 0.8 kg (1.76 lb)
MHT1-Up .......................................... 1.2 kg (2.65 lb)
CEC1-Up .......................................... 1.2 kg (2.65 lb)

TH560B
SLG1-Up ........................................... 0.8 kg (1.76 lb)
TH215
MHS1-Up .......................................... 1.2 kg (2.65 lb)
CEG1-Up .......................................... 1.2 kg (2.65 lb) TH580B
SLH1-Up ........................................... 0.8 kg (1.76 lb)
TH220B i02517608
SLA1-Up ........................................... 0.8 kg (1.76 lb)

Refrigerant (Track-Type
TH330 Refrigerant Capacities Loaders)
TH330B SMCS Code: 1809
SLB1-Up ........................................... 0.8 kg (1.76 lb) Reference: For the proper procedure to handle
System - Charge.
TH340B 933C Refrigerant Capacities
933C
SLC1-Up ........................................... 0.8 kg (1.76 lb)
8FL70-Up ......................................... 1.8 kg (4 lb)
TH350 Refrigerant Capacities 9EL48-Up ........................................ 1.8 kg (4 lb)
5JS1-Up ........................................ 1.9 kg (4.2 lb)
4MS1-Up ...................................... 1.9 kg (4.2 lb)
TH350B
SLD1-Up ........................................... 0.8 kg (1.76 lb) 939C Refrigerant Capacities
939C
9GL1-Up .......................................... 1.8 kg (4 lb)
TH355B 6DS1-Up ....................................... 1.9 kg (4.2 lb)
JRK1-Up ........................................... 0.8 kg (1.76 lb) 953 Refrigerant Capacities

953B
5KM1651-Up ................................ 1.6 kg (3.5 lb)
84 SENR5664-13
953C 4TS1-Up ....................................... 1.9 kg (4.2 lb)

2ZN1-1748 .................................... 1.1 kg (2.4 lb) D3C Series III HS LGP
2ZN1749-Up ................................. 1.4 kg (3.0 lb)
BBX1-Up ....................................... 1.4 kg (3.0 lb) 5GS1-Up ....................................... 1.9 kg (4.2 lb)
D3C Series III XL

9TS1-Up ....................................... 1.9 kg (4.2 lb)
963
21Z5346-Up .................................. 1.7 kg (3.7 lb) D3G Refrigerant Capacities
963B D3G
9BL1-Up ....................................... 1.6 kg (3.5 lb) CFC1-Up ...................................... 1.1 kg (2.4 lb)
CFF1-Up ....................................... 1.1 kg (2.4 lb)
963C
D3G LGP
2DS1-Up .......................................... 1.4 kg (3 lb)
BBD1-Up ......................................... 1.4 kg (3 lb) BYR1-Up ...................................... 1.1 kg (2.4 lb)
973 Refrigerant Capacities D3G XL

JMH1-Up ...................................... 1.1 kg (2.4 lb)
973
86G1556-Up ................................. 1.6 kg (3.5 lb) D4C series III Refrigerant
973C
Capacities
3RZ1-Up .......................................... 1.4 kg (3 lb) D4C series III
BCP1-Up ......................................... 1.4 kg (3 lb)
6YL141-Up ................................... 1.9 kg (4.2 lb)
LDX1-Up .......................................... 1.4 kg (3 lb)
7SL78-Up ..................................... 1.9 kg (4.2 lb)
8EL57-Up ..................................... 1.9 kg (4.2 lb)
i02549026 1FW1-Up ...................................... 1.9 kg (4.2 lb)
System Capacities for D4C series III HS

Refrigerant (Track-Type 6BS1-Up ....................................... 1.9 kg (4.2 lb)
Tractors) 4DC series III HS XL
SMCS Code: 1809 8CS1-Up ....................................... 1.9 kg (4.2 lb)
Reference: For the proper procedure to handle D4C series III HS LGP
System - Charge. 4LS1-Up ....................................... 1.9 kg (4.2 lb)
D3C Series III Refrigerant D4G Refrigerant Capacities

Capacities
D4G
D3C Series III CFN1-Up ...................................... 1.1 kg (2.4 lb)
6SL172-Up ................................... 1.9 kg (4.2 lb) FDC1-Up ...................................... 1.1 kg (2.4 lb)
7XL107-Up ................................... 1.9 kg (4.2 lb)
9CL78-Up ..................................... 1.9 kg (4.2 lb) D4G LGP
8DL35-Up ..................................... 1.9 kg (4.2 lb) TXL1-Up ....................................... 1.1 kg (2.4 lb)
D3C Series III HS D4G XL
4KS1-Up ....................................... 1.9 kg (4.2 lb) HYD1-Up ...................................... 1.1 kg (2.4 lb)
D3C Series III HS XL
SENR5664-13 85
D4H Series II Refrigerant Capacities 3MD5594-Up ................................ 1.6 kg (3.5 lb)

2SD5549-Up ................................. 1.6 kg (3.5 lb)
D4H Series II 4KD5585-Up ................................. 1.6 kg (3.5 lb)
9GJ945-Up ................................... 1.6 kg (3.5 lb) D5H Series II XL
4NK147-Up ................................... 1.6 kg (3.5 lb)
8RJ4387-Up ................................. 1.6 kg (3.5 lb)
D4H Series II XL
8PJ533-Up .................................... 1.6 kg (3.5 lb) D5M Refrigerant Capacities
D5M
D4H TSK Series III Refrigerant
3CR1-Up ....................................... 1.6 kg (3.5 lb)
Capacities 3DR1-Up ....................................... 1.6 kg (3.5 lb)
4BR1-Up ....................................... 1.6 kg (3.5 lb)
D4H TSK Series III
4JS1-Up ........................................ 1.6 kg (3.5 lb)
7PK135-Up ................................... 1.6 kg (3.5 lb) 7LR1-Up ....................................... 1.6 kg (3.5 lb)
5ES1-Up ....................................... 1.6 kg (3.5 lb)
5FS1-Up ....................................... 1.6 kg (3.5 lb)
D5C Series III Refrigerant 6AS1-Up ....................................... 1.6 kg (3.5 lb)
Capacities 6GN1-Up ...................................... 1.6 kg (3.5 lb)
D5C Series III D5N Refrigerant Capacities

6ZL116-Up .................................... 1.9 kg (4.2 lb)
7YL64-Up ..................................... 1.9 kg (4.2 lb) D5N
9DL209-Up ................................... 1.9 kg (4.2 lb) AGG1-Up ...................................... 1.8 kg (4.0 lb)
AKD1-Up ...................................... 1.8 kg (4.0 lb)
D5C Series III HS
5HS1-Up ....................................... 1.9 kg (4.2 lb) D5N LPG
CKT1-Up ....................................... 1.8 kg (4.0 lb)
D5C Series III HS XL
7PS1-Up ....................................... 1.9 kg (4.2 lb) D5N XL
CFH1-Up ...................................... 1.8 kg (4.0 lb)
D5C Series III HS LPG
6CS1-Up ....................................... 1.9 kg (4.2 lb) D6C Refrigerant Capacities
D5G Refrigerant Capacities D6C
8ZS1-Up ....................................... 1.8 kg (4.0 lb)
D5G
FDH1-Up ...................................... 1.1 kg (2.4 lb) D6G Refrigerant Capacities
FDW1-Up ...................................... 1.1 kg (2.4 lb)
D6G
D5G LGP
3SR1-Up ....................................... 1.7 kg (3.7 lb)
RKG1-Up ...................................... 1.1 kg (2.4 lb)
D5G XL
D6H Series II Refrigerant Capacities
WGB1-Up ..................................... 1.1 kg (2.4 lb) D6H Series II
8FC5612-Up .................................... 2 kg (4.4 lb)
D5H Series II Refrigerant Capacities 1KD5600-Up .................................... 2 kg (4.4 lb)
2KD5618-Up .................................... 2 kg (4.4 lb)
D5H Series II 5HF5582-Up .................................... 2 kg (4.4 lb)
6CF5565-Up .................................... 2 kg (4.4 lb)
7NC5527-Up ................................. 1.6 kg (3.5 lb) 2TG5593-Up .................................... 2 kg (4.4 lb)
8RC5967-Up ................................. 1.6 kg (3.5 lb) 4GG5632-Up ................................... 2 kg (4.4 lb)
9HC5521-Up ................................. 1.6 kg (3.5 lb) 4LG5598-Up .................................... 2 kg (4.4 lb)
1DD6006-Up ................................. 1.6 kg (3.5 lb) 1FJ5542-Up ..................................... 2 kg (4.4 lb)
1YD5522-Up ................................. 1.6 kg (3.5 lb)
86 SENR5664-13
D6H Series II XR D6R Refrigerant Capacities

4RC5589-Up .................................... 2 kg (4.4 lb) D6R
6FC5542-Up .................................... 2 kg (4.4 lb)
3ZF5736-Up .................................... 2 kg (4.4 lb) 1RW1-Up ...................................... 1.6 kg (3.5 lb)
3YG5772-Up .................................... 2 kg (4.4 lb) 2YN1-Up ....................................... 1.6 kg (3.5 lb)
5KK336-Up ...................................... 2 kg (4.4 lb) 3ZN1-Up ....................................... 1.6 kg (3.5 lb)
6CK354-Up ...................................... 2 kg (4.4 lb) 4FM1-Up ....................................... 1.6 kg (3.5 lb)
7ZK349-Up ...................................... 2 kg (4.4 lb) 4HN1-Up ....................................... 1.6 kg (3.5 lb)
1YL320-Up ...................................... 2 kg (4.4 lb) 4JR1-Up ....................................... 1.6 kg (3.5 lb)
2BL347-Up ...................................... 2 kg (4.4 lb) 4MN1-Up ...................................... 1.6 kg (3.5 lb)
2TL346-Up ....................................... 2 kg (4.4 lb) 4TR1-Up ....................................... 1.6 kg (3.5 lb)
9MN1-Up ...................................... 1.6 kg (3.5 lb)
D6H Series II XL 9PN1-Up ....................................... 1.6 kg (3.5 lb)
4WR1-Up ...................................... 1.6 kg (3.5 lb)
4YF5575-Up .................................... 2 kg (4.4 lb) 5LN1-Up ....................................... 1.6 kg (3.5 lb)
8ZJ319-Up ....................................... 2 kg (4.4 lb) 5PR1-Up ....................................... 1.6 kg (3.5 lb)
9KJ441-Up ....................................... 2 kg (4.4 lb) 5RR1-Up ....................................... 1.6 kg (3.5 lb)
8KK314-Up ...................................... 2 kg (4.4 lb) 6FR1-Up ....................................... 1.6 kg (3.5 lb)
8SK369-Up ...................................... 2 kg (4.4 lb) 6HR1-Up ....................................... 1.6 kg (3.5 lb)
9LK464-Up ...................................... 2 kg (4.4 lb) 6JN1-Up ....................................... 1.6 kg (3.5 lb)
9RK308-Up ...................................... 2 kg (4.4 lb) 6MR1-Up ...................................... 1.6 kg (3.5 lb)
6GR1-Up ...................................... 1.6 kg (3.5 lb)
D6M Refrigerant Capacities 7AR1-Up ....................................... 1.6 kg (3.5 lb)
7DR1-Up ....................................... 1.6 kg (3.5 lb)
D6M 7GR1-Up ...................................... 1.6 kg (3.5 lb)
7KN1-Up ....................................... 1.6 kg (3.5 lb)
3WN1-Up ...................................... 1.6 kg (3.5 lb) 8LN1-Up ....................................... 1.6 kg (3.5 lb)
4JN1-UP ....................................... 1.6 kg (3.5 lb) 8TM1-Up ....................................... 1.6 kg (3.5 lb)
2RN1-Up ....................................... 1.6 kg (3.5 lb) 8XN1-Up ....................................... 1.6 kg (3.5 lb)
2YS1-Up ....................................... 1.6 kg (3.5 lb) 9BM1-Up ...................................... 1.6 kg (3.5 lb)
4GS1-Up ....................................... 1.6 kg (3.5 lb) 2HM1-Up ...................................... 1.6 kg (3.5 lb)
4HS1-Up ....................................... 1.6 kg (3.5 lb) 9ZS1-Up ....................................... 1.6 kg (3.5 lb)
5NR1-Up ....................................... 1.6 kg (3.5 lb) BMJ1-Up ....................................... 1.6 kg (3.5 lb)
5WR1-Up ...................................... 1.6 kg (3.5 lb) BMY1-Up ...................................... 1.6 kg (3.5 lb)
6LR1-Up ....................................... 1.6 kg (3.5 lb) DAE1-Up ...................................... 1.6 kg (3.5 lb)
9ZM1-Up ....................................... 1.6 kg (3.5 lb) DMP1-Up ...................................... 1.6 kg (3.5 lb)
D6N Refrigerant Capacities D6R Series II Refrigerant Capacities

D6N D6R Series II
ALH1-Up ....................................... 1.8 kg (4.0 lb) AEM1-Up ...................................... 1.6 kg (3.5 lb)
ALR1-Up ....................................... 1.8 kg (4.0 lb) BLE1-Up ....................................... 1.6 kg (3.5 lb)
AFM1-Up ...................................... 1.6 kg (3.5 lb)
D6N LGP BLT1-Up ....................................... 1.6 kg (3.5 lb)
AGM1-Up ...................................... 1.6 kg (3.5 lb)
ALY1-Up ....................................... 1.8 kg (4.0 lb) AAX1-Up ....................................... 1.6 kg (3.5 lb)
CCG1-Up ...................................... 1.8 kg (4.0 lb) ACJ1-Up ....................................... 1.6 kg (3.5 lb)
CCS1-Up ...................................... 1.8 kg (4.0 lb) ADE1-Up ...................................... 1.6 kg (3.5 lb)
BNC1-Up ...................................... 1.6 kg (3.5 lb)
D6N XL AEP1-Up ....................................... 1.6 kg (3.5 lb)
AKM1-Up ...................................... 1.8 kg (4.0 lb) AFD1-Up ....................................... 1.6 kg (3.5 lb)
CCK1-Up ...................................... 1.8 kg (4.0 lb) FDT1-Up ....................................... 1.6 kg (3.5 lb)
CBJ1-Up ....................................... 1.8 kg (4.0 lb) BRJ1-Up ....................................... 1.6 kg (3.5 lb)
CBL1-Up ....................................... 1.8 kg (4.0 lb) BPM1-Up ...................................... 1.6 kg (3.5 lb)
CBF1-Up ....................................... 1.8 kg (4.0 lb) CAD1-Up ...................................... 1.6 kg (3.5 lb)
BRZ1-Up ....................................... 1.6 kg (3.5 lb)
BMK1-Up ...................................... 1.6 kg (3.5 lb)
BPP1-Up ....................................... 1.6 kg (3.5 lb)
BNL1-Up ....................................... 1.6 kg (3.5 lb)
SENR5664-13 87
BRE1-Up ...................................... 1.6 kg (3.5 lb) 3DN1-Up ....................................... 1.6 kg (3.5 lb)
BPS1-Up ....................................... 1.6 kg (3.5 lb) 3ZR1-Up ....................................... 1.6 kg (3.5 lb)
BPZ1-Up ....................................... 1.6 kg (3.5 lb) 4SR1-Up ....................................... 1.6 kg (3.5 lb)
5KZ1-Up ....................................... 1.6 kg (3.5 lb)
D6R Series III Refrigerant 5MR1-Up ...................................... 1.6 kg (3.5 lb)
6ER1-Up ....................................... 1.6 kg (3.5 lb)
Capacities 9HM1-Up ...................................... 1.6 kg (3.5 lb)
CBZ1-Up ....................................... 1.6 kg (3.5 lb)
D6R Series III
HKE1-Up ...................................... 1.6 kg (3.5 lb) D8N Refrigerant Capacities
GJB1-Up ....................................... 1.6 kg (3.5 lb)
WCB1-Up ..................................... 1.6 kg (3.5 lb) D8N
HDC1-Up ...................................... 1.6 kg (3.5 lb)
5TJ1317-Up .................................. 1.6 kg (3.5 lb)
WRG1-Up ..................................... 1.6 kg (3.5 lb)
7TK1-Up ....................................... 1.6 kg (3.5 lb)
MRT1-Up ...................................... 1.6 kg (3.5 lb)
HCD1-Up ...................................... 1.6 kg (3.5 lb) 1XJ1-Up ........................................ 1.6 kg (3.5 lb)
9TC1-Up ....................................... 1.6 kg (3.5 lb)
TBC1-Up ....................................... 1.6 kg (3.5 lb)
LFM1-Up ....................................... 1.6 kg (3.5 lb)
DPS1-Up ...................................... 1.6 kg (3.5 lb) D8R Refrigerant Capacities
DMK1-Up ...................................... 1.6 kg (3.5 lb)
RFC1-Up ...................................... 1.6 kg (3.5 lb) D8R
MTJ1-Up ....................................... 1.6 kg (3.5 lb)
DLM1-Up ...................................... 1.6 kg (3.5 lb) 7XM1-Up ...................................... 1.7 kg (3.7 lb)
GMT1-Up ...................................... 1.6 kg (3.5 lb) 9EM1-Up ...................................... 1.7 kg (3.7 lb)
JDL1-Up ....................................... 1.6 kg (3.5 lb) 6YZ1-Up ....................................... 1.7 kg (3.7 lb)
AKA1-Up ....................................... 1.7 kg (3.7 lb)
D7H Series II Refrigerant Capacities
D8R Refrigerant Capacities
D7H Series II
Note: Remote condenser
4AB5532-Up ................................. 1.6 kg (3.5 lb)
5WB5586-Up ................................ 1.6 kg (3.5 lb) D8R
5BF5690-Up ................................. 1.6 kg (3.5 lb)
2RG5622-Up ................................ 1.6 kg (3.5 lb) 7XM1-Up ...................................... 1.6 kg (3.5 lb)
3XG5515-Up ................................. 1.6 kg (3.5 lb) 9EM1-Up ...................................... 1.6 kg (3.5 lb)
4FG5537-Up ................................. 1.6 kg (3.5 lb) 6YZ1-Up ....................................... 1.6 kg (3.5 lb)
79Z5611-Up .................................. 1.6 kg (3.5 lb) AKA1-Up ....................................... 1.6 kg (3.5 lb)
80Z5518-Up .................................. 1.6 kg (3.5 lb)
D8T Refrigerant Capacities
D7R Series II Refrigerant Capacities
Note: Remote condenser
D7R Series II
D8T
ADW1-Up ..................................... 1.6 kg (3.5 lb)
ACS1-Up ...................................... 1.6 kg (3.5 lb) KPZ1-Up ....................................... 1.7 kg (3.7 lb)
AFG1-Up ...................................... 1.6 kg (3.5 lb) J8B1-Up ........................................ 1.7 kg (3.7 lb)
AEC1-Up ...................................... 1.6 kg (3.5 lb)
AGN1-Up ...................................... 1.6 kg (3.5 lb) D8T Refrigerant Capacities
ABJ1-Up ....................................... 1.6 kg (3.5 lb)
BPK1-Up ....................................... 1.6 kg (3.5 lb) D8T
BNM1-Up ...................................... 1.6 kg (3.5 lb)
BPT1-Up ....................................... 1.6 kg (3.5 lb) KPZ1-Up ....................................... 1.9 kg (4.2 lb)
BNX1-Up ...................................... 1.6 kg (3.5 lb) J8B1-Up ........................................... 1.8 kg (3 lb)
BRM1-Up ...................................... 1.6 kg (3.5 lb)
BRP1-Up ...................................... 1.6 kg (3.5 lb) D9N Refrigerant Capacities
D7R Refrigerant Capacities D9N
D7R 5FJ1-Up ........................................ 1.6 kg (3.5 lb)

1JD1-Up ....................................... 1.6 kg (3.5 lb)
2EN1-Up ....................................... 1.6 kg (3.5 lb) 6XJ523-Up .................................... 2.1 kg (4.6 lb)
2HR1-Up ....................................... 1.6 kg (3.5 lb)
88 SENR5664-13
D9R Refrigerant Capacities D10R Refrigerant Capacities

D9R Note: Roof mount with large accumulator
7TL1-Up ........................................ 2.1 kg (4.6 lb) D10R
8BL1-Up ....................................... 2.1 kg (4.6 lb)
JJB1-Up ........................................ 2.8 kg (6.2 lb) 3KR1-Up ....................................... 2.1 kg (4.6 lb)
WDM1-Up ..................................... 2.8 kg (6.2 lb)
ACL1-Up ....................................... 2.8 kg (6.2 lb)
D9R Refrigerant Capacities Note: Remote condenser
Note: Remote condenser D10T
D9R RJG1-Up ....................................... 2.1 kg (4.6 lb)
7TL1-Up ........................................ 1.6 kg (3.5 lb)

8BL1-Up ....................................... 1.6 kg (3.5 lb)
WDM1-Up ..................................... 2.3 kg (5.1 lb)
D10T
ACL1-Up ....................................... 2.3 kg (5.1 lb)
ABK1-Up ....................................... 2.3 kg (5.1 lb) RJG1-Up ....................................... 2.0 kg (4.4 lb)
D9T Refrigerant Capacities D11N Refrigerant Capacities

Note: Remote condenser D11N
D9T 4HK366-Up ................................... 2.5 kg (5.5 lb)
RJS1-Up ....................................... 2.3 kg (5.1 lb)

D9T Refrigerant Capacities D11R
Note: Fender mount condenser 8ZR1-Up ....................................... 2.5 kg (5.5 lb)

9TR1-Up ....................................... 2.5 kg (5.5 lb)
D9T 9XR1-Up ....................................... 2.5 kg (5.5 lb)
7PZ1-Up ....................................... 2.5 kg (5.5 lb)
RJS1-Up ....................................... 2.3 kg (5.1 lb) AAF1-Up ....................................... 2.5 kg (5.5 lb)
D10N Refrigerant Capacities D11R Refrigerant Capacities

D10N Note: Large accumulator
3SK410-Up ...................................... 2 kg (4.4 lb)
D11R
92V410-Up ...................................... 2 kg (4.4 lb)
8ZR1-Up .......................................... 3 kg (6.6 lb)
D10R Refrigerant Capacities 9TR1-Up .......................................... 3 kg (6.6 lb)
9XR1-Up .......................................... 3 kg (6.6 lb)
D10R 7PZ1-Up .......................................... 3 kg (6.6 lb)
AAF1-Up .......................................... 3 kg (6.6 lb)
3KR1-Up ....................................... 2.1 kg (4.6 lb)
AKT1-Up ....................................... 2.1 kg (4.6 lb)
D10R Refrigerant Capacities Note: Roof mount with large accumulator
Note: Large accumulator D11R
D10R 8ZR135-Up ................................... 2.1 kg (4.6 lb)

9TR135-Up ................................... 2.1 kg (4.6 lb)
3KR1-Up ....................................... 2.6 kg (5.7 lb) 9XR135-Up ................................... 2.1 kg (4.6 lb)
7PZ135-Up ................................... 2.1 kg (4.6 lb)
SENR5664-13 89
AAF135-Up ................................... 2.1 kg (4.6 lb) AD55 Refrigerant Capacities

583T Pipelayer Refrigerant AD55
Capacities ANW1-380 .......................................... 1.8 kg (4.0 lb)
583T Pipelayer ANW381-Up ........................................ 2.3 kg (5.0 lb)
CMX1-Up ...................................... 1.8 kg (4.0 lb)
DNW1-Up ........................................... 2.3 kg (5.0 lb)
i02517675
i02507768
System Capacities for System Capacities for
Refrigerant (Underground Refrigerant (Wheel Dozers)
Articulated Truck)
SMCS Code: 1809
SMCS Code: 1809
Reference: For the proper procedure to handle refrigerant, refer to Testing and Adjusting, Refrigerant
refrigerant, refer to Testing and Adjusting, Refrigerant System - Charge.
System - Charge.
AD30 Refrigerant Capacities
814B
AD30
16Z368-Up .................................... 1.4 kg (3.1 lb)
CXR1-Up ............................................ 1.8 kg (4.0 lb)
814F
DXR1-Up ............................................ 1.8 kg (4.0 lb) 9DM1-Up ...................................... 2.1 kg (4.6 lb)
BGF1-Up ...................................... 1.9 kg (4.2 lb)
AD40 and AE40 Refrigerant
814FII
Capacities
BXG1-Up ...................................... 1.9 kg (4.2 lb)
AD40
1YZ1-Up ............................................. 2.5 kg (5.5 lb)
824B
AE40
36H1-Up ....................................... 1.9 kg (4.2 lb)
1ZZ1-Up .............................................. 2.5 kg (5.5 lb)
824C
AE40 Series II 85X1651-Up ................................. 2.5 kg (5.5 lb)
BLW1-Up ............................................ 2.5 kg (5.5 lb) 824G
4SN1-Up ....................................... 2.5 kg (5.5 lb)
AD45 Refrigerant Capacities
824G II
AD45
AWW1-Up ..................................... 2.5 kg (5.5 lb)
BKZ1-Up ............................................. 2.5 kg (5.5 lb)
824H
AD45B ASX1-Up ....................................... 2.5 kg (5.5 lb)
CXM1-Up ............................................... 2 kg (4.4 lb)
834B
92Z580-Up ....................................... 3 kg (6.6 lb)
90 SENR5664-13
7BR1-Up ....................................... 2.8 kg (6.1 lb) 615 Refrigerant Capacities

834G 615 Series II
6GZ1-Up ....................................... 2.6 kg (5.7 lb) 9XG343-Up ................................... 1.7 kg (3.7 lb)
BPC1-Up ...................................... 2.6 kg (5.7 lb)
834H
BTX1-Up ....................................... 2.6 kg (5.7 lb) 621F
4SK22-Up ........................................ 1.8 kg (4 lb)
844 Refrigerant Capacities 8PL1-Up .......................................... 1.8 kg (4 lb)
590B/844 621G
2KZ1-Up ....................................... 4.1 kg (9.0 lb) APL1-Up .......................................... 1.8 kg (4 lb)
CEN1-Up ......................................... 1.8 kg (4 lb)
844 DBB1-Up ......................................... 2 kg (4.4 lb)
BBN1-Up ...................................... 2.7 kg (5.9 lb)
844H
623F
BTW1-Up ...................................... 2.3 kg (5.0 lb)
6BK1-Up .......................................... 1.8 kg (4 lb)
5EW1-Up ......................................... 1.8 kg (4 lb)
854G Refrigerant Capacities
623G
790G/854G
ARW1-Up ........................................ 1.8 kg (4 lb)
IJW1-Up ........................................ 2.6 kg (5.7 lb) CES1-Up ......................................... 1.8 kg (4 lb)
DBC1-Up ......................................... 2 kg (4.4 lb)
854G
AMP1-Up ...................................... 2.3 kg (5.0 lb) 627 Refrigerant Capacities
A4W1-Up ...................................... 2.3 kg (5.0 lb)
627F
i02503863 1DL18-Up ........................................ 1.8 kg (4 lb)
System Capacities for 627G
Refrigerant (Wheel AXF1-Up .......................................... 1.8 kg (4 lb)
Tractor-Scrapers) CEX1-Up ......................................... 1.8 kg (4 lb)
DBD1-Up ......................................... 2 kg (4.4 lb)
SMCS Code: 1809

631E Series II
System - Charge.
1NB1-Up .......................................... 2 kg (4.4 lb)
611 Refrigerant Capacities 1AB1510-Up .................................... 2 kg (4.4 lb)
611 631G
6SZ1-Up ....................................... 1.7 kg (3.7 lb) AWK1-Up ......................................... 1.8 kg (4 lb)

CLR1-Up .......................................... 1.8 kg (4 lb)
DFA1-Up ....................................... 2.4 kg (5.3 lb)
613 Series II 633 Refrigerant Capacities
8LJ884-Up .................................... 1.7 kg (3.7 lb) 633E
SENR5664-13 91
2PS1-Up .......................................... 2 kg (4.4 lb)

637E
1JB1-Up ........................................ 2.4 kg (5.3 lb)
637E Series II
1FB571-Up ...................................... 2 kg (4.4 lb)
637G
AXT1-Up .......................................... 1.8 kg (4 lb)
CEH1-Up ......................................... 1.8 kg (4 lb)
DFJ1-Up ....................................... 2.4 kg (5.3 lb)

651E
89Z271-Up .................................... 2.1 kg (4.6 lb)
4YR1-Up ....................................... 2.1 kg (4.6 lb)

657E
6TR1-Up ....................................... 2.1 kg (4.6 lb)
5YR1-Up ....................................... 2.1 kg (4.6 lb)
90Z223-Up .................................... 2.4 kg (5.3 lb)
91Z453-Up .................................... 2.4 kg (5.3 lb)
657G
W1B1-Up ...................................... 2.1 kg (4.6 lb)
W1C1-Up ...................................... 2.1 kg (4.6 lb)
92 SENR5664-13
Systems Operation Section

i02414078
General Information
SMCS Code: 7309
The air conditioning system is a closed circuit that

uses the refrigerant , which is under pressure, to cool
the operator compartment.
The five components of the expansion valve

system are the compressor, the condenser coil,
g00649373
the receiver-dryer, the expansion valve and the Illustration 26
evaporator coil. (1) Compressor block fittings
(2) R-134a charging ports
The six components of the manual orifice tube
system are the compressor, the condenser coil, If the machine has R-134a charging ports (2), a tag
the accumulator, the dryer, the orifice tube and the should identify the type of refrigerant oil that is used
evaporator coil. in the system. The tag will be located inside the cab
or near the compressor. The tag will identify the type
The seven components of the electronic orifice of refrigerant oil that is present in the air conditioning
tube system are the compressor, the condenser system. The tag will also show the amount of
coil, the accumulator, the dryer, the orifice tube, the refrigerant that is needed in the air conditioning
evaporator coil and the heater valve. system.
Note: Some orifice tube systems use an accumulator Machines that have factory installed R-134a air
with a desiccant instead of a separate dryer. conditioning systems will contain Poly Alkaline Glycol
oil in the air conditioning system.
i02510357 If the machine has been retrofitted with a R-134a
air conditioning system, the identification tag will
Identifying the Air Conditioning indicate ESTER oil as the type of refrigerant oil. The
System identification tag will be located in the cab or near
the compressor.
SMCS Code: 1808; 7320-ZJ; 7322
When a new R-134a compressor is required in order
The type of air conditioning system must be identified to retrofit a R-134a air conditioning system onto
before the system is serviced. The refrigerant must a machine with the R12 air conditioning system,
be identified so that the correct service manual can the Poly Alkaline Glycol Oil must be replaced with
be selected. ESTER oil.
By examining charging ports (2), you can determine

if the air conditioning system contains R-134a
refrigerant.
SENR5664-13 93
g00649393
Illustration 27
(3) Receiver-dryer for the expansion valve system
g00649412
Illustration 28
g01256773
Illustration 29
(4) Accumulator for an orifice tube system
The R-134a air conditioning system must be

identified as an orifice tube system or an expansion
valve system. If the system has a receiver-dryer
(3), the system is an expansion valve system. If an
accumulator (4) is present the system is an orifice
tube system.
94 SENR5664-13
i02513667 The air conditioner refrigerant begins to flow in

the air conditioning system at the air conditioning
Refrigerant Expansion Valve compressor (1). The primary purpose of the
System compressor (1) is changing the air conditioner
refrigerant from a vapor that has low pressure into a
SMCS Code: 7320 vapor that has high pressure. Also, the compressor
(1) changes the air conditioner refrigerant to a vapor
with high temperature. An increase in the pressure
from the compressor (1) causes the increase in the
temperature of the refrigerant. The refrigerant is sent
through the condenser coil (2). In the condenser
coil, the refrigerant loses a small amount of heat.
This changes the air conditioner refrigerant to a high
temperature and high pressure liquid.
In the condenser coil (2), heat is transferred from the

refrigerant to the outside air. From the condenser coil
(2), the refrigerant moves to the receiver-dryer (3).
In the receiver-dryer, moisture is removed from the
refrigerant. The air conditioner refrigerant moves from
the receiver-dryer (3) to the expansion valve (4). In
the expansion valve, the air conditioner refrigerant is
changed from a high pressure and high temperature
liquid. The refrigerant expands in the evaporator coil
(6). The refrigerant becomes a low pressure and low
temperature liquid. When the refrigerant expands
in the evaporator coil, the refrigerant absorbs heat
from the cab. This changes the refrigerant to a low
pressure and low temperature vapor. The refrigerant
returns to the compressor (1) as a low pressure and
low temperature vapor. This marks the end of the
cycle. The cycle is repeated continuously.
Note: In an expansion valve system, frost can

be used as an indication of blockage in the air
conditioning system.
g00358258
Illustration 30
Refrigerant Flow Through Air Conditioning System
(1) Compressor
(2) Condenser Coil
(3) Receiver-Dryer
(4) Expansion Valve
(5) External Equalizer Line
(6) Evaporator Coil
(A) Air conditioner refrigerant as a high pressure, high temperature
vapor
(B) Air conditioner refrigerant as a high pressure, high temperature
liquid
(C) Air conditioner refrigerant as a low pressure and low
temperature liquid
(D) Air conditioner refrigerant as a low pressure and low
temperature vapor
SENR5664-13 95
Refrigerant Expansion Valve The liquid refrigerant with high pressure and high
temperature enters the expansion valve (4) at the
inlet (12). Only a small amount of the liquid refrigerant
is allowed to flow through the metered restriction (10)
and into the outlet. The size of the metered restriction
(10) is controlled by a ball and rod (9). The spring
(11) moves the ball and rod (9) up the expansion
valve. This makes the restriction (10) smaller. The
diaphragm (8) moves the ball and rod (9) down the
expansion valve. This makes the restriction (10)
larger. A temperature sensing bulb with a capillary
tube (7) is connected to the evaporator coil outlet
pipe. The temperature sensing bulb measures the
temperature at the outlet of the evaporator coil. If the
temperature increases, the pressure in the capillary
tube (7) increases. The pressure in the capillary
tube (7) pushes down on the diaphragm (8). The
diaphragm pushes down on the ball and rod (9).
When the ball and rod are pushed down by the
diaphragm the size of the restriction (10) increases.
The pressure that pushes on the diaphragm allows
more liquid refrigerant to flow into the evaporator coil
(6). When the temperature decreases, the pressure
decreases on the diaphragm (8). The spring (11)
pushes up the ball and rod (9) and this makes
the restriction (10) smaller. As a result, less liquid
refrigerant flows into the evaporator coil (6).
The external equalizer line (5) connects the low

Illustration 31
g00645819 pressure from the outlet of the evaporator coil (6)
Expansion Valve in the open position (typical example) to the underside of the expansion valve (4) and
the diaphragm (8). The pressure from the external
(4) Expansion valve
(5) External equalizer line equalizer line pushes up against the bottom of the
(7) Capillary tube diaphragm. The pressure that is created by the
(8) Diaphragm temperature sensing bulb in the capillary tube (7)
(9) Ball and rod pushes down the top of the diaphragm (8). The
(10) Metered restriction
(11) Spring
pressures on each side of the diaphragm act against
(12) Inlet each other. The variation of pressure on each side
(13) Outlet of the diaphragm will help to regulate the refrigerant
flow by moving the ball and rod (9) up and down.
Expansion valve (4) converts the liquid refrigerant Regulating the refrigerant flow will prevent the
from a high pressure high temperature liquid to flooding of the evaporator coil (6) with refrigerant.
a low pressure low temperature liquid/vapor. The
expansion valve provides a metered restriction (10).
The expansion valve allows the high pressure liquid
to be reduced to a low pressure liquid. When the
pressure of the refrigerant is reduced, the boiling
temperature of the refrigerant will also be reduced.
The refrigerant will enter the evaporator coil (6). Heat
from the cab will be absorbed by the refrigerant.
96 SENR5664-13
Receiver-Dryer
g01257657
Illustration 33
Top View of Receiver-Dryer
(3) Receiver-dryer
(14) Low pressure cutoff switch
(15) Quick coupler
(16) High pressure relief valve
(19) Sight glass
(20) Moisture indicator
g01257653
Illustration 32
The liquid refrigerant under high pressure and
Typical Receiver-Dryer
under high temperature leaves condenser coil (2)
(3) Receiver-dryer and passes through receiver-dryer (3). The liquid
(14) Low pressure cutoff switch
(15) Quick coupler
refrigerant inside the receiver-dryer passes through
(16) Relief valve filter (17) and desiccant (18). The desiccant will
(17) Filter absorb a small amount of moisture.
(18) Desiccant
Receiver-dryer (3) will also store a small amount of
refrigerant. This stored refrigerant is used in order
to compensate for the changing system demands.
The demands can result from different speeds of the
compressor and small losses of refrigerant.
Some receiver-dryers are equipped with quick

couplers (15). Receiver-dryers that have quick
couplers can be removed and installed without
recovering the refrigerant in the air conditioner
system. Refer to Disassembly and Assembly,
Receiver-Dryer - Remove and Install.
High pressure relief valve (16) is located on most

receiver-dryers. The valve allows the refrigerant to be
released to the atmosphere if the pressure increases
to approximately 3450 kPa (500 psi).
Most receiver-dryers (3) will have low pressure

cutoff switch (14). If the system pressure lowers to
approximately 175 kPa (25 psi), the switch will open.
This will open the electric circuit to the magnetic
clutch and the compressor will not operate.
SENR5664-13 97
Moisture Indicator i02513649
Some air conditioning systems will have moisture Refrigerant Orifice Tube
indicator (20). This moisture indicator is used in order System
to determine the relative moisture in the system.
SMCS Code: 7320-QT
In order to check for moisture, the air conditioning
system must be operated for two to three hours. The
moisture indicator may indicate a problem that is
false. The system must be operated for 2 to 3 hours
before the system is checked for moisture. Look at
moisture indicator (20). If the moisture indicator is
blue, the system is dry. If the moisture indicator is
pink or white, the system is full of moisture.
If the system is full of moisture, the moisture must

be removed. Refer to Disassembly and Assembly,
Receiver-Dryer - Remove and Install.
g00647547
Illustration 34
Typical Refrigerant Orifice Tube System
(1) Compressor
(2) Condenser coil
(3) In-Line dryer
(4) Evaporator coil
(5) Accumulator
(A) Refrigerant is shown as a gas with high pressure and high
temperature.
(B) Refrigerant is shown as a liquid with high pressure and high
temperature.
(C) Refrigerant is shown as a low pressure and low temperature
liquid.
(D) Refrigerant is shown as a gas with low pressure and low
temperature.
98 SENR5664-13
Note: In an orifice tube system that is properly In models without an in-line dryer, the desiccant is
charged, frost may form between the orifice tube located in the accumulator (5). The accumulator is
and the compressor. The frost may be present if located in the line that extends from the evaporator
the system is operating properly and if the system coil (4) to the compressor (1). The orifice tube
is properly charged. assembly (7) may be located before the inlet of the
evaporator coils or the orifice tube may be located at
Note: In an orifice tube system, a combination of the inlet of the evaporator coils.
abnormal pressure and frost may indicate blockage
in the system. NOTICE
The orifice tube systems do not have a sight glass for
determining whether the system is low on refrigerant.
Orifice Tube
g00364412
Illustration 36
Typical Orifice Tube Assembly
(7) Orifice tube assembly
(10) Orifice tube
(11) O-Ring seal
(12) Tab
(13) Screens
The orifice tube assembly (7) has a plastic body,

two screens (13) and a small brass tube (10) that is
located in the center of the body. The O-Ring seals
(11) are positioned on the body of the orifice tube to
seal against leakage. The orifice tube assembly (7 )
is contained in the dryer. The orifice tube assembly is
g00647550
used in place of the thermostatic expansion valve.
Illustration 35
Typical In-Line Dryer The orifice tube assembly (7) changes the refrigerant
(6) Quick coupler from a high pressure and high temperature refrigerant
(7) Orifice tube assembly into a low pressure and low temperature liquid. The
(8) Desiccant orifice tube (10) has a restriction. The restriction in
the orifice tube assembly allows the liquid refrigerant
The orifice tube system uses an orifice tube in place to be reduced from a high pressure to a low pressure.
of the expansion valve. The accumulator (5) and The flow rate is controlled by pressure differences
the in-line dryer with orifice tube (3) replace the across the orifice. The flow rate is also controlled by
receiver-dryer. the temperature of the liquid refrigerant that is in the
bottom of the condenser. The flow rate is sensitive to
The orifice tube assembly (7) is located in one end temperature differences and pressure differences.
of the in-line dryer (3). The in-line dryer (3) is located The flow rate is more sensitive to temperature
in the line that goes from the condenser coil (2) to differences.
the evaporator coil (4). Quick couplers enable the
in-line dryer (3) to be replaced without recovering the
system. (6).
SENR5664-13 99
Refrigerant Accumulator i02531921
SMCS Code: 1802
g01257036
Illustration 38
(1) Compressor
(2) Magnetic clutch and pulley assembly
g01257625
Illustration 37
(5) Accumulator
(14) Inlet
(15) Desiccant
(16) Liquid refrigerant
(17) Oil drain hole
(18) Outlet
The accumulator (5) is located at the outlet of the

evaporator coil (4). The accumulator (5) separates
the liquid refrigerant from the refrigerant vapor
that passes through the evaporator coil (4). The
accumulator (5) retains the liquid refrigerant (16) that
is separated. Also, the accumulator (5) releases the
vapor to the compressor (1).
The oil drain hole (17) is located in the bottom of

the accumulator (5). The oil drain hole will drain
refrigerant oil that is separated. The oil drain hole will
also drain some of the liquid refrigerant. This liquid
refrigerant will go back to the compressor.
The flow of refrigerant out of the accumulator (5) g01266606

Illustration 39
to the compressor (1) is mostly vapor. The vapor (2) Magnetic clutch and pulley assembly
contains a small amount of liquid refrigerant. This (3) Coil assembly
liquid refrigerant comes from the oil drain hole (17). (4) Drive plate
(5) Bearing
(6) Compressor shaft
When a dryer is not used in the system, desiccants
(7) are located in the base of the accumulator (5).
The compressor is driven by the engine. A belt
The desiccant is a moisture collection agent.
connects the engine to the clutch and pulley
assembly (2). The pulley assembly is located on the
In an orifice tube system that has an in-line dryer (3),
clutch. The drive plate (4) is fastened to the shaft
there is no desiccant (15) in the accumulator (5).
of the compressor. The clutch and pulley assembly
(2) turns on the bearing (5). The clutch and pulley
assembly (2) are not connected to the shaft (6).
The electric current from the thermostat controls a
magnetic field in the coil assembly (3).
100 SENR5664-13
The magnetic field pulls the drive plate (4) against When the refrigerant leaves the compressor, the
the clutch and pulley assembly (2). The clutch and refrigerant is a vapor. The temperature of the
the pulley assembly (2) turns the shaft (6) that refrigerant is high and the pressure of the refrigerant
operates the compressor. When the current to the is high when the refrigerant leaves the compressor.
coil assembly (3) is stopped, the magnetic field is The increase in pressure of the refrigerant causes
removed. This allows the drive plate (4) to move an increase in temperature of the refrigerant. The
away from the clutch and pulley assembly (2). The refrigerant vapor leaves the compressor and the
clutch and the pulley assembly (2) will turn freely on refrigerant enters the condenser (1).
the bearing (5). The sequence of connecting and
disconnecting the pulley to the compressor shaft (6) The refrigerant must be converted into a liquid
is called compressor cycling. The compressor cycling that has high temperature and high pressure. The
is controlled by the thermostat . The thermostat is refrigerant must be converted into a liquid in order to
controlled by the capillary tube, which is installed increase the efficiency of the air conditioning system.
between the fins of the evaporator coil. The condenser (1) converts the refrigerant vapor into
a liquid that has high temperature and high pressure.
i02414132
When the refrigerant vapor leaves the compressor,
Refrigerant Condenser the refrigerant vapor enters the condenser. The
condenser is in a location that is exposed to outside
SMCS Code: 1805 air. In order to convert the refrigerant into a liquid, the
refrigerant must lose heat. The refrigerant must reach
the temperature of saturation. At the temperature of
saturation, the refrigerant vapor will become a liquid.
The temperature of saturation of the refrigerant
depends on the pressure of the refrigerant.
As the high temperature, high pressure refrigerant

vapor passes through the condenser (1), the
condenser absorbs heat from the refrigerant vapor.
The condenser transfers the heat to the outside
air. The temperature of the refrigerant and the
pressure of the refrigerant decrease until the
temperature of saturation is reached. When the
temperature of the refrigerant vapor is equal to the
temperature of saturation, the refrigerant becomes
Illustration 40
g00289099 a high temperature, high pressure liquid. When the
Typical Condenser refrigerant is converted into a liquid, the refrigerant
leaves the condenser (1).
i02414153
Evaporator Coil
SMCS Code: 7343
g00650466
Illustration 41
Typical Condenser
g01265314
Illustration 42
(1) Typical evaporator coil
SENR5664-13 101
In an expansion valve system, the evaporator coil Nonadjustable Thermostat (Freeze

receives liquid refrigerant from the expansion valve.
In an orifice tube system, the evaporator receives
Control System)
liquid refrigerant from the orifice tube assembly. The
liquid refrigerant that is received by the evaporator
has low pressure and low temperature. Since
the pressure of the liquid refrigerant is low, the
temperature of saturation of the refrigerant is low.
At the temperature of saturation, the refrigerant
changes from a liquid into a vapor. The temperature
of saturation of a fluid increases when the pressure
of a fluid increases.
The evaporator coil is exposed to the air that is inside

of the cab. The heat from the air that is inside of the
cab is absorbed by the evaporator. The evaporator
transfers the heat to the refrigerant. The amount
of heat that is required to reach the temperature of
saturation is called the latent heat of vaporization.
When this heat is absorbed by the refrigerant,
the temperature of the refrigerant will reach the
temperature of saturation. The refrigerant will change
from a liquid into a vapor. The vaporized refrigerant
will leave the evaporator. The vaporized refrigerant
g00668537
will carry away the heat from the cab. The vaporized Illustration 43
refrigerant will return to the compressor when the
refrigerant leaves the evaporator. This process is A nonadjustable thermostat contains one
repeated continuously. temperature control knob. The temperature control
knob is connected to the heater control valve, which
controls the flow of coolant through the heater coil.
i01254073
The temperature of the air across the evaporator
Heating and Air Conditioning coil is preset by the nonadjustable thermostat. The
temperature of the cab is maintained by the position
Control System of the temperature control knob on the heater.
SMCS Code: 1802; 7309; 7337; 7343 Condensation that is frozen will restrict the air flow
through the evaporator coils. The compressor will
Adjustable Thermostat continue operating only if the condensation does
not freeze. In order to prevent the condensation
An adjustable thermostat contains two temperature from freezing, the thermostat switch opens at a
control knobs. The temperature control knob for the temperature of approximately 1.1C (30F). Also,
air conditioning system is connected to an adjustable the thermostat switch closes at approximately 2.2C
thermostat. A thermostat is a switch. Changes in the (36F). When the switch opens, the electric circuit
temperature will open the thermostat. Changes in that connects the switch to the magnetic clutch is
the temperature will also close the thermostat. When OPEN and the compressor does not operate. When
the temperature control knob is in the OFF position, the switch is CLOSED, the current moves through
the electric circuit that connects the adjustable the switch to the coil assembly in the magnetic clutch
thermostat and the magnetic clutch is OPEN. In the and the compressor operates.
OFF position, the compressor does not operate.
The temperature of the air and the position of the In order to operate the system in the correct manner,
temperature control knob determines if the switch the heater core supply must not be closed. Also, in
is CLOSED. When the switch is CLOSED, current order to operate the system in the correct manner,
moves through the thermostat to the coil assembly the return coolant line valve must not be closed.
in the magnetic clutch and the compressor operates.
The temperature of the air through the evaporator i02514978
coil is monitored by a capillary tube that is placed
between the fins of the evaporator coil. Refrigerant Compressor
The temperature control knob for heating is Protection System
connected to the heater control valve. The
temperature of the cab is maintained by the position SMCS Code: 1802
of the air conditioning and heating temperature S/N: 1011-Up
control knobs.
102 SENR5664-13
S/N: 3011-Up S/N: RJG1-Up

S/N: 5111-Up S/N: SLG1-Up
S/N: 5211-Up S/N: CEH1-Up
S/N: 5411-Up S/N: M2H1-Up
S/N: 5511-Up S/N: SAH1-Up
S/N: 1021-Up S/N: SLH1-Up
S/N: 2021-Up S/N: BZJ1-Up
S/N: 3021-Up S/N: DFJ1-Up
S/N: 5221-Up S/N: 3SK410-Up
S/N: 5321-Up S/N: 4SK22-Up
S/N: 5521-Up S/N: ABK1-Up
S/N: 1031-Up S/N: AWK1-Up
S/N: 1041-Up S/N: B1K1-Up
S/N: DFA1-Up S/N: BZK1-Up
S/N: SLA1-Up S/N: C7K1-Up
S/N: DBB1-Up S/N: E4K1-Up
S/N: FDB1-Up S/N: H3K1-Up
S/N: J8B1-Up S/N: L2K1-Up
S/N: JJB1-Up S/N: M2K1-Up
S/N: SLB1-Up S/N: ACL1-Up
S/N: W1B1-Up S/N: BZL1-Up
S/N: DBC1-Up S/N: C8L1-Up
S/N: SLC1-Up S/N: G1L1-Up
S/N: W1C1-Up S/N: B3M1-Up
S/N: DBD1-Up S/N: BZM1-Up
S/N: GAD1-Up S/N: C9M1-Up
S/N: SLD1-Up S/N: JSM1-Up
S/N: WBD1-Up S/N: S3M1-Up
S/N: SLE1-Up S/N: WDM1-Up
S/N: AAF1-Up S/N: B4N1-Up
S/N: AXF1-Up S/N: CEN1-Up
S/N: B3F1-Up S/N: SBN1-Up
S/N: B4F1-Up S/N: ALP1-Up
S/N: B5F1-Up S/N: 3KR1-Up
S/N: SLF1-Up S/N: 4YR1-Up
SENR5664-13 103
S/N: 6TR1-Up
S/N: 9TR1-Up
S/N: 9XR1-Up
S/N: C3R1-Up
S/N: CBR1-Up
S/N: CLR1-Up
S/N: JKR1-Up
S/N: LAR1-Up
S/N: MER1-Up
g00754063
Illustration 44
S/N: TAR1-Up On Delay Timer Assembly for the Refrigerant Compressor
S/N: TBR1-Up
The protection system uses an on delay timer
S/N: 4CS130-Up assembly for the refrigerant compressor that monitors
three switches in order to protect the refrigerant
S/N: 6ZS1-Up compressor. The on delay timer assembly will
perform the following functions:
S/N: 8BS1-Up
S/N: CES1-Up Increase the life of the refrigerant compressor if
the air conditioning system has a low refrigerant
S/N: JLS1-Up charge.
S/N: RJS1-Up Delay the refrigerant compressor from engaging
during engine start-up.
S/N: AKT1-Up
S/N: AXT1-Up Protect the compressor clutch from low voltage
and high voltage.
S/N: 2BW1-Up
S/N: ARW1-Up
S/N: RAW1-Up
S/N: APX1-Up
S/N: CEX1-Up
S/N: ATY1-Up
S/N: 2PZ1-Up
S/N: 4HZ1-Up
S/N: 5AZ1-Up
g00754249
Illustration 45
S/N: 7PZ1-Up
(1) Output (signal voltage)
S/N: 89Z271-Up (2) Chassis ground
(3) Compressor clutch
(4) Power supply
S/N: KPZ1-Up
104 SENR5664-13
When the air conditioning switch is activated inside The heating system uses the coolant from the
the cab, the air conditioning switch supplies voltage engine cooling system. The heater control valve
to the on delay timer assembly through pin (4). (2) is connected to the temperature control knob in
If the voltage at pin (4) is outside the acceptable the cab. With the temperature control knob in the
range, the on delay timer assembly will not engage OFF position, the heater control valve prevents the
the compressor clutch coil. If the proper voltage is flow of the coolant through the heater coil (1). When
present, the on delay timer assembly delays the the control knob is moved from the OFF position
engagement of the compressor clutch for 30 seconds the control valve (2) will open. The control valve
after the air conditioning switch is activated. The on allows coolant that is warm to flow from the outlet
delay timer assembly monitors the status of three (3) through the control valve (2) to the heater coil
switches by sending a signal voltage through pin (1). (1). As the warm coolant flows through the heater
The following three switches are monitored by the coil, the temperature of the air flow across the heater
on delay timer assembly: coil increases.
The high/low pressure switch on the high side of The temperature of the heater is controlled by the
the air conditioning system amount of coolant that flows through the heater coil.
The increase of the coolant flow through the heater
The low pressure switch on the low side of the air coil will increase the temperature of the air that flows
conditioning system across the heater coil. The coolant from the heater
coil will flow to the return connection (4). Then, the
The thermostat switch coolant is sent back through the engine cooling
system.
The three switches are connected in series to ground.
If any one switch creates an open circuit, the on delay
i01719754
timer assembly detects the signal.
If any of the switches cycle on and off in rapid

Preparation of Air Conditioner
succession, the on delay timer assembly will start Units for Seasonal Use
a time delay. The time delay limits the cycles of the
refrigerant compressor to 4 times per minute. SMCS Code: 7320
In order to improve the performance of the air

i02414160 conditioning units, regular maintenance must be
Heating System Schematic performed before the air conditioning units are
used. In order to decrease downtime, troubleshoot
the air conditioning units before use. Failure to
SMCS Code: 7304
inspect the air conditioning units will cause the air
conditioning units to fail prematurely. In order for the
air conditioning unit to operate at optimum efficiency,
all inspections must be performed.
1. Clean the fresh air filters or install new fresh air

filters. Clean the recirculating air filters or install
new recirculating air filters.
2. Inspect the condenser coils. Inspect the

evaporator coils. If necessary, clean the coils. Do
not steam clean the coils. In order to straighten
the fins, use the 208-1350 Radiator Tool Gp (Fin
Straightener).
Illustration 46
g00343853 3. Inspect the drain lines for flow of condensate.
Heating System
Check for the proper location of the drain valve. If
necessary, flush the lines with water and relocate
(1) Heater coil
(2) Heater Control Valve
the valve. The valve should be located between
(3) Outlet supply connection for the coolant 0.0 mm (0.00 inch) and 76 mm (3 inch) from the
(4) Return connection for the coolant end of the drain line.
SENR5664-13 105
4. Inspect the wire connections for the compressor. 8. Remember that charging an R134a system is
If necessary, clean the wire connections for the different from charging an R12 system. An R134a
compressor. To check clutch operation on systems system requires an exact charge by weight. The
with adjustable thermostats, turn the thermostat charge must be within 0.01 kg (0.022 lb) of the
on and off. On some other systems, turn the listed charge. The R12 method of determining a
A/C switch on and off. Systems that have the blockage is frost, but frost is acceptable on an
compressor protection system will need up to 30 R134a systems low side. Frost on the R134a high
seconds before the clutch engages. side indicates that the R134a charge is low. Use
the evaporator temperatures to determine the
For systems that are not used for extended condition of the R134a system charge.
periods, run the compressor monthly for a
minimum of 30 seconds. This will keep the shaft 9. Replace the dryer annually.
seal from drying out, leaking oil, and leaking
refrigerant. 10. Inspect the dust caps in order to ensure that the
dust caps that are on the service ports are in place
5. Check the condition and tension of the compressor and that the dust caps are tight. Use 2L-1224
drive belt. For compressors that are driven by a Air Conditioner Valve Cap for the high side or
V-belt, use 144-0235 Belt Tension Gauge. 8C-5248 Air Conditioner Valve Cap for the low
side on R12 systems. Use 3E-4052 Seal Cap for
6. Check all hoses and connections for refrigerant the high side or 3E-4051 Seal Cap for the low
leaks. Leaks can be identified by the following side on R134a systems. Some Excavators require
items: accumulation of oil, accumulation of using the 150-2174 Cap and 203-7888 Cap on
dust, and accumulation of dye. Check hoses the R134a system.
for damaged areas. Replace hoses that are
damaged. As required, add protection to the
i02513741
hoses or relocate the hoses.
7. Do the performance check in this manual. The

Cab Air Filters
outside temperature needs to be at least 10 C SMCS Code: 7342
(50 F) for R12 systems. The outside temperature
needs to be at least 21 C (70 F) for R134a Most Caterpillar machines with the R134a system
systems. have two cab air filters. One type of air filter is
the fresh air filter and the other type of filter is
If the performance check shows a low charge a recirculation filter inside the cab. Some of the
and the system has been used for two or more machines have a third air filter that is made of foam.
years (R12) or one year (R134a) then perform the The third filter is designed to remove large debris
following steps: before the air reaches the fresh air filter.
a. Inspect the system for leaks. Some Caterpillar machines are equipped with a
precleaner for the cab. The system is designed to
b. Recover the system charge. remove excessive dust and dirt from the air that
is entering the cab. The precleaner is part of the
c. Change the receiver-dryer, the dryer, the in-line pressurized cab.
dryer, and the accumulator with desiccant .
Reference: For D9R, see Operation and
d. Evacuate the system for 30 minutes. Maintenance Manual, SEBU7228, Maintenance
Section, Cab Air Filter (Pressurized Assembly) -
e. Recharge the system according to the Replace If Equipped.
specifications.
f. Inspect the system for leaks. Maintenance Manual, SEBU7244, Maintenance
g. Do the performance check again after the Replace If Equipped.
system has been charged.
Maintenance Manual, SEBU7185, Maintenance
Replace If Equipped.
106 SENR5664-13
The cab air filters are designed to provide clean air to

the air conditioning and the heating coils. The cab air
filters are designed to pressurize the cab. If the filters
are not properly maintained, the coils will be coated
with dirt. Dirty coils will result in loss of heating. Dirty
coils will result in loss of cooling. Dirty coils could also
result in failure of the compressor.
g00884577
Illustration 48
In moderate dust conditions, the cab air filters should

be cleaned weekly. In extreme dust conditions, the
filters should be inspected daily. In extreme dust
conditions, clean the filters whenever it is necessary.
Remove loose dirt with compressed air. Do not

exceed 690 kPa (100 psi) from an air nozzle that is
an eighth inch in diameter. Keep the air nozzle at
least 2 inches away from the filter.
The filters that are made of foam can be blown

out with low pressure air. The filters can be gently
washed with a mild detergent. After washing the
filters, dry the filters with low pressure air.
If the carbon is still active, the carbon impregnated

filters may be blown out with low pressure air. Do not
wash the carbon impregnated filters.
g00884664
Illustration 47
Standard filters or high efficiency filters may be blown
Cab air filters should be inspected weekly. Inspect out with low pressure air. Do not wash the standard
the filter for holes. Look through the filter toward a filters. Do not wash the high efficiency filters.
bright light. Check for damaged gaskets or dented
metal parts. Do not use damaged filters.
SENR5664-13 107
i01209937 Expansion Valve The expansion valve is a

component in the air conditioning system that
Glossary of Terms regulates the flow of liquid refrigerants into the
evaporator.
SMCS Code: 7320
Fluid Fluid is a liquid or a gas.
Accumulator The accumulator is a component of
an air conditioning system that has an orifice tube. Flush Flushing is the removal of foreign material
The accumulator separates liquid refrigerants from and oil from the air conditioning system. You must
the circuit. The accumulator is used to store a small flush the system with fluid that is approved. The fluid
amount of liquid refrigerant. The accumulator may must be approved by S.A.E. and I.S.O. standards.
also contain a desiccant which will remove moisture
from the system. Freeze Freezing causes a liquid to become a solid.
Ambient air Outside air Gas A gas is a substance that contains very small
particles which float in the air. A gas does not contain
Charge The charge is a predetermined amount of liquid or solid particles.
refrigerant that is put into the air conditioning system.
The charge is measured in units of weight. Graduated Container A graduated container is
a glass container with markings on the side of the
Compressor The compressor is a component container. The markings are used in order to measure
in the system that increases the pressure of the the amount of fluid in the container. The markings
refrigerant. The compressor increases the pressure normally have units of ounces or units of milliliters.
of the refrigerant in the system by pumping.
Heat Thermal energy
Condenser The condenser is a component in the
system that changes the refrigerant from a vapor to Identifier The identifier is an instrument that is
a liquid. used for testing the system. The identifier is used
for determining the type of refrigerant that is in the
Contaminants Dirt, water, and air system. The identifier is also used for determining
the percentage of air that is in the system.
Desiccant The desiccant is used in the
receiver-dryer and in the accumulator. The desiccant In-line Dryer The in-line dryer is a component in
removes moisture from the air conditioning system. the air conditioning system that removes moisture
from the system. The in-line dryer will have air
Detecting Detecting is finding the source of the conditioner quick disconnect in the system. The
problem in the system. in-line dryer will have an orifice tube in the system.
Diaphragm The diaphragm is a rubber-like Latent heat of evaporation The quantity of heat
material. The diaphragm divides the upper chamber that is absorbed by a liquid as the liquid is changed
and the lower chamber in the thermostatic expansion from a liquid into a vapor at a constant temperature.
valve.
Leak detector The leak detector is a device that is
Discharge Discharge is the removal of some of used to locate leaks in the air conditioning system.
the refrigerant or the removal of all the refrigerant
from the air conditioning system. Liquid line The liquid line is the line that connects
the condenser coil, the dryer receiver, and the
Discharge side The discharge side is the outlet expansion valve together in an expansion valve
from the compressor to the condenser coil. system. The liquid line is also the line that connects
the condenser coil and the orifice tube together in an
Evacuating Evacuating is the removal of air and orifice tube system.
moisture from the air conditioning system.
Magnetic clutch The magnetic clutch is a device
Evaporation Evaporation is the process of which is used as a coupling between the pulley
changing a liquid to a vapor. and the compressor. The magnetic clutch turns the
compressor on and off. An electric current activates
Evaporator The evaporator is the component the clutch.
in the air conditioning system that changes the
refrigerant from a liquid to a vapor. The evaporator Manifold gauge set The manifold gauge set
transfers heat to the liquid refrigerant in order to contains gauges and hoses that are used to measure
convert the refrigerant into a vapor. the pressures in the air conditioning system.
108 SENR5664-13
Moisture Moisture is water that is in the air or Recycle The recycling of the refrigerant is usually
water that is in the refrigerant. completed at the site or at the service shop. The
refrigerant can be cleaned by using oil separation.
Moisture indicator The moisture indicator is a The refrigerant can be cleaned by passing the
device that uses color to indicate if the material in refrigerant through a filter dryer.
the dryer is fully soaked with moisture. The moisture
indicator will display a pink color or a white color Refrigerant The refrigerant is the fluid that is
if the moisture indicator is soaked with moisture. used in the air conditioning system. The refrigerant
The moisture indicator will display a blue color if removes heat from the operators compartment.
the moisture indicator is capable of absorbing more
moisture. Refrigerant oil Refrigerant oil is the oil that is
used in the air conditioning system. The refrigerant
Orifice tube The orifice tube has a body that is oil lubricates the compressor.
plastic with a metal tube device. The orifice tube is a
metering control. The orifice tube is located between Sight glass The sight glass is used to observe the
the high pressure side and the low pressure side in flow of refrigerant in the air conditioning system. The
the orifice tube system. sight glass is located at the top of the receiver-dryer
or in the line that is leaving the receiver-dryer.
Overcharge A system is overcharged when an
excessive amount of refrigerant is present in the air Stabilize If the performance of the system is
conditioning system. constant, the system is stabilized.
Partial charge A partial charge is less than a full Stuck Sticking will cause the prevention of free
charge of refrigerant. An air conditioning system has movement.
a partial charge when there is not enough refrigerant
in the system. Sub-cooling The additional cooling of the
refrigerant in the bottom of the condenser after the
Performance test The performance test is the refrigerant has changed from a vapor to a liquid.
notation of temperatures and pressures under
controlled conditions. The performance test is used Suction side The suction side is the connection
in order to determine if the air conditioning system is that is between the evaporator coil and the
operating normally. compressor.
Refrigerant quick-check procedure The Superheat The additional heating of the refrigerant
refrigerant quick-check procedure is a brief inspection in the bottom of the evaporator after the refrigerant
of the system. No instruments are required in order has changed from a liquid to a vapor.
to perform a refrigerant quick-check procedure.
Temperature of saturation At the temperature
Receiver-dryer The receiver-dryer is the of saturation, a liquid will change into a vapor and
component in the air conditioning system that a vapor changes into a liquid. The temperature of
removes the contaminants (moisture) from the circuit. saturation depends on the pressure of the fluid.
The receiver-dryer is also a storage area for a small The temperature of saturation increases when the
amount of liquid refrigerant. The receiver-dryer may pressure of a fluid increases.
also have a pressure switch that deactivates the
compressor if the pressure of the refrigerant is lower Vapor Gas
than approximately 175 kPa (25 psi).
Reclaim The reclaiming and the restoring of air

conditioner refrigerant must meet the S.A.E. and the
I.S.O. specifications. The reclaiming of air conditioner
refrigerant requires processes that are available only
at a remanufacturing facility.
Recover Recovering is the removal of the air

conditioner refrigerant from the air conditioner
system. The refrigerant must be stored in an
approved container. The refrigerant is not required
to be tested or processed when the refrigerant is
recovered from the system.
SENR5664-13 109
Testing and Adjusting Section
Testing and Adjusting (Table 2, contd)

Required Tools
Section Part Number Part Description
208-1333 Refrigerant Hose
Troubleshooting 208-1332 Refrigerant Hose
208-1340 Refrigerant Coupler (High Pressure)
i02548753 208-1339 Refrigerant Coupler (Low Pressure)
Required Tools 5P-7277 Voltage Tester
8T-0500 Continuity Tester
SMCS Code: 7320
9U-5325 Thermometer
Table 2
Refrigerant Identifier (110/220 Volt
Required Tools 138-6629
60/50 Hz)
Part Number Part Description 174-0839 Refrigerant Analyzer Tool Gp
Refrigerant Service Unit 153-8537 Air Conditioner Flushing Unit (Cart)
208-1316 (Recovery/Recyling/Recharging)(110
V / 60 Hz) 153-9032 Air Conditioner Flushing Unit (Portable)
Refrigerant Service Unit (230 V / 50/60 153-9033 Adapter Kit (Air Conditioner Flushing)
197-1915
Hz)
153-8538 Refrigerant Flushing Solution
Refrigerant Service Unit
9U-7804 O-ring Kit
208-1323 (Recovery/Recyling/Recharging)(115
V / 60 Hz) 192-4723 Dye/Oil Injection Tool Gp
Refrigerant Service Unit (Recovery/ 192-2331 Leak Detection Lamp Gp
208-1326 Recyling/Recharging)(220-240 V / 50
Hz) 192-4727 Dye Cleaning Solution
Electronic Charging Scale (115 V / 60 208-1375 Orifice Tool Gp
168-1959
Hz)
8T-9275 Radiator Tool Gp
Electronic Charging Scale (220-240 V
168-1961
/ 50 Hz)
168-1958 Electronic Charging Scale (Battery)
208-1317 Refrigerant Filter-Drier
208-1341 Manifold Gauge Set
208-1353 Thermistor Gauge
4C-2964 Refrigerant Leak Detector
9U-6494 Refrigerant Oil Injector
208-1338 Refrigerant Service Unit(Recovery)
208-1319 Refrigerant Tank (22.7 kg (50 lb))
Vacuum Pump (1.2 CFM, 110 V / 60
208-1381
Hz)
208-1556 Vacuum Pump (4 CFM, 110V / 60Hz)
Vacuum Pump (1.2 CFM, 220 V /
208-1382
50-60 Hz)
Vacuum Pump (4 CFM, 220-250 V /
208-1357
50-60 Hz)
1U-9763 Vacuum Pump Oil
1U-8085 Eye Protection Goggles (Vented)
208-1331 Refrigerant Charging Hose
(continued)
110 SENR5664-13
i01693240 Always wear goggles when you are working on or

testing any part of the air conditioning system.
Machine Preparation for
Troubleshooting Place a clean cloth over any valve or any
connection that is opened.
SMCS Code: 7320
Never weld any charged components.
Never solder any charged components.
Personal injury can result from contact with refrig- Never steam clean any charged components.
erant.
Do not smoke when you recover the refrigerant or
This system is under pressure at all times, even when you recycle the refrigerant.
if the engine is not running. Heat should never be
applied to a charged system. Do not smoke when you charge the system.
Contact with refrigerant can cause frost bite. Keep Do not smoke when you perform a leak test on the
face and hands away to help prevent injury. system.
Protective goggles must always be worn when re- Do not smoke when you flush the system.
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant. Do not leave refrigerant drums exposed to direct
sunlight.
Always use caution when a fitting is removed.
Slowly loosen the fitting. If the system is still Do not carry refrigerant drums into the passenger
under pressure, evacuate the system recovering compartment of the machine.
the refrigerant before removing the fitting.
Dispose of any oil that is poly alkaline glycol
Personal injury or death can result from inhaling (PAG) that has been opened but not used. The
refrigerant through a lit cigarette. moisture will contaminate the unused oil and the
air conditioning system.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Before any checks of the air conditioning and

heating system are made, move the machine to a
smooth horizontal surface. Lower all implements
to the ground. Make sure the transmission is
in neutral or park and that the parking brake is
engaged. Keep all other personnel away from the
machine or where they can be seen.
Before any problem solving procedures are

performed, read the manual for the heating and air
conditioning system. Make a visual inspection of the
complete air conditioning and heating system.
All charging and leak testing must be done in a

well ventilated area.
Avoid any physical contact with refrigerant. Contact

can cause frostbite.
SENR5664-13 111
i02546131 A small amount of moisture will penetrate the

hoses that are used in R134a systems. Change the
General Troubleshooting dryer or change the accumulator and the desiccant
Information annually. Moisture causes sludge and moisture
results in plugged systems. Moisture also causes
SMCS Code: 7320 the formation of ice at the orifice tube assembly.
Gauge readings for an undercharged R134a

system may appear as symptoms of overcharge
under certain conditions. This occurs when the
Personal injury can result from contact with refrig- ambient temperature is above 32 C (90 F) or in
erant. high humidity. Gauge readings that are Incorrect
lead to a loss of cooling ability and failure of the
This system is under pressure at all times, even compressor.
applied to a charged system. Refrigerant that is removed from a system cannot
be weighed accurately. A 20 to 30% error can
Contact with refrigerant can cause frost bite. Keep occur. The error is a result of oil that is removed
face and hands away to help prevent injury. from the system and a result of the inaccuracies of
devices that are used for recovery.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in- Check the scale that is used for charging for
dicate the system is empty of refrigerant. accuracy after every 30 days or after every 30
uses.
Slowly loosen the fitting. If the system is still After recovering a system, if the system pressure
under pressure, evacuate the system recovering rises above 0 kPa (0 psi) within 5 minutes, the
the refrigerant before removing the fitting. system must be recovered again until the pressure
does not increase. Recovering the system again
Personal injury or death can result from inhaling will empty the accumulator of refrigerant.
refrigerant through a lit cigarette.
The presence of frost on the accumulator is a
Inhaling air conditioner refrigerant gas through a normal condition. The thickness of the frost will
lit cigarette or other smoking method or inhaling depend on ambient temperature and humidity.
ditioner refrigerant gas, can cause bodily harm or Frost can appear anywhere on a R134a air
death. conditioning system. The appearance of frost does
not always indicate a failure. In order to diagnose
Do not smoke when servicing air conditioners or a blockage in the air conditioning system properly,
wherever refrigerant gas may be present. the air temperature at the evaporator must be
checked and pressure readings must be taken.
heating system are made, move the machine to a In order to check the function of the compressor,
smooth horizontal surface. Lower all implements disconnect the hose from the inlet of the in-line
to the ground. Make sure the transmission is dryer. Measure the pressure of suction of the
in neutral or park and that the parking brake is compressor . The pressure should be a vacuum
engaged. Keep all other personnel away from the that is between 81 kPa (24 in Hg) to 95 kPa
machine or where they can be seen. (28 in Hg). Do not operate the compressor for
more than 2 minutes when the system pressure
Low refrigerant charge will cause a loss of cooling is below vacuum.
ability and a loss of lubrication in the compressor,
which will result in failure of the compressor. Perform regular maintenance on the refrigerant
service units and change the oil in the vacuum
Overcharge of refrigerant will cause a loss of pumps.
cooling ability. A system that is overcharged will
contain excess liquid refrigerant, which will severely Secure lines and wires in order to prevent damage
damage the compressor. An overcharged system to the lines and wires.
will fail two times faster than an undercharged
system. The formation of black sludge deposits in the
system is caused by the presence of moisture in
Too much oil in the system will contribute to a low R134a systems and by mixing charges of R134a
refrigerant charge. and R12. The black sludge deposits can cause
a blockage in the system.
112 SENR5664-13
The presence of white foam during recovery is i01683564

normal. The foam is caused by the mixing of oil
and refrigerant. Visual Inspection
R134a system charges must be within 0.03 kg SMCS Code: 7320
(1.000 oz) to .06 kg (2.000 oz) of the specified
charge for the machine.
A drain line that is plugged or a drain line that is Personal injury can result from contact with refrig-
pinched may cause a backup of condensate and erant.
leakage into the cab.
This system is under pressure at all times, even
Missing drain valves may cause a backup of if the engine is not running. Heat should never be
condensate and leakage into the cab. applied to a charged system.
Missing drain valves will allow dust to be sucked Contact with refrigerant can cause frost bite. Keep
into the evaporator coil and the heater coil. face and hands away to help prevent injury.
A cab pressure of 0.05 kPa (0.200 inch of H2O) to Protective goggles must always be worn when re-
0.15 kPa (0.600 inch of H2O) and proper maintenance frigerant lines are opened, even if the gauges in-
of the air conditioner filter will result in the following dicate the system is empty of refrigerant.
conditions:
Reduction of dust Slowly loosen the fitting. If the system is still
under pressure, evacuate the system recovering
Reduction of noise the refrigerant before removing the fitting.
More efficient HVAC performance Personal injury or death can result from inhaling
A loss of cooling ability of the system and failure of
the compressor may be caused by one or more of Inhaling air conditioner refrigerant gas through a
the following conditions. lit cigarette or other smoking method or inhaling
Low charge ditioner refrigerant gas, can cause bodily harm or
death.
Overcharge
Too much oil wherever refrigerant gas may be present.
Too little oil Before any checks of the air conditioning and
Dirty filter or plugged filter smooth horizontal surface. Lower all implements
Dirty condenser or plugged condenser in neutral or park and that the parking brake is
Dirty evaporator or plugged evaporator machine or where they can be seen.
Dirty orifice tube or plugged orifice tube

Before you conduct a performance check of the air
Dirty expansion valve or plugged expansion valve conditioning system, the following items should be
checked:
Too much moisture in the system
1. Check the condenser and the evaporator.
Missing drain valves for the evaporator
a. Check for any type of restriction that will
obstruct the air flow. Check for dirt, insects,
plastic bags, etc.
SENR5664-13 113
b. For machines that are equipped with i02520703

condensers that are mounted on the roof,
always make sure that both fan motors Heating and Air Conditioning
are running. Check for restrictions. A clean System Troubleshooting
condenser will lead to longer life for the
compressor. SMCS Code: 7309-035-YC
2. Clean the fresh air filters and clean the
recirculation filters.
3. Check for a loose belt on the compressor. Personal injury can result from contact with refrig-
erant.
4. Check the moisture indicator on either the
receiver-dryer or the in-line dryer. If the indicator This system is under pressure at all times, even
is pink or white, there is moisture in the system. if the engine is not running. Heat should never be
Replace the receiver-dryer or the in-line dryer. applied to a charged system.
Refer to Disassembly and Assembly, Receiver
(Refrigerant Dryer) Remove and Install for Contact with refrigerant can cause frost bite. Keep
instructions on replacing the receiver-dryer. face and hands away to help prevent injury.
Refer to Disassembly and Assembly, In-Line
Refrigerant Dryer- Remove and Install for Protective goggles must always be worn when re-
instructions on replacing the in-line dryer. If the frigerant lines are opened, even if the gauges in-
moisture indicator is blue, the system is normal. dicate the system is empty of refrigerant.
5. Check the drain tube on the evaporator. The drain Always use caution when a fitting is removed.
plug should not be obstructed. Slowly loosen the fitting. If the system is still
6. For machines that are equipped with an the refrigerant before removing the fitting.
accumulator, start the machine. Set the air
conditioner on HIGH. Feel the accumulator with Personal injury or death can result from inhaling
the hand. In a properly charged system, the entire refrigerant through a lit cigarette.
accumulator will be cool to the touch or cold to
the touch. Inhaling air conditioner refrigerant gas through a
death.


Refrigerant Quick-Check Procedure

for R-134a Expansion Valve And
Orifice Tube Systems
NOTICE
In an expansion valve system which uses poly alkaline
glycol (PAG), the sight glass is not a reliable way to
determine system charge.
114 SENR5664-13
Note: This procedure does not call for the installation Remove the restriction or replace the
of the manifold gauge set. The procedure should component.
be used only as an indication of the actual
system condition. For the detailed troubleshooting Evacuate the system. Refer to the Service
procedures, refer to the Problem Solving Procedure Manual, SENR5664, Refrigerant System -
section. Evacuate section in Testing and Adjusting.
Note: In order to use this procedure, the temperature Charge the system with the correct amount
of the ambient air must be at least 21C (70F). of refrigerant. Measure the refrigerant
by weight. Refer to the Service Manual,
1. Start the engine and run the engine at SENR5664, Refrigerant System - Charge
approximately 1000 rpm. Move the control knob section in Testing and Adjusting.
on the air conditioner to the position of MAXIMUM
so that cooling is at a maximum. In order to Perform a leak test. Refer to the Service
stabilize the system, put the fan switch in the Manual, SENR5664, Refrigerant Leakage -
HIGH position and operate the system for a Testsection in Testing and Adjusting.
minimum of 10 minutes.
Perform a performance check. Refer to
For systems that have air conditioner quick Performance Checks for the Air Conditioning
disconnects, the dryer can be removed without System section.
recovering the refrigerant.
c. If frost is present on the expansion valve, check
Replace the receiver-dryer. Refer to the the moisture indicator on the receiver-dryer.
Service Manual, SENR5664, Receiver-Dryer If the indicator is pink or white, and the
- Remove and Install section in Disassembly receiver does not have air conditioner quick
and Assembly. disconnects, perform the following procedures.
Perform a leak test. Refer to the Service Recover the refrigerant. Refer to the Service
Manual, SENR5664, Refrigerant Leakage - Manual, SENR5664, Refrigerant Recovery
Test section in Testing and Adjusting. section.
Perform a performance check. Refer to Replace the receiver-dryer. Refer to the

Performance Checks for the Air Conditioning Service Manual, SENR5664, Receiver-Dryer
System section. - Remove and Install section in Disassembly
and Assembly.
2. Check for restrictions that are present in the
refrigerant lines from the compressor to the Evacuate the system. Refer to the Service
receiver-dryer. The refrigerant lines and the Manual, SENR5664, Refrigerant System -
components that are high pressure and high Evacuate section in Testing and Adjusting.
temperature come from the outlet side of the
compressor. The lines go to the inlet side of the Charge the system with the correct amount
expansion valve or orifice tube. The outlet side of refrigerant. Measure the refrigerant
will be warm during normal operation. Heavy frost by weight. Refer to the Service Manual,
or a decrease in the temperature in a line or in a SENR5664, Refrigerant System - Charge
component on the high pressure side may be an section in Testing and Adjusting.
indication of a restriction or blockage.
Perform a leak test. Refer to the Service
a. If there is no evidence of a restriction in the Manual, SENR5664, Refrigerant Leakage -
condenser coil, the receiver-dryer or refrigerant Test section in Testing and Adjusting.
lines from the compressor to the receiver-dryer,
use the procedure in Step 3. Perform a performance check. Refer to
Performance Checks for the Air Conditioning
b. If there is a restriction in the condenser coil, System section.
the receiver-dryer or refrigerant lines from the
compressor to the receiver-dryer, perform the Refer to the Service Manual, SENR5664,
following procedures. Receiver-Dryer - Remove and Install section
if the receiver-dryer has air conditioner quick
Recover the refrigerant. Refer to the Service disconnects. Refer to the Service Manual,
Manual, SENR5664, Refrigerant Recovery SENR5664, In-Line refrigerant Dryer -
section. Remove and Install section if the in-line dryer
has air conditioner quick disconnects.
SENR5664-13 115
d. On air conditioning systems that have a dryer 4. Feel the low pressure line and feel the high
with a moisture indicator, if the indicator is pressure line at the compressor. In order to
blue and the system is free of moisture, the indicate normal systems operation, the high
expansion valve may be blocked. pressure line to the condenser coil must be warm,
while the low pressure line to the evaporator coil
Recover the refrigerant. Refer to the Service must be cool.
Manual, SENR5664, Refrigerant Recovery
section. The high pressure line and the low pressure line
at the compressor have a minimal temperature
Replace the expansion valve. Refer to the difference between the two lines. Use the
Service Manual, SENR5664, Expansion procedure in Step 5.
Valve - (Air Conditioner) Remove and Install
section in Disassembly and Assembly. If there is a definite temperature difference
between the high pressure line and the low
Evacuate the system. Refer to the Service pressure line at the compressor, the system is
Manual, SENR5664, Refrigerant System - operating correctly. The high pressure line will
Evacuate section in Testing and Adjusting. be warm. The low pressure line will be cool. Use
the procedure in Step 6.
Charge the system with the correct amount
of refrigerant. Measure the refrigerant 5. If the system has no refrigerant charge or if the
by weight. Refer to the Service Manual, system is nearly empty of refrigerant charge,
SENR5664, Refrigerant System - Charge perform the following procedure:
section in Testing and Adjusting.
Stop the engine.
Manual, SENR5664, Refrigerant Leakage - Perform a partial charge of the system.
Testsection in Testing and Adjusting.
Perform a performance check. Refer to Manual, SENR5664, Refrigerant Leakage -
Performance Checks for the Air Conditioning Test section in Testing and Adjusting.
System section.
Repair leaks.
3. Low system charge is indicated. Perform a leak
test. Evacuate the system. Refer to the Service
Manual, SENR5664, Refrigerant System -
Note: If the system is very low on refrigerant, a Evacuate section in Testing and Adjusting.
partial charge may be needed before you perform
a leak test. Charge the system with the correct amount of
refrigerant. Measure the refrigerant by weight.
Recover the remaining refrigerant. Refer to Refer to the Service Manual, SENR5664,
the Service Manual, SENR5664, Refrigerant Refrigerant System - Charge section in Testing
Recovery section. and Adjusting.
Repair all leaks. Perform a performance check. Refer to

Evacuate the system. Refer to the Service System section.
Evacuate section in Testing and Adjusting. 6. An overcharge of the system is possible even
though the system can have a definite difference
Charge the system with the correct amount of in temperature at the low pressure line and at the
refrigerant. Measure the refrigerant by weight. high pressure line.
Refer to the Service Manual, SENR5664,
Refrigerant System - Charge section in Testing Recover the refrigerant. Refer to the Service
and Adjusting. Manual, SENR5664, Refrigerant Recovery
section.
Performance Checks for the Air Conditioning Evacuate the system. Refer to the Service
System section. Manual, SENR5664, Refrigerant System -
Evacuate section in Testing and Adjusting.
116 SENR5664-13
Charge the system with the correct amount of 1. Install the manifold gauge set. Refer to the
refrigerant. Measure the refrigerant by weight. Service manual, SENR5664, Manifold Gauge Set
Refer to the Service Manual, SENR5664, (Refrigerant) - Install section.
Refrigerant System - Charge section in Testing
and Adjusting. 2. Start the engine and operate the engine at 1000
rpm. Move the temperature control knob to the
Perform a performance check. Refer to the maximum cool position. Put the fan switch in
Performance Checks for the Air Conditioning the HIGH position on the AIR CONDITIONING
System section. side. In order to stabilize the system, operate the
system for a minimum of ten minutes. Operate
Note: For an orifice tube system, an additional the engine at 1000 rpm.
inspection is required. The additional inspection
procedure determines the level of the system charge. During normal operation of the air conditioning
When both the inlet of the accumulator and the outlet system in 21C (70F) weather, the discharge
of the accumulator are cool to the touch, the system pressure will be 820 to 1300 kPa (120 to 190 psi).
is charged correctly. The pressure will be 70 to 130 kPa (10 to 20 psi).
Refer to Table 3 for temperature range. The
If the outlet is warmer than the inlet, the system may outside temperature and humidity will have an
not contain enough refrigerant. effect on the pressures. If the outside temperature
is high, the discharge pressure will be high.
Recover the refrigerant. Refer to the Service
Manual, SENR5664, Refrigerant Recovery In very hot weather, the suction and the discharge
section. pressures will be high. In cooler weather, the
suction and the discharge pressure will be normal
Evacuate the system. Refer to the Service Manual, or the pressure can be lower.
SENR5664, Refrigerant System - Evacuate
section in Testing and Adjusting. If the suction and the discharge pressures are not
within the normal operating range, refer to the
Charge the system with the correct amount of Problem Solving section.
Refer to the Service Manual, SENR5664, Note: Most system failures are caused by improper
Refrigerant System - Charge section in testing refrigerant charge. Refrigerant charge should be
and adjusting. measured by weight only. Do not use gauge pressure
when you charge the system with refrigerant.
Perform a leak test. Refer to the Service Manual,
SENR5664, Refrigerant Leakage - Test section in
Testing and Adjusting.
Problem Solving
The following problem solving section is provided for
Perform a performance check. Refer to identifying and correcting problems that may occur
in the air conditioning system. Several problems can
System section. have the same system condition or similar system
conditions. Before you start the procedure in order to
Performance Checks for the Air correct the problems, it is necessary to be complete
in the diagnosis of the problems.
Conditioning System
A performance check of the air conditioning system
must be made with a manifold gauge set. The
manifold gauge set must be connected to the service
ports on the compressor.
Note: Before you conduct a performance check,

refer to the Service Manual, SENR5664, Visual
Inspection section.
Refer to the Service Manual, SENR5664, Machine

Preparation for Troubleshooting section before
service work is performed on the air conditioning
system.
SENR5664-13 117
The problem solving procedures are based on the Note: All pressures are given as a guide only.
system condition during the problem. In order to Weight is the only absolute means of determining
indicate the system pressures, the manifold gauge proper refrigerant charge. Improper refrigerant
set must be installed. The manifold gauge set is used charge will cause premature failure of the
only in order to diagnose problems. The refrigerant compressor .
lines can give an indication of system operation that
is abnormal. Temperature differences between the Table 3
high pressure side and the low pressure side can be Pressure Range (1)
an indication of abnormal operation in a line. This
can also be found by cold spots (frost) on the line. Ambient Air High Pressure Low Pressure
In R134a air conditioning systems, the lines can Temperature Test Fitting Test Fitting
C (F) kPa (psi)(2) kPa (psi)(3)
have spots of frost and the system can be operating
normally. Frost will most often form after the orifice 21C (70F) 820 to 1300 kPa 70 to 138 kPa
and on the lower portion of the accumulator. The (120 to 190 psi) (10 to 20 psi)
temperature of the air flow from the evaporator will
27C (80F) 950 to 1450 kPa 70 to 173 kPa
also indicate a problem with the system. Knowing the (140 to 210 psi) (10 to 25 psi)
complete system condition is an important step in
making a correct diagnosis. 32C (90F) 1175 to 1650 kPa 105 to 210 kPa
(170 to 240 psi) (15 to 30 psi)
Note: R134a air conditioning system problem 38C (100F) 1300 to 1850 kPa 105 to 210 kPa
diagnosis requires a combination of symptoms or (190 to 270 psi) (15 to 30 psi)
indicators in order to correctly identify problems and
solve problems. 43C (110F) 1450 to 2075 kPa 105 to 210 kPa
(210 to 300 psi) (15 to 30 psi)
Problem Solving Procedure (1)

(2)
This table is only for reference.
Pressure may be slightly higher in very humid conditions and
lower in very dry conditions.
1. Install the manifold gauge set. Refer to the (3) Pressure before clutch disengagement
Service Manual, SENR5664, Manifold Gauge
Set (Refrigerant) - Install section in Testing and
Adjusting. Refrigerant Circuit Problems
2. Run the engine at 1000 rpm. Put the air conditioner There is no or only little cool temperature
temperature control knob in the Maximum COOL to the air flow from the evaporator.
position. Put the fan switch in the HIGH position
on the AIR CONDITIONING side. In order to System Condition 1
stabilize the system, operate the engine for a
minimum of ten minutes. 1. Low pressure gauge reading is below normal.
For normal operating pressures, refer to Table 3.
3. Adjust the engine speed to approximately 1300
to 1400 rpm. Record the readings on the low 2. High pressure gauge reading is below normal.
pressure gauges and the high pressure gauges. For normal operating pressures, refer to Table 3.
The gauge readings will be a partial indication of
the system condition. Note: Ambient temperature is above 21C (70F).
Note: When the ambient temperature is above 3. From the evaporator, the temperature of the air
21C (70F), a low pressure gauge reading of flow is partially cool.
70 to 138 kPa (10 to 20 psi) is a normal operating
pressure for the air conditioning system. Also, when Probable Cause
the ambient temperature is above 21C (70F), a
high pressure gauge reading of 820 to 1300 kPa Leaks in the refrigerant circuit will cause the system
(120 to 190 psi) is a normal operating pressure for the to be low on refrigerant.
air conditioning system. In very hot weather, the low
pressure readings and the high pressure readings
will be at the high end of the normal operating range.
Perform a leak test. refer to the Service Manual,
In cooler weather, the low pressure reading will be Testing and Adjusting.
in the middle to the low end of the normal operating
range, while the high pressure reading will be low.
For the correct gauge reading in relation to ambient
If leaks are found, recover the refrigerant. Refer
to the Service Manual, SENR5664, Refrigerant
temperature condition, refer to Table 3. Recovery section.
Repair leaks.
118 SENR5664-13
If a large amount of refrigerant was lost, it is Replace the receiver-dryer or the in-line dryer. The
important to check the compressor for loss of oil. desiccant may be full of moisture. This will release
water into the system. Refer to the Service Manual,
Perform a partial charge of the system. SENR5664, Receiver-Dryer - Remove and Install
section in Disassembly and Assembly. For in-line
Evacuate the system. Refer to the Service Manual, dryers, refer to the Service Manual, SENR5664,
SENR5664, Refrigerant System - Evacuate In-Line Refrigerant Dryer - Remove and Install
section in Testing and Adjusting. section in Disassembly and Assembly.
Charge the system with the correct amount of Evacuate the system. Refer to the Service Manual,
refrigerant. Measure the refrigerant by weight. SENR5664, Refrigerant System - Evacuate
Refer to the Service Manual, SENR5664, section in Testing and Adjusting.
Refrigerant System - Charge section in testing
and adjusting. Charge the system with the correct amount of
After the system is charged and operated for a Refer to the Service Manual, SENR5664,
minimum of ten minutes, perform a performance Refrigerant System - Charge section in Testing
check. Refer to Performance Checks for the Air and Adjusting.
Conditioning System section.
After the system is charged and operated for a
System Condition 2 minimum of ten minutes, perform a performance
check. Refer to Performance Checks for the Air
1. Low pressure gauge reading is normal. For Conditioning System section.
normal operating pressures, refer to Table 3.
System Condition 4
2. High pressure gauge reading bounces or the
reading is unsteady. 1. Low pressure gauge reading is below normal.
Probable Cause
2. High pressure gauge reading is normal to
Air is in the system. the below normal range. For normal operating
pressures, refer to Table 3.
Reclaim the refrigerant from the air conditioning
system. Note: Ambient temperature is above 21C (70F).
Evacuate the air conditioning system. 3. The temperature of the air flow from the evaporator
is partially cool.
Recharge the air conditioning system.
4. The high side liquid line or the receiver-dryer
System Condition 3 is frosted. The high side liquid line or the
receiver-dryer is cool to the touch.
1. Low pressure gauge reading is below normal.
For normal operating pressures, refer to Table 3. Probable Cause
2. High pressure gauge reading is above normal. Restriction in the high pressure liquid line can cause
For normal operating pressures, refer to Table 3. the refrigerant to be removed from the evaporator at
a faster rate. The restriction can cause the evaporator
Note: Ambient temperature is above 21C (70F). to be low on refrigerant from the receiver-dryer or
from the in-line dryer. Clogged filters or a failure of
3. The temperature of the air flow from the evaporator the blower motor can cause possible restrictions to
is warm. the air flow.
Probable Cause Recover the refrigerant. Refer to the Service

Air or moisture (water) in the system section.
Recover the refrigerant. Refer to the Service If the restriction is found at the receiver-dryer,
Manual, SENR5664, Refrigerant Recovery replace the receiver-dryer. Refer to the Service
section. Manual, SENR5664, Receiver-Dryer - Remove
and Install section in Disassembly and Assembly.
SENR5664-13 119
If the restriction is found at the in-line dryer, replace Recover the refrigerant from the system. Refer
the in-line dryer. to the Service Manual, SENR5664, Refrigerant
Recovery section in Testing and Adjusting.
If the restriction is found at the liquid line, replace
the liquid line. Replace the receiver-dryer or the in-line dryer.
Cap all the open lines and fittings. Receiver-Dryer - Remove and Install section in
Disassembly and Assembly. For in-line dryers,
Note: Restrictions of the refrigerant flow are identified refer to the Service Manual, SENR5664, In-Line
by frost or cold spots in the line. Also, restrictions Refrigerant Dryer - Remove and Install section in
of the refrigerant flow are identified by frost or cold Disassembly and Assembly.
spots in the receiver-dryer or the in-line dryer.
Remove the moisture from the system. Refer to the
Replace filters or remove any of the restrictions. Service Manual, SENR5664, Refrigerant System -
Evacuate the system. Refer to the Service Manual,
SENR5664, Refrigerant System - Evacuate Charge the system with the correct amount of
section in Testing and Adjusting. refrigerant. Measure the refrigerant by weight.
Charge the system with the correct amount of Refrigerant System - Charge section in Testing
refrigerant. Measure the refrigerant by weight. and Adjusting.
Refrigerant System - Charge section in Testing After the system is charged and operated for a
and Adjusting. minimum of ten minutes, perform a performance
After the system is charged and operated for a Conditioning System section.
minimum of ten minutes, perform a performance
check. Refer to Performance Checks for the Air Note: Low pressure (suction) drops into vacuum
Conditioning System section. when ice forms in the expansion valve. High pressure
(discharge) drops when low pressure drops into
System Condition 5 vacuum.
Note: The system only cools the cab in the morning System Condition 6
and in the evening. The system does not cool the
cab during the hot part of the day. 1. The low pressure gauge reading does not
change. The pressure should rise when the
1. Low pressure gauge reading is normal, but compressor is not in operation. For normal
the gauge reading may drop into the vacuum operating pressures, refer to Table 3.
range during the testing procedure. For normal
operating pressures, refer to Table 3. 2. High pressure gauge reading is at the high end
of the normal range.
2. The high pressure gauge reading is normal,
but the gauge reading is below normal when Note: Ambient temperature is above 21C (70F).
the low pressure gauge drops into the vacuum
range. For normal operating pressures, refer to 3. The temperature of the air flow from the evaporator
Table 3. is partially cool.
Note: Ambient temperature is above 21C (70F). Probable Cause
3. Air flow from the evaporator is very cold, but the The system has air or moisture in the system. The
air flow will become warm when the low pressure system does not have a full charge of refrigerant.
gauge drops into vacuum.
Perform a leak test and carefully test around the
Probable Cause compressor seal. Refer to the Service Manual,
The system has a large amount of moisture. The Testing and Adjusting.
desiccant in the receiver-dryer or the in-line dryer
is full of water. The water is released during high Recover the refrigerant from the system. Refer
ambient temperatures. Ice collects in the orifice or to the Service Manual, SENR5664, Refrigerant
the expansion valve and the ice can block the flow of Recovery section in Testing and Adjusting.
refrigerant.
Repair leaks.
120 SENR5664-13
Check the compressor for loss of oil. Recover the refrigerant. Refer to the Service
Evacuate the system. Refer to the Service Manual, section.
section in Testing and Adjusting. Evacuate the system. Refer to the Service Manual,
Charge the system with the correct amount of section in Testing and Adjusting. If service work
refrigerant. Measure the refrigerant by weight. has not been performed for a extended period of
Refer to the Service Manual, SENR5664, time, replace the receiver-dryer or the in-line dryer.
and Adjusting. Charge the system with the correct amount of
refrigerant by weight. Refer to the Service Manual,
After the system is charged and operated for a SENR5664, Refrigerant System - Charge section
minimum of ten minutes, perform a performance in Testing and Adjusting.
Conditioning System section. After the system is charged and operated for a
System Condition 7 check. Refer to Performance Checks for the Air
1. Low pressure gauge reading is above normal.
For normal operating pressures, refer to Table 3. System Condition 8
2. High pressure gauge reading is above normal. 1. Low pressure gauge reading is above normal.
For normal operating pressures, refer to Table 3. For normal operating pressures, refer to Table 3.
Note: Ambient temperature is above 21C (70F). 2. High pressure gauge reading is below normal.
3. High pressure (liquid line) is very hot.
Note: Ambient temperature is above 21C (70F)
4. The compressor may become noisy and the drive and the system has a refrigerant charge that is full.
belt may slip.
3. The temperature of the air flow from the evaporator
Note: The compressor is not operating under ambient is partially cool.
temperatures that are extreme. The compressor is
not operating under high humidity that is extreme. Probable Cause
Probable Cause The compressor has internal leaks. The reed valve
has leakage. The compressor piston, rings or
The system is overcharged. cylinders are worn.
Recover the remaining refrigerant. Refer to Check the compressor drive belt for the correct
the Service Manual, SENR5664, Refrigerant tension.
Recovery section.
Perform a leak test. Isolate the problem to
Charge the system with the correct amount of the compressor. Refer to the Service Manual,
refrigerant. Measure the refrigerant by weight. SENR5664, Refrigerant Leakage - Test section in
Refer to the Service Manual, SENR5664, Testing and Adjusting.
and Adjusting. If an internal leak is found, perform the following
procedure.
Performance Checks for the Air Conditioning Replace the compressor. Refer to the Service
System section. Manual, SENR5664, refrigerant Compressor -
remove and Install section in Disassembly and
Note: Perform the following procedure if the system Assembly.
has not been serviced for a extended period of time.
Perform the following procedure if the pressures of Replace the receiver-dryer. Refer to the Service
the system are not within the correct specifications. Manual, SENR5664, Receiver-Dryer - Remove
and Install section in Testing and Adjusting.
SENR5664-13 121
Evacuate the system. Refer to the Service Manual, 1. Test the expansion valve for the correct operation.
SENR5664, Refrigerant System - Evacuate Use the following procedure.
Position the air conditioner temperature control
Charge the system with the correct amount of knob in the maximum COOL position and the
refrigerant by weight. Refer to the Service Manual, fan switch in the HIGH position.
SENR5664, Refrigerant System - Charge section
in Testing and Adjusting. Cool the head of the expansion valve diaphragm
chamber and the capillary tube with ice or
After the system is charged and operated for a liquid nitrogen. Record the low pressure gauge
minimum of ten minutes, perform a performance reading. The low pressure gauge should
check. Refer to Performance Checks for the Air indicate a vacuum.
If the low pressure gauge indicates a vacuum,
If an external leak such as a hose connection is place a hand over the expansion valve
found, perform the following procedure. diaphragm chamber. The hand will warm the
expansion valve diaphragm chamber. In order
Recover the refrigerant. Refer to the Service to ensure the correct operation of the expansion
Manual, SENR5664, Refrigerant Recovery valve, cool the head of the expansion valve
section. diaphragm chamber and the capillary tube with
ice or liquid nitrogen again. If the operation of
Repair leaks. the expansion is correct, refer to Step 2.
If a large amount of refrigerant is lost, check the If the low pressure gauge does not indicate
compressor for the loss of oil. the proper operation of the expansion valve,
recover the refrigerant from the system. Refer
Evacuate the system. Refer to the Service Manual, to the Service Manual, SENR5664, Refrigerant
SENR5664, Refrigerant System - Evacuate Recovery section in Testing and Adjusting.
Replace the expansion valve. Refer to the
Charge the system with the correct amount of Service Manual, SENR5664, Expansion Valve
refrigerant. Measure the refrigerant by weight. - (Air Conditioner) Remove and Install section
Refer to the Service Manual, SENR5664, in Disassembly and Assembly.
and Adjusting. Note: The sensing bulb must be installed correctly in
order to ensure the proper operation of the expansion
After the system is charged and operated for a valve.
check. Refer to Performance Checks for the Air Evacuate the system. Refer to the Service
Conditioning System section. Manual, SENR5664, Refrigerant System -
System Condition 9
Charge the system with the correct amount of
1. Low pressure gauge reading is above normal. refrigerant. Measure the refrigerant by weight.
For normal operating pressures, refer to Table 3. Refer to the Service Manual, SENR5664,
2. High pressure gauge reading is normal or low. and Adjusting.
Note: Ambient temperature is above 21C (70F) minimum of ten minutes, perform a performance
and the system has a refrigerant charge that is full. check. Refer to Performance Checks for the Air
3. The temperature of the air flow from the evaporator
is warm. 2. If the pressure gauge indicates the correct
operation of the expansion valve, perform the
4. The suction hose and the evaporator is covered following procedure.
with moisture (sweating).
Probable Cause
Flow of refrigerant through the evaporator coil is

excessive. The expansion valve could be stuck or
held in the OPEN position.
122 SENR5664-13
Use a 8P-6355 Clip in order to hold the 3. The temperature of the air flow from the evaporator
sensing bulb onto the evaporator outlet pipe. is partially cool or warm.
The sensing bulb should be as close to the
evaporator as possible. The bulb should be 4. Moisture (water) or frost is on the expansion valve
upstream of the pressure sensing connection inlet or orifice tube assembly.
on the evaporator outlet pipe. The following
items must be wound tightly with 5P-7070 Probable Cause
Strip Insulation: the clip, the sensing bulb, and
the outlet pipe. There should be no insulation The problems that are described in Step 1 through
between the bulb and the outlet pipe. Step 4 can be caused by the following faults:
In order to ensure that the system operates Note: The following faults will cause a restriction of
correctly, perform a performance check. Refer the flow of refrigerant to the evaporator.
to Performance Checks for the Air Conditioning
System section. Improper operation of the expansion valve (stuck
valve)
Blockage at the evaporator inlet

No charge in temperature sensing bulb
Note: The inlet to the expansion valve will be warm
during normal operation.
1. If the expansion valve inlet is cool to the touch,

perform the following procedure:
Position the air conditioner temperature control

knob to the maximum COOL position and the
fan switch to the HIGH position.
Cool the head of the expansion valve diaphragm

chamber and capillary tube with ice or liquid
nitrogen. Record the low pressure gauge
reading. The low pressure gauge should
indicate a vacuum.
If a vacuum is indicated on the low pressure

gauge, place a hand over the expansion valve
diaphragm chamber. The hand will warm the
expansion valve diaphragm chamber. In order
to ensure the correct operation of the expansion
valve, cool the head of the expansion valve
diaphragm chamber and the capillary tube with
ice or liquid nitrogen again. If the operation of
g00409166
Illustration 49 expansion valve is correct, refer to Step 2.
Expansion valve in the open position (Typical Example)
(1) Capillary tube If the low pressure gauge does not indicate
(2) Expansion valve diaphragm chamber proper operation of the expansion valve,
(3) Inlet remove the refrigerant from the system. Refer
(4) Outlet to the Service Manual, SENR5664, Refrigerant
System Condition 10
Replace the expansion valve. Refer to the
1. Low pressure gauge reading is too low. For Service Manual, SENR5664, Expansion Valve
normal operating pressures, refer to Table 3. - (Air Conditioner) Remove and Install section
in Disassembly and Assembly.
2. High pressure gauge reading is too low. For
Note: Ambient temperature is above 21C (70F).

SENR5664-13 123
Note: The sensing bulb must be installed correctly

in order to ensure the correct operation of the
expansion valve. Clean the location for the sensing
bulb with steel wool or emery paper. Use a 8P-6355
Clip in order to attach the sensing bulb securely to
the evaporator coil outlet pipe. Completely cover the
assembly with 5P-7070 Strip Insulation.
Evacuate the system. Refer to the Service


and Adjusting.

2. If the low pressure gauge indicates the correct

operation of the expansion valve, perform the
following procedure:
The sensing bulb must be in the correct position g00415456

on the evaporator outlet pipe and the sensing Illustration 50
bulb must be the correct distance away from the Expansion valve in the closed position (Typical Example)
evaporator outlet. The bulb should be upstream (1) Capillary tube
from the pressure sensing connection in the (2) Expansion valve diaphragm chamber
evaporator outlet pipe. The insulation must be (3) Inlet
(4) Outlet
around the sensing bulb and the clip on the
evaporator outlet pipe.
Note: For expansion valve systems, refer to Step 1.
For orifice tube systems, refer to Step 3.
In order to ensure the correct systems operation,
perform a performance check.
System Condition 11
3. Replace the in-line dryer or replace the orifice
tube. 1. Low pressure gauge reading is too high. For
Evacuate the system. Refer to the Service 2. High pressure gauge reading is too high. For
Evacuate section in Testing and Adjusting. normal operating pressures, refer to Table 3.

Refer to the Service Manual, SENR5664, 3. The temperature of the air flow from the evaporator
Refrigerant System - Charge section in Testing is warm.
and Adjusting.
Probable Cause
minimum of ten minutes, perform a performance The condenser is not functioning properly.
Conditioning System section. Note: The system may have a normal or overcharge
of refrigerant.
1. Check for a blockage in the flow of air through the

condenser.
124 SENR5664-13
2. If a blockage is found in the condenser, remove Charge the system with the correct amount of
all blockages and perform a performance check. refrigerant. Measure the refrigerant by weight.
The performance check will ensure proper system Refer to the Service Manual, SENR5664,
operation. Refer to Performance Checks for the Refrigerant System - Charge section in Testing
Air Conditioning System section. and Adjusting.
3. If the problem still exists, perform the following After the system is charged and operated for a
procedure. Check the system for an overcharge minimum of ten minutes, perform a performance
of refrigerant. check. Refer to Performance Checks for the Air
Note: Do not operate the engine.
System Condition 12
Recover the refrigerant. Refer to the Service
Manual, SENR5664, Refrigerant Recovery Water is in the vents.
Water is leaking from the unit.
Evacuate the system. Refer to the Service
Manual, SENR5664, Refrigerant System - Probable Cause
The non-return valve of the drain
Recharge the system with the correct amount of
refrigerant. Measure the refrigerant by weight. 1. Check the non-return valve for proper positioning
Refer to the Service Manual, SENR5664, and proper direction.
and Adjusting. The Compressor will not Engage
Note: With the ambient temperature above 21C If the machine is equipped with the protection system
(70F), the normal gauge reading for the low for the refrigerant compressor, Refer to the Service
pressure side is 70 to 138 kPa (10 to 20 psi) while Manual, SENR 5664, Troubleshooting Heating
the normal gauge reading for the high pressure side and Air Conditioning Control Systems in order to
is 820 to 1300 kPa (120 to 190 psi). test the on delay timer assembly for the refrigerant
compressor.
In order to ensure the correct systems
operation, perform a performance check. Refer System Condition 13
to Performance Checks for the Air Conditioning
System section. 1. Low pressure gauge reading is above normal.
4. If the low pressure gauge reading and the high
pressure gauge readings are too high, perform 2. High pressure gauge reading is below normal.
the following procedure: For normal operating pressures, refer to Table 3.
Recover the refrigerant from the system. Refer Note: Ambient temperature is above 21C (70F).
to the Service Manual, SENR5664, Refrigerant
Recovery section in Testing and Adjusting. 3. Air flow to the operators compartment is warm.
Replace the receiver-dryer or replace the in-line Probable Cause

dryer. Refer to the Service Manual, SENR5664,
Receiver-Dryer - Remove and Install section 1. The thermostatic switch is stuck open. This
in Disassembly and Assembly. For in-line does not allow the magnetic clutch to cycle the
dryers, refer to the Service Manual, SENR5664, compressor.
In-Line Refrigerant Dryer - Remove and Install
section in Disassembly and Assembly. a. Check the wire connectors on the thermostatic
switch and on the magnetic clutch.
If the receiver-dryer or the in-line dryer is
not equipped with quick couplers, evacuate 2. The connection of wire leads on switch is
the system. Refer to the Service Manual, improper. The connection of wire leads on the
SENR5664, Refrigerant System - Evacuate magnetic clutch is improper.
a. Check for insulation that is broken. The
insulation failure can expose the wires from the
switch to the magnetic clutch.
SENR5664-13 125
3. The wire that connects the switch to the magnetic 3. The air flow to the operators compartment is very
clutch has an opening. cold, or the air flow may be restricted completely
at times.
a. Check the resistance of the coil with a
multimeter. Refer to the Service Manual, Probable Cause
SENR5664, Refrigerant Compressor section
in Specifications. The thermostat switch is held closed. There is a short
in the wire to the magnetic clutch. The magnetic
b. Check for the proper electrical ground at the clutch will not release.
magnetic clutch.
Check the wire that goes to the magnetic clutch.
c. Touch the two wires on the switch together. The wire may have an electrical short.
Check for the proper operation of the magnetic
clutch. Replace the thermostat switch.
d. In order to check the electrical components, Make the necessary repairs to the magnetic clutch.
refer to Service Manual, SENR5664,
Troubleshooting Heating and Air Conditioning
Control System in Testing and Adjusting.
Additional Refrigerant Circuit
Problems for Orifice Tube System
System Condition 15
If the problem is a loose wire on the switch
or a loose wire on the magnetic clutch, make The compressor clutch is engaged but the system
the repairs that are needed. If the wires to the has insufficient cooling.
clutch were damaged, the damaged wires
can cause the switch to remain open. Make Probable Cause
the needed repairs to the damaged wires. In
order to ensure the correct system operation, The system is improperly charged.
perform a performance check.
A compressor drive belt that is loose or a
4. The charge of refrigerant in the capillary tube has compressor drive belt that is worn can cause
been lost. insufficient cooling.
a. If the capillary tube has no charge or the Restrictions, insects, foreign material in the
switch remains open, the problem is in the condenser, or any restriction of air flow can cause
thermostatic switch. insufficient cooling.
Replace the switch. A missing or a plugged orifice tube can cause

insufficient cooling.
In order to ensure the correct system
operation, perform a performance check. A restriction in a liquid line or a low amount of
Refer to Performance Checks for the Air refrigerant charge can cause insufficient cooling.
1. Install the manifold gauge set. Refer to the
The Compressor Continues to Cycle or Service manual, SENR5664, Manifold Gauge Set
the Clutch will not Disengage. (Refrigerant) - Install section.
Note: The cause of the problem may be one of the 2. Start the engine. Operate the engine at 1400
following conditions: low charge, overcharge, and rpm. Move the temperature control knob to the
evaporator freeze-up . Maximum position and the fan to the High position.
Close all windows and doors. In order to stabilize
System Condition 14 the system, operate the system for a minimum
of ten minutes.
1. Low pressure gauge reading is below normal.
For normal operating pressures, refer to Table 3. Note: Ambient temperature is above 21C (70F).
2. High pressure gauge reading is below normal. 3. The outlet on the accumulator should be cold
For normal operating pressures, refer to Table 3. to the touch. If the outlet is not cold, check the
readings on the manifold gauges.
126 SENR5664-13
If the low side reading is above 345 kPa 2. After the clutch drive plate is movable, rotate
(50 psi), check for a missing orifice tube. Refer the clutch drive plate at least three complete
to Service Manual, SENR5664, Orifice Tube revolutions in the counterclockwise direction.
(Air Conditioner) - Remove and Install in
Disassembly and Assembly. 3. Start the engine. Operate the compressor for a
minimum of one minute.
If the low side reading is into vacuum, check for
a plugged orifice tube or a restriction in the line. This procedure will not correct a seized
compressor. However, this procedure should be
A restriction in the liquid line can be detected attempted before you replace a compressor that
by running a hand along the line until there has been idle for a month or longer.
is a change in temperature. A change in
temperature in the line will usually indicate the
location of the restriction.
4. If the inlet and the outlet on the accumulator are

warm, refer to the Service Manual, SENR5664,
and Adjusting. Also, refer to the Service Manual,
SENR5664, Refrigerant Leakage-Test section in
False Seizure of the Compressor

Table 4
Required Tools
Part Number Part Description
1U-8590 Spanner Wrench
On the initial start-up of the air conditioner system,

slipping drive belts and broken drive belts may be
experienced if the air conditioner system has not been
used for an extended period of time. Also, scored
clutch surfaces may be experienced. This would
indicate a seized compressor. However, replacement
of the compressor may not be necessary.
Changes in temperature can cause expansion of

the refrigerant in the compressor during extended
periods of nonuse. Also, changes in temperature can
cause contraction of the refrigerant in the compressor
during extended periods of nonuse. During this
movement, lubricating oil that is carried by the
refrigerant migrates. The lubricating oil moves away
from highly polished surfaces in the compressor.
Without lubricating oil at the polished surfaces, the
polished surfaces rub together. This can appear as a
seized compressor.
The compressor should be checked for seizure before

the compressor is replaced. Use the procedures that
follow in order to check the compressor for seizure.
1. With a spanner wrench on the clutch drive plate,

rock the shaft in the opposite direction of normal
rotation.
SENR5664-13 127
i02528971 4. When the engine coolant temperature is in the

normal operating range, the temperature of the air
Troubleshooting Heating that is flowing from the louvers (air ducts) should
and Air Conditioning Control be warm.
System If the temperature of the air that is flowing is not

warm within 10 minutes of operation, refer to
SMCS Code: 7309-035-YC Problem 2 section.
Problem 1
Personal injury can result from contact with refrig- There is little warm air flow or no warm air flow
erant. when the heater control knob is set for maximum
heating.
if the engine is not running. Heat should never be 1. Perform the following procedure:
applied to a charged system.
a. Check the engine coolant temperature. The
Contact with refrigerant can cause frost bite. Keep temperature of the coolant must be at normal
face and hands away to help prevent injury. operating range.
Protective goggles must always be worn when re- b. The heater control valve must be functioning
frigerant lines are opened, even if the gauges in- properly. Check for the correct linkage
dicate the system is empty of refrigerant. adjustment from the temperature control
lever to the heater control valve. The heater
Always use caution when a fitting is removed. control valve must open completely when the
Slowly loosen the fitting. If the system is still temperature control knob is set for maximum
under pressure, evacuate the system recovering heating.
c. Check for blockage and check for bends in
Personal injury or death can result from inhaling the heater hoses. Blockages and bends in the
refrigerant through a lit cigarette. heater hoses would stop the flow of coolant
through the system.
lit cigarette or other smoking method or inhaling d. Inspect the petcocks that connect the heater
fumes released from a flame contacting air con- hoses to the engine block. Make sure that the
ditioner refrigerant gas, can cause bodily harm or petcocks are adjusted so that the petcocks are
death. fully open.
Do not smoke when servicing air conditioners or 2. Make repairs to the components or replace any
wherever refrigerant gas may be present. damaged component.

Electrical System
to the ground. Make sure the transmission is Problem 2
engaged. Keep all other personnel away from the There is no flow to the operators compartment.
machine or where they can be seen. The evaporator blower motors do not operate
when the fan switch is activated.
Heating System 1. Perform the following procedure:
In order to conduct a performance check of the a. Inspect the circuit breaker or inspect the fuses
heating system, perform the following procedure. for an open circuit.
1. Run the engine at 1000 rpm. b. Perform a visual inspection of all wire
connections. Use the electrical schematic for
2. Adjust the temperature control knob to the setting the respective machine.
for maximum heating.
c. Check for blockages at the fan blade.
3. Put the fan switch in the HIGH position on heat.
128 SENR5664-13
d. Check for the proper function of the fan switch

at each setting. The evaporator blower motor
will run at each setting. The evaporator blower
motor should be operating in the cold mode
and in the heating mode.
e. Use a 5P-7277 Voltage Tester or use a

9U-7330 Multimeter in order to check the
voltages in all components of the electrical
system. Refer to the electrical schematic
section for additional information for the
machine.
2. If necessary, make repairs or replace the

components. g00754249
Illustration 51
(1) Output (signal voltage)
Test Procedure for Testing (2) Chassis ground
Electrical Components in the Air (3)
(4)
Compressor clutch
Power supply
Conditioning System
1. Separate the four pin connectors from the wiring
The air conditioning systems on Caterpillar machines harness.
use pressure switches in order to protect the
air conditioning system. Some air conditioning 2. Set the 146-4080 Digital Multimeter to DC
systems on Caterpillar machines use pressure voltage. Connect the positive probe to pin (4) on
switches and the on delay timer assembly for the wiring harness and connect the negative probe
the refrigerant compressor in order to protect the to a suitable ground. The multimeter should read
air conditioning system. Arc suppressors protect 12 volts for a 12 volt system or the multimeter
other electrical components in the air conditioning should read 24 volts for a 24 volt system.
system. Arc suppressors are applied in order to
discharge electrical inductance when the compressor Note: If the voltage is below 9 volts or the voltage is
disengages. Failure of the arc suppressor can affect above 24 volts for a 12 volt system the on delay timer
the reliability of the pressure switch. Failure of the arc assembly will not supply power to the compressor.
suppressor may cause failure of the pressure switch.
Note: If the voltage is below 18 volts or the voltage is
The following procedures are for the testing of the above 32 volts for a 24 volt system the on delay timer
on delay timer assembly, pressure switches, and assembly will not supply power to the compressor.
components of the arc suppressor.
3. Set the 146-4080 Digital Multimeter to OHMS.
Table 5 Connect the positive probe to pin location (2) on
Required Tools the wiring harness and connect the negative probe
to a suitable chassis ground. The multimeter will
Part Number Part Description display OL if the ground is not present.
146-4080 Digital Multimeter (RS-232)
4. Set the 146-4080 Digital Multimeter OHMS.
Connect the positive probe to pin location (1) on
On Delay Timer Assembly for the the wiring harness and connect the negative probe
Refrigerant Compressor Tests to a suitable chassis ground. If the multimeter
displays OL one of the three switches are open.
In order to diagnose a faulty on delay timer assembly Check each of the switches if an open condition
for the refrigerant compressor, the engine start switch occurs.
must be in the ON position and the air conditioning
switch activated. Note: There must be refrigerant in the air conditioning
system in order to close both of the pressure
Note: The on delay timer assembly will delay the switches.
power supply to the compressor clutch coil for 30
seconds after the air conditioning switch is activated.
SENR5664-13 129
5. In order to check that power is getting from the on Table 6

delay timer assembly to the compressor clutch Pressure Range Contact Contact
coil, reconnect the on delay timer assembly to Position Position
the wiring harness. Set the 146-4080 Digital (Pressure (Falling
Multimeter to DC voltage. Remove the 2-pin Rise) Pressure)
connector from the compressor clutch coil.
Connect the negative probe to a suitable chassis High Above OPEN OPEN
Position 3 2800 kPa
ground. Check each one of the two pins on the
(406 psi)
wiring harness for voltage. One of the two pins
should supply 12 volts for a 12 volt system or 24 Hysteresis 1750 kPa CLOSED OPEN
volts for a 24 volt system. Band(1) (254 psi) to
2800 kPa
6. In order to check the ground path from the (406 psi)
compressor clutch coil to the chassis, turn off Middle 275 kPa CLOSED CLOSED
the air conditioning switch in the cab. Set the (Position 2) (40 psi) to
146-4080 Digital Multimeter OHMS. Remove 1750 kPa
the 2-pin connector from the compressor clutch (254 psi)
coil. Connect the negative lead to a suitable Hysteresis 170 kPa OPEN CLOSED
ground. Check each of the two pins on the two Band(1) (25.0 psi)
pin connectors for continuity. One of the two pins to 275 kPa
should display OL. (40 psi)
7. If both the correct voltage and ground are Low 0 kPa (0 psi) OPEN OPEN
Position 1 to 170 kPa
present check the resistance of the compressor
(25.0 psi)
clutch coil. Refer to the Service Manual, SENR
5664, Refrigerant Compressor section in (1) Pressure must pass through the hysteresis band in order to
Specifications. provide the correct conditions for the switch contact.
Pressure Switch Tests

Test Procedure for 114-5333 Pressure Switch
and 114-5334 Pressure Switch (NORMALLY
OPEN)
Pressure switches are used in order to protect the air

conditioning compressor. The two most commonly
used pressure switches are the 114-5333 Pressure
Switch and the 114-5334 Pressure Switch. The only
difference between the two switches is the connector.
Only one of these switches is used per machine. The
high pressure and low pressure switches have three
possible switch positions which are given below: Illustration 52
g00651406
OPEN System pressure is low. Use the following procedures in order to test the
pressure switch:
CLOSED System pressure is correct.
1. Disconnect the pressure switch from the machine
OPEN System pressure is high. harness.
The two OPEN positions of the pressure switch 2. Connect the 146-4080 Digital Multimeter to the
protect the air conditioning system. The OPEN two connector pins. Set the multimeter to the
position prevents the compressor from actuating OHMS test mode.
when potentially harmful pressures exist in the
system. The CLOSED position is the normal 3. Measure the resistance of the pressure switch.
operating switch position. The following table
contains the logic for the pressure switches: 4. If the system pressure is between 275 kPa (40 psi)
and 1750 kPa (254 psi), the multimeter will display
a value that is less than 1 ohm.
130 SENR5664-13
5. If the resistance that is displayed is a value of 4. If the system pressure is above 344 34 kPa
OL (high resistance), and the system pressure (50 5 psi), the multimeter will display less than
is within acceptable limits, replace the pressure 1 ohm.
switch.
5. If the resistance that is displayed is a value of OL
6. When the pressure switch fails, test the arc (high resistance), and the system pressure is not
suppressor for proper operation. below the acceptable limit, replace the pressure
switch.
7. If the pressure switch is removed, make sure
that the wires on the new pressure switch 6. When the pressure switch fails, test the arc
are tie-wrapped. Securing the pressure switch suppressor for proper operation.
prevents damage that may be caused by vibration.
7. If the pressure switch is removed, make sure
Note: The multimeter may display OL if the contacts that the wires on the new pressure switch
on the pressure switch are dirty. The contacts on are tie-wrapped. Securing the pressure switch
the pressure switch can become dirty if the arc prevents damage that may be caused by vibration.
suppressor is no longer functioning.
Note: The multimeter may display OL if the contacts
Note: The multimeter will display OL if the pressure on the pressure switch are dirty. The contacts on
switch is not threaded into the air conditioning the pressure switch can become dirty if the arc
system. suppressor is no longer functioning.
8T-8639 Low Pressure Switch (NORMALLY Note: The multimeter will display OL if the pressure
OPEN) switch is not threaded into the air conditioning
system.
149-6371 Low Pressure Switch (NORMALLY

OPEN)
g00651418
Illustration 53
Table 7
Specifications for Pressure Switch g00651452

Illustration 54
Actuation Pressure(2) 344 34 kPa (50 5 psi)
Table 8
Deactuation Pressure(3) 172 21 kPa (25 3 psi)
(2) Close when pressure increases.
Specifications for Pressure Switch
(3) Open when pressure decreases. Actuation Pressure(2) 103 14 kPa (15 2 psi)
Use the following procedures in order to test the Deactuation Pressure(3) 35 7 kPa (5 1 psi)
pressure switch: (2) Close when pressure increases.
(3) Open when pressure decreases.
harness. Use the following procedures in order to test the
pressure switch:
2. Connect the 146-4080 Digital Multimeter to the
two connector pins. Set the multimeter to the 1. Disconnect the pressure switch from the machine
OHMS test mode. harness.
3. Measure the resistance of the pressure switch.

SENR5664-13 131
2. Connect the 146-4080 Digital Multimeter to the Note: A pressure switch that is NORMALLY CLOSED
two connector pins. Set the multimeter to the will open when the system pressure increases. The
OHMS test mode. pressure switch will close when the system pressure
decreases.
Use the following procedures in order to test the
4. If the system pressure is above 103 14 kPa pressure switch:
(15 2 psi), the multimeter will display less than
1 ohm. 1. Disconnect the pressure switch from the machine
harness.
5. If the resistance that is displayed is a value of OL
(high resistance), and the system pressure is not 2. Connect the 146-4080 Digital Multimeter to the
below the acceptable limit, replace the pressure two connector pins. Set the multimeter to the
switch. OHMS test mode.
6. When the pressure switch fails, test the arc 3. Measure the resistance of the pressure switch.
suppressor for proper operation.
4. If the system pressure is below 2400 140 kPa
7. If the pressure switch is removed, make sure (348 20 psi), the multimeter will display less than
that the wires on the new pressure switch 1 ohm.
are tie-wrapped. Securing the pressure switch
prevents damage that may be caused by vibration. 5. If the resistance that is displayed is a value of OL
(high resistance), and the system pressure is not
Note: The multimeter may display OL if the contacts above the acceptable limit, replace the pressure
on the pressure switch are dirty. The contacts on switch.
the pressure switch can become dirty if the arc
suppressor is no longer functioning. 6. When the pressure switch fails, test the arc
Note: The multimeter will display OL if the pressure
switch is not threaded into the air conditioning 7. If the pressure switch is removed, make sure
system. that the wires on the new pressure switch
are tie-wrapped. Securing the pressure switch
3E-6462 High Pressure Switch (NORMALLY prevents damage that may be caused by vibration.
CLOSED)
on the pressure switch are dirty. The contacts on
suppressor is no longer functioning.
Note: The multimeter will display OL if the pressure

switch is not threaded into the air conditioning
system.
7X-1076 High Pressure Switch (NORMALLY

CLOSED)
g00651464
Illustration 55
Table 9

Actuation Pressure(4) 2400 140 kPa
(348 20 psi)
Deactuation Pressure(5) 1725 100 kPa
(250 15 psi)
(4) Open when pressure increases.
(5) Close when pressure decreases. g00651571
Illustration 56
132 SENR5664-13
Table 10 Test Procedures for Arc Suppressors:

106-8704 Arc Suppressor
Actuation Pressure(4) 2412 140 kPa
(350 20 psi)
Deactuation Pressure(5) 1723 100 kPa
(250 15 psi)
(4) Open when pressure increases.
(5) Close when pressure decreases.
Use the following procedures in order to test the

pressure switch:

harness.
2. Connect the 146-4080 Digital Multimeter to the

two connector pins. Set the multimeter to the Illustration 57
g00651378
OHMS test mode.
106-8704 Arc Suppressor

1. Place the multimeter in the DIODE test mode.
4. If the system pressure is below 2412 140 kPa
(350 20 psi), the multimeter will display less than 2. Place the red probe in the red terminal (positive
1 ohm. terminal) of the multimeter.
5. If the resistance that is displayed is a value of OL 3. Place the black probe in the black terminal
(high resistance), and the system pressure is not (negative terminal) of the multimeter.
above the acceptable limit, replace the pressure
switch. 4. Place the red probe on Pin 2 of the connector on
the arc suppressor. Place the black probe on Pin
6. When the pressure switch fails, test the arc 1 of the connector.
5. The multimeter should display a value between
7. If the pressure switch is removed, make sure 0.5 VDC and 1.0 VDC.
that the wires on the new pressure switch
are tie-wrapped. Securing the pressure switch 6. Place the red probe on Pin 1 of the connector on
prevents damage that may be caused by vibration. the arc suppressor. Place the black probe on Pin
2 of the connector on the arc suppressor.
on the pressure switch are dirty. The contacts on 7. The multimeter should display OL.
suppressor is no longer functioning. 8. If the above conditions do not exist, the component
should be considered faulty. The component will
Note: The multimeter will display OL if the pressure not provide adequate protection if the above
switch is not threaded into the air conditioning conditions do not exist.
system.
9. Replace the component if the component has
failed.
SENR5664-13 133
3E-9169 Arc Suppressor and 130-8134 Arc 8. Place the red probe on pin 1 of the female
Suppressor connector. Place the black probe on pin 1 of the
male connector.
9. The multimeter should have a reading of less than

0.01 VDC.
10. Place the red probe on Pin 2 of the female

connector. Place the black probe on Pin 2 of the
male connector.
11. The multimeter should have a reading of less

than 0.01 VDC.
12. The component is faulty if any of the conditions

do not exist.
g00651923
Illustration 58 13. If the component is faulty, replace the component.
Arc Suppressor with Sure Seal Connectors
(1) Pin 1 105-8827 Arc Suppressor and 130-0956 Arc
(2) Pin 2 Suppressor
g00651621 g00651923
Illustration 59 Illustration 60
Arc Suppressor with DT Connectors Arc Suppressor with Sure Seal Connectors
(1) Pin 1 (1) Pin 1
(2) Pin 2 (2) Pin 2
1. Place the multimeter in the DIODE test mode.
2. Place the red probe in the red terminal (positive

terminal) of the multimeter.
3. Place the black probe in the black terminal

(negative terminal) of the multimeter.
4. Place the red probe on Pin 1 of either connector

on the arc suppressor. Place the black probe on
Pin 2 of either connector.
5. The multimeter should display a value between

0.5 VDC and 1.0 VDC. g00651621
Illustration 61
6. Place the red probe on Pin 2 of either connector Arc Suppressor with DT Connectors
of arc suppressor. Place the black probe on Pin 1 (1) Pin 1
of either connector on the arc suppressor. (2) Pin 2
7. The multimeter should display OFL or OL. 1. Place the multimeter in the DIODE test mode.
134 SENR5664-13
2. Place the red probe in the red terminal (plus The Sure Seal connectors on the 3E-9169 Arc
terminal) of the multimeter. Suppressor and the 105-8827 Arc Suppressor
should be secured with two 9G-9150 Clips in order
3. Place the black probe in the black terminal to prevent movement of the connectors relative to the
(negative terminal) of the multimeter. body of the arc suppressor. The DT connectors on
the 130-0956 Arc Suppressor and 130-8134 Arc
4. Place the red probe on Pin 1 of either connector Suppressor should be secured with two 9U-2297
on the arc suppressor. Place the black probe on Clips. The clips should be bolted through the slotted
Pin 2 of either connector. holes on the 116-6100 Plate.
5. The multimeter should display a value between The 106-8704 Arc Suppressor is an integral arc
0.5 VDC and 1.0 VDC. suppressor. The integral arc suppressor can be
found on the newer machines. The 106-8704 Arc
6. Place the red probe on pin 2 of either connector of Suppressor is lighter than the other arc suppressors.
arc suppressor. Place the black probe on pin 1 of The 106-8704 Arc Suppressor can be strapped
either connector on the arc suppressor. directly to the wiring harnesses that are connected to
the arc suppressor.
7. The multimeter should display OFL or OL.
8. Place the red probe on pin 1 of the female

connector. Place the black probe on pin 1 of the
male connector.
9. The multimeter should have a reading of less than

0.01 VDC.
10. Place the red probe on pin 2 of the female

connector. Place the black probe on pin 2 of the
male connector.
11. The multimeter should have a reading of less

than 0.01 VDC.
12. The component is faulty if any of the conditions

do not exist.
13. If the component is faulty, replace the component.
Correct Mounting of Arc Suppressors

Certain arc suppressors may experience failure of
the wire leads due to vibration if the arc suppressor is
not properly supported.
Use a 2U-4497 Strap to tie-wrap the arc suppressor.

The arc suppressor should be securely tie-wrapped
to a stationary support in order to prevent any motion
of the body of the arc suppressor. Additionally, the
connectors on both ends of the arc suppressor
should be secured.
A suitable bracket for supporting an arc suppressor

is the 116-6100 Plate. The addition of a 9R-2926
Plate should permit the mounting of the 116-6100
Plate around obstacles. Use the 9R-2926 Plate if
the 116-6100 Plate cannot be installed directly in an
existing application.
SENR5664-13 135
Testing and Adjusting

i02514009
Refrigerant Recovery
SMCS Code: 1809-576
Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

dicate the system is empty of refrigerant.

Slowly loosen the fitting. If the system is still
Personal injury or death can result from inhaling


death.


If service work is required on an air conditioning

system, the refrigerant must be recovered first before
components are removed or installed. Use the
following procedure:
1. Use the refrigerant identifier. The refrigerant

identifier will detect refrigerants that are not
R134a. The refrigerant identifier will prevent
the refrigerants from contaminating the tools
for recovery and the tools for charging. The
refrigerant identifier will also detect the percentage
of air that may be in the system.
136 SENR5664-13
g00389232
Illustration 62
(1) Low pressure valve. (2) High pressure valve. (3) Charging hose. (4) Low pressure hose. (5) High pressure hose. (6) Manifold gauge set.
(7) Control panel. (8) Inlet on recovery station. (9) Accumulator/oil separator. (10) Drain valve. (11) Pressure valve on accumulator. (12)
Compressor. (13) Refrigerant tank. (14) Hose (liquid). (15) Hose (vapor). (16) Refrigerant pump. (17) Filter dryer. (18) Scale. (A) Refrigerant
compressor. (B) Low pressure side (suction). (C) High pressure side (discharge).
2. Install the manifold gauge set (6). Make sure that 4. Slowly open valves (1) and (2) in order to release
both valves are closed. Turn the valves clockwise the air from the charging hose. Ensure that the
in order to close the valves. Refer to theTesting valves on the refrigerant tank (13) are open. One
and Adjusting, Manifold Gauge Set (Refrigerant) valve is for vapor and the other valve is for liquid.
- Install section.
5. Plug the recovery station into an electrical outlet
Note: Do not operate the engine. and turn the power switch ON. This switch is
located on the control panel (7).
3. Attach charging hose (3) of the Manifold gauge
set to the inlet (8) on the refrigerant service unit. 6. Press the Compressor Start. The amber
Compressor On light will come on and
compressor (12) will start. The compressor will
automatically shut off when the recovery of
refrigerant is complete.
SENR5664-13 137
7. Drain accumulator (9) of refrigerant oil. Open 7. Replace any other failed component such as
accumulator pressurizing valve (11) long enough coils, fittings, etc. Flush the remainder of the
so that some discharge from the compressor can system. The air conditioning system should be
flow back to the accumulator. Open oil drain valve flushed with a 153-8537 Air Conditioner Flushing
(10) slowly and drain the oil into a measuring Unit. Also, a 153-9032 Air Conditioner Flushing
cup. Do not allow a complete loss of pressure in Unit can be used in order to flush the system.
the accumulator/oil separator. When the oil stops Refer to the information that is provided with the
draining, close oil drain valve (10). flushing unit. Flush the system with 153-8538
Refrigerant Flushing Solution.
8. If 15.0 mL (.50 fl oz) of compressor oil was lost
during the recovery process, new oil must be 8. Blow out the air conditioning system with dry shop
added to the system. Refer to the Testing and air for 5 to 10 minutes.
Adjusting, Refrigerant Compressor Oil - Check
section. 9. Install a new receiver-dryer or an in-line dryer.
Receiver-Dryer - Remove and Install section in
System Contamination Disassembly and Assembly. For in-line dryers,
refer to the Service Manual, SENR5664, In-Line
The system must be cleaned and the system must
Refrigerant Dryer - Remove and Install section in
be flushed if any particles of metal or other foreign
material from a component failure have circulated Disassembly and Assembly.
through the system.
10. Install a new accumulator. Refer to the Service
Debris in the system can cause the compressor to Manual, SENR5664, Air Conditioner Accumulator
- Remove and Install section in Disassembly and
fail. Use the following procedure for cleaning and
Assembly.
flushing the system.
11. Clean the original expansion valve. The orifice
1. Identify the refrigerant and then recover the
tube can not be cleaned. If necessary, replace
refrigerant. Refer to the Service Manual,
SENR5664, Refrigerant Recovery section. the original expansion valve or replace the orifice
tube. Clean the original quick couplers or replace
the original quick couplers.
2. Remove the compressor. Refer to the Service
Manual , SERN5664, Refrigerant Compressor -
12. Install a new compressor. New compressors are
Remove and Install section.
shipped with the correct amount of oil inside the
3. Remove the receiver-dryer or the in-line dryer. compressor. Do not add extra oil.
Note: Compressors that are new or remanufactured
Receiver-Dryer - Remove and Install section in
Disassembly and Assembly. For in-line dryers, are shipped with the correct amount of refrigerant oil
in the system.
refer to the Service Manual, SENR5664, In-Line
Refrigerant Dryer - Remove and Install section in
Disassembly and Assembly. 13. Refer to the Service Manual, SENR5664,
Refrigerant System - Evacuate section in Testing
and Adjusting.
4. Remove the accumulator. Refer to the Service
Manual, SENR5664, Air Conditioner Accumulator
14. Refer to the Service Manual, SENR5664,
- Remove and Install section in Disassembly and
Assembly.
and Adjusting.
5. Remove the expansion valve or the orifice
15. In order to ensure proper operation of the system,
tube. Refer to the Service Manual, SENR5664,
Expansion Valve - (Air Conditioner) Remove and refer to the Service Manual, SENR5664, Air
Conditioning System Troubleshooting section in
Install section in disassembly and assembly.
Refer to the Service Manual, SENR5664, Orifice
Tube (Air Conditioner) - Remove and Install
section in Disassembly and Assembly.
6. Remove the quick couplers.
NOTICE
In order to avoid component damage, do not clean
system components with solvents, compressed air,
etc..
138 SENR5664-13
i01693224 2. Connect the manifold gauge set to the service

ports near the refrigerant compressor. The service
Manifold Gauge Set ports for charging are located on the refrigerant
(Refrigerant) - Install lines. Connect the low pressure hose to the
service port on the suction side of the compressor.
SMCS Code: 7465-012 Connect the high pressure hose to the service
port on the discharge side of the compressor.
Make sure that the valved couplings are turned
counterclockwise for installation. Then, turn the
valved couplings clockwise in order to open the
Personal injury can result from contact with refrig- valves.
erant.
3. Turn the pressure valves clockwise and make
This system is under pressure at all times, even sure that both pressure valves on the manifold
if the engine is not running. Heat should never be gauge set are closed.
4. Place a clean rag over the charging hose fitting
Contact with refrigerant can cause frost bite. Keep that is loosened at the manifold gauge set. This
face and hands away to help prevent injury. will prevent the spraying of compressor oil. Open
the low pressure valve on the gauge set about 1/2
Protective goggles must always be worn when return. Keep the valve open for 2 to 3 seconds in
frigerant lines are opened, even if the gauges in- order to flush air from the low pressure hose. This
dicate the system is empty of refrigerant. will also flush air from the gauge set. Close the
low pressure valve on the gauge set. Repeat this
Always use caution when a fitting is removed. process for the high pressure valve. Tighten the
Slowly loosen the fitting. If the system is still charging hose fitting at the manifold gauge set.
the refrigerant before removing the fitting. Note: Use the refrigerant identifier. The refrigerant
identifier will prevent refrigerants that are not R134a
Personal injury or death can result from inhaling from contaminating the recovery and charging tools.

death.


1. Use the 138-6629 Refrigerant Identifier in order

to verify that the refrigerant that is in the air
conditioning system is R134a.
SENR5664-13 139
i02414167 Testing and Adjusting, Refrigerant Compressor

Oil - Check
Refrigerant System - Evacuate
If the system has been left open for more than 1/2
SMCS Code: 1809-541 hour, the system has been exposed to air or moisture
and a new receiver-dryer, an in-line dryer or a
desiccant accumulator needs to be installed. Moisture
will combine with metals in the refrigerant system and
Personal injury can result from contact with refrig- this will produce highly corrosive by-products. The
erant. by-products are oxides, iron hydroxide, and aluminum
hydroxide. Moisture can freeze the expansion valve
This system is under pressure at all times, even and moisture can freeze the orifice tube. If there
if the engine is not running. Heat should never be is water in the system the water must be removed.
applied to a charged system. Remove the water by pumping the system with a
vacuum pump and boiling the water. Refer to Table
Contact with refrigerant can cause frost bite. Keep 11 that is shown below.
The time for the evacuation process will increase
Protective goggles must always be worn when re- under the following conditions:
dicate the system is empty of refrigerant. The air conditioning system has been rebuilt.
Always use caution when a fitting is removed. The air conditioning system has been flushed.
under pressure, evacuate the system recovering The air conditioning system has new components.
The air conditioning system has been retrofitted.
refrigerant through a lit cigarette. Table 11
Boiling Point of Water Under Vacuum
lit cigarette or other smoking method or inhaling Vacuum That Is Required
Temperature of Work In Order To Boil Water
fumes released from a flame contacting air con- Area (C (F)) In An Air Conditioning
ditioner refrigerant gas, can cause bodily harm or System (m bar (Hg))
death.
38 C (100 F) 95 kPa (28 in Hg)
Do not smoke when servicing air conditioners or 32 C (89.6000 F) 96.5 kPa (28.50 in Hg)
27 C (81 F) 97.5 kPa (28.80 in Hg)
Before any checks of the air conditioning and 21 C (70 F) 98.8 kPa (29.20 in Hg)
to the ground. Make sure the transmission is Note: After the leak test is completed, the system
in neutral or park and that the parking brake is must be evacuated for a minimum of 30 minutes. In
engaged. Keep all other personnel away from the order to correctly evacuate the system, the vacuum
machine or where they can be seen. gauge must be less than three inches away from the
system port. If the gauge is more than three inches
away from the system port, pull a vacuum and allow
If replacement of a component is necessary or repair the system to equalize for ten minutes. This will
to a component is necessary, the refrigerant in ensure an accurate gauge reading.
the system must be recovered. Also, if the system
has lost any charge after a long period of time, the
refrigerant in the system must be recovered. It is NOTICE
necessary to perform the evacuating procedure in All refrigerant must be recovered before the evacuat-
order to delete the system of all air and moisture. A ing procedure is started. Never discharge the refrig-
complete charge must never be given to a system erant through the vacuum pump. Never discharge the
without first performing the evacuating procedure. refrigerant into the atmosphere. Always use the Re-
Before evacuating the system, refer to the following frigerant Identifier tool in order to ensure that contam-
manual. ination of the system does not occur.
Testing and Adjusting, Refrigerant Leakage - Test

Testing and Adjusting, Refrigerant Recovery
140 SENR5664-13
g00452649
Illustration 63
(1) Low pressure valve (6) Service valve (discharge)
(2) High pressure valve (7) Service valve (suction)
(3) Charging hose (8) Vented exhaust valve
(4) Compressor block fitting (discharge) (9) Line from condenser
(5) Compressor block fitting (suction) (10) Line from evaporator
SENR5664-13 141
1. After the refrigerant is recovered from the system, 10. After 95 kPa (28 in hg) to 98 kPa (29 in hg)
make sure that the low pressure valve (1) and the vacuum has been reached and held for an
high pressure valve (2) are closed. Disconnect the additional 90 minutes, close valve (1) and close
charging hose (3) of the manifold gauge set from valve (2) completely. Turn the power switch on the
the refrigerant service unit. vacuum pump to the OFF position. The maximum
amount of vacuum loss in five minutes must not be
2. Check the oil level in the vacuum pump. more than 7 kPa (2 in hg). Excessive vacuum loss
Refer to the Testing and Adjusting, Refrigerant is an indication of a possible leak in the system.
Compressor Oil - Check for the correct procedure. Refer to the Testing and Adjusting, Refrigerant
Add oil if oil is needed. If contamination of the Leakage - Test section. Perform the procedures
system is indicated, change the oil. that are indicated. Repair all leaks and repeat
Step 1 of the evacuating procedure.
3. Connect the electrical plug from the vacuum pump
to an approved electrical outlet. 11. If the vacuum loss does not exceed 7 kPa
(2 in hg) in five minutes, the system is then ready
4. Connect the charging hose (3) to the inlet fitting for a complete charge. Refer to the Testing and
on the vacuum pump. Refer to Illustration 63. Adjusting, Refrigerant System - Charge section.
Perform the procedures that are indicated.
5. Open low pressure valve (1) and open high
pressure valve (2) on the manifold gauge set
completely. Turn the valves counterclockwise.
6. In order to start the pump motor, turn the power

switch to the ON position.
7. In order to open the vented exhaust valve (8), turn

the valve counterclockwise.
Note: The vented exhaust valve (8) must be closed

until the vacuum pump has started.
8. Operate the vacuum pump until the low pressure

gauge indicates a pressure that is between 95 kPa
(28 in hg) and 98 kPa (29 in hg). After the vacuum
in the system reaches a value that is between
95 kPa (28 in hg) and 98 kPa (29 in hg), close the
vented exhaust valve (8). Operate the vacuum
pump for a minimum of 90 minutes after the
vented exhaust valve is closed. Use a 113 L/min
(4 cfm) pump. Make allowances for pumps that
are smaller than 113 L/min (4 cfm) cfm.
Note: 95 kPa (28 in hg) to 98 kPa (29 in hg) is the

required specification at sea level. For every 305 m
(1000 ft) above sea level, decrease the required
specification by 3 kPa (1 in hg). At high elevations,
less vacuum is required.
9. If the specific vacuum cannot be reached, the

system may have a leak. Refer to the Testing and
Adjusting, Refrigerant Leakage - Test section.
Perform the procedures that are indicated. Repair
all leaks and repeat Step 1 of the evacuating
procedure.
Note: The evacuating procedure removes air and

moisture from the system. Do not use the vacuum
pump primarily to indicate a system leak.
142 SENR5664-13
i01727454 In the middle of 1999, Caterpillar began installing dye

in the refrigeration systems of Caterpillar machines.
Refrigerant Leakage - Test The dye is used in order to assist in identifying points
of leakage in the refrigeration system.
SMCS Code: 1809-081
Finding leaks and repairing leaks from refrigerant is
Dye important since the air conditioner is a closed circuit
system.
The system must contain at least 0.4 kg (.88 lb)

of refrigerant. Install the manifold gauge set. The
Personal injury can result from contact with refrig- manifold gauge set can determine if pressure exists
erant. in the system. A leak test can be performed if the
system indicates pressure.
if the engine is not running. Heat should never be Note: Refrigerant vapor is heavier than air. For best
applied to a charged system. results, place the black light directly below possible
leaks.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury. Note: Leaks that are in the high pressure side of the
system are more easily found if the air conditioner is
Protective goggles must always be worn when re- operated for 5 to 10 minutes. The leak test must be
frigerant lines are opened, even if the gauges in- performed immediately after the unit is turned OFF.
dicate the system is empty of refrigerant. The leak test for the high pressure side is performed
before the pressures in the system equalize. Leaks
Always use caution when a fitting is removed. that are in the low pressure side of the system are
Slowly loosen the fitting. If the system is still more easily found if the air conditioner has been
under pressure, evacuate the system recovering turned OFF for 5 to 10 minutes. The leak test for the
the refrigerant before removing the fitting. low pressure side is performed after the pressures in
the system equalize.
refrigerant through a lit cigarette. 1. Move the black light along possible leak points.
When a leak is present, the black light will
Inhaling air conditioner refrigerant gas through a illuminate the dye that is in the refrigerant.
fumes released from a flame contacting air con- Note: Leaks that are indicated by the presence
ditioner refrigerant gas, can cause bodily harm or of dye should always be confirmed with an
death. electronic leak detector.
Do not smoke when servicing air conditioners or 2. If a leak is found in the air conditioning system,
wherever refrigerant gas may be present. use a 4C-2964 Refrigerant Leak Detector in order
to confirm the leak that was detected by the use
Before any checks of the air conditioning and of the black light.
smooth horizontal surface. Lower all implements 3. Repair the leak In the air conditioning system
to the ground. Make sure the transmission is and clean the area with 192-4727 Dye Cleaning
in neutral or park and that the parking brake is Solution.
Leak Detector
Table 12 The 208-1374 Refrigerant Leak Detectors are
Required Tools designed in order to detect leaks as small as 7.4 mL
(.25 oz) per year of refrigerant in the air conditioning
Part Number Part Description Quantity system. Perform the following procedure in order to
Leak Detection Lamp determine if the system has a leak.
192-2331 1
Gp
SENR5664-13 143
The system must contain at least 0.4 kg (.88 lb) i02549022

of refrigerant. Install the manifold gauge set. The
manifold gauge set can determine if pressure exists Refrigerant Compressor Oil -
in the system. A leak test can be performed if the Check
system indicates pressure.
SMCS Code: 1802-535-FLV
Note: Refrigerant vapor is heavier than air. For best
results, place the sensor tip directly below possible
leaks.
Note: Leaks in the high pressure side of the system Personal injury can result from contact with refrig-
are more easily found if the air conditioner is operated erant.
for a few minutes. The leak test must be performed
immediately after the unit is turned OFF. The leak test This system is under pressure at all times, even
for the high pressure side is performed before the if the engine is not running. Heat should never be
pressures in the system equalize. Leaks in the low applied to a charged system.
pressure side of the system are more easily found if
the air conditioner has been turned OFF for several Contact with refrigerant can cause frost bite. Keep
minutes. The leak test for the low pressure side is face and hands away to help prevent injury.
performed after the pressures in the system equalize.
1. Move the sensor tip along possible leak points at frigerant lines are opened, even if the gauges in-
a rate of one inch per second. dicate the system is empty of refrigerant.
2. It may not be necessary to recover refrigerant if Always use caution when a fitting is removed.
a loose fitting or a loose connection is causing a Slowly loosen the fitting. If the system is still
leak. Tighten the loose connection and perform the under pressure, evacuate the system recovering
performance check procedure. If necessary, add the refrigerant before removing the fitting.
refrigerant to the air conditioning system. Refer to
the Testing and Adjusting, Refrigerant System - Personal injury or death can result from inhaling
Charge section for the proper procedure. refrigerant through a lit cigarette.
3. If the repair of a leak calls for the removal or the Inhaling air conditioner refrigerant gas through a
replacement of a component, refer to the Service lit cigarette or other smoking method or inhaling
Manual, SENR5664, Machine Preparation fumes released from a flame contacting air con-
for Disassembly and Assembly section in ditioner refrigerant gas, can cause bodily harm or
Disassembly and Assembly. death.
Note: Under normal conditions, R134a air Do not smoke when servicing air conditioners or
conditioning systems that have P80 hoses may lose wherever refrigerant gas may be present.
as much as 0.018 kg (0.0400 lb) of refrigerant per
foot of hose per year. Before any checks of the air conditioning and
Note: Refrigerants that are not approved by smooth horizontal surface. Lower all implements
Caterpillar may have higher leakage rates. to the ground. Make sure the transmission is
A special refrigerant oil is used in the air conditioning

system. The oil mixes completely with the refrigerant
so that all the components receive lubrication. A
check of the refrigerant oil in the compressor will give
an indication of the amount of oil that is in the system.
Reference: Refer to System Operations, Refrigerant

Compressor for more information.
Note: Generally, the oil in the compressor is checked

when there is evidence of a major loss of oil. The
following conditions may cause the loss of oil:
Broken refrigerant hose

144 SENR5664-13
Hose fitting (leaks) Metal chips

Badly leaking compressor seal Rubber particles
Component damage Foreign material
Dispose of the oil in a suitable container. Use the
Complete Check of Compressor Oil following list as a guide for adding oil into the
compressor:
When the replacement of a component is necessary,
follow the procedures below. The procedure
determines the amount of refrigerant oil (lost oil) that If the amount of oil that is drained from the
compressor is 177 mL (6 fl oz) to 237 mL
is needed in the compressor.
(8 fl oz), put the same amount of new refrigerant
1. Operate the engine at 1000 rpm. Set the oil in the compressor. Never refill with more
than 237 mL (8 fl oz) of oil to the compressor
temperature on maximum cooling setting. Move
unless the system has been flushed.
the fan speed switch to HIGH. The system will
stabilize in a minimum of 10 minutes.
If the amount of oil that is drained from the
compressor is less than 177 mL (6 fl oz), add
2. Stop the engine. Remove the refrigerant charge
from the system. Install a plug in all open lines. 177 mL (6 fl oz) to 237 mL (8 fl oz) of new
refrigerant oil to the compressor.
Refer to Testing and Adjusting, Refrigerant
Recovery for the proper procedure.
If a new compressor or a rebuilt compressor is
installed, drain all of the oil from the compressor
3. Remove the compressor from the machine. Place
and add 177 mL (6 fl oz) to 237 mL (8.0 fl oz) of
protective caps on all fittings and hoses.
new refrigerant oil in the compressor.
If the system was flushed do not remove the oil

from a new compressor.
Refer to 13 if individual components are

replaced without charging the compressor or
without flushing the system.
Table 13
Oil Capacities for Component Replacements
Accumulator 30 mL (1 fl oz)
Compressor Refer to the Service Manual,
SENR5664, Refrigerant Compressor
Illustration 64
g00296421 Oil-Check section in Testing and
Adjusting.
(1) Pulley
(2) Hose (low pressure) Condenser 30 mL (1 fl oz)
(3) Hose (high pressure)
(4) Electrical harness Evaporator 90 mL (3 fl oz)
(5) Service valve (low pressure)
(6) Service valve (high pressure) In-Line Dryer(1) 30 mL (1 fl oz)
(7) Plug (oil change)
(8) Belt Receiver-Dryer 30 mL (1 fl oz)
(1) Refer to the Service Manual, SENR5664,
4. Place the compressor in a horizontal position so In-Line-Refrigerant Dryer - Remove and Install
oil plug (7) is facing downward. Remove oil plug before any oil is added.
(7) from the compressor. Drain the oil into a clean
container. Rock the compressor back and forth If too much oil has been added to the system and
in order to remove all of the oil. Also, rotate the a total of more than 325 mL (11 fl oz) of oil is in
compressor shaft in order to drain the rest of the the system, the cooling capacity of the system will
oil that is in the oil sump. Record the volume of be reduced. If too little oil has been added to the
drained refrigerant. Inspect the oil for the following system, the compressor may fail due to a lack of
items: lubrication.
Contaminants
SENR5664-13 145
If the failure of a component causes particles of i02529426

metal or other foreign material to be present in the
system, it is necessary to flush the system. Refer Refrigerant System - Charge
to Troubleshooting, Air Conditioning System
Troubleshooting for the proper diagnostics. SMCS Code: 1809-045
Note:
a. Add oil to the compressor through opening for Personal injury can result from contact with refrig-
the oil plug (7) or inject the oil through the ports erant.
that are for charging. The compressor must
be positioned so that the refrigerant oil will not This system is under pressure at all times, even
flow out of service valves (5) and (6). Do not if the engine is not running. Heat should never be
rest the compressor on the compressor shaft. applied to a charged system.
Turn the compressor shaft by hand when you
fill the compressor. The oil will slowly flow into Contact with refrigerant can cause frost bite. Keep
the compressor. Only use refrigerant oil that is face and hands away to help prevent injury.
approved and recommended.
b. Add oil to any components that are being frigerant lines are opened, even if the gauges in-
installed. dicate the system is empty of refrigerant.
c. Inject oil into the pressurized system through Always use caution when a fitting is removed.
the port for low pressure charging while the Slowly loosen the fitting. If the system is still
engine is running and the compressor is under pressure, evacuate the system recovering
operating. the refrigerant before removing the fitting.
5. After the correct amount of refrigerant oil has Personal injury or death can result from inhaling
been added to the system, install the compressor refrigerant through a lit cigarette.
and the drive belt. Refer to Testing and Adjusting,
Refrigerant System - Charge for the proper Inhaling air conditioner refrigerant gas through a
procedure. lit cigarette or other smoking method or inhaling
death.


Table 14
Required Tools
Part
Part Description Quantity
Number
4C-4874 Heater Blanket As 1
146 SENR5664-13
Relationship Between Temperature (Table 15, contd)
and Pressure (R-134a Refrigerant) Relationship Between Temperature and Pressure

(R-134a Refrigerant)
Table 15 can be used in order to determine the Temperature C (F) Pressure kPa (psi)(1)
pressure level and contamination level of a container
of refrigerant. Table 15 can also be used for an 1 C (31.0 F) 185 kPa (26.8 psi)
air conditioning system that is not operating. This 0 C (32.0 F) 191 kPa (27.7 psi)
same system must be stabilized to the ambient
temperature. In order to stabilize an air conditioning 1 C (33.0 F) 197 kPa (28.5 psi)
system at the ambient temperature, the machine 1 C (34.0 F) 203 kPa (29.4 psi)
must not operate for 10 to 12 hours. The machine
must not be stored in direct sunlight. 2 C (35.0 F) 209 kPa (30.3 psi)
2 C (36.0 F) 215 kPa (31.2 psi)
If the pressure that is measured at any specific
temperature does not match the pressure that is 3 C (37.0 F) 221 kPa (32.1 psi)
given in the chart, the following problems may exist: 3 C (38.0 F) 228 kPa (33.0 psi)
Contaminants in the system 4 C (39.0 F) 234 kPa (34.0 psi)

4 C (40.0 F) 241 kPa (34.9 psi)
Incorrect refrigerant
5 C (41.0 F) 248 kPa (35.9 psi)
Incorrect refrigerant charge 6 C (42.0 F) 254 kPa (36.9 psi)
Table 15 6 C (43.0 F) 261 kPa (37.9 psi)
Relationship Between Temperature and Pressure 7 C (44.0 F) 263 kPa (38.9 psi)
(R-134a Refrigerant)
7 C (45.0 F) 275 kPa (39.9 psi)
Temperature C (F) Pressure kPa (psi)(1)
8 C (46.0 F) 283 kPa (41.0 psi)
18 C (0.0 F) 44 kPa (6.4 psi)
8 C (47.0 F) 290 kPa (42.0 psi)
17 C (2.0 F) 51 kPa (7.4 psi)
9 C (48.0 F) 297 kPa (43.1 psi)
16 C (4.0 F) 59 kPa (8.5 psi)
9 C (49.0 F) 305 kPa (44.2 psi)
14 C (6.0 F) 66 kPa (9.6 psi)
10 C (50.0 F) 312 kPa (45.3 psi)
13 C (8.0 F) 74 kPa (10.7 psi)
11 C (51.0 F) 320 kPa (46.4 psi)
12 C (10.0 F) 82 kPa (11.9 psi)
11 C (52.0 F) 328 kPa (47.5 psi)
11 C (12.0 F) 90 kPa (13.1 psi)
12 C (53.0 F) 336 kPa (48.7 psi)
10 C (14.0 F) 99 kPa (14.3 psi)
12 C (54.0 F) 344 kPa (49.9 psi)
9 C (16.0 F) 108 kPa (15.6 psi)
13 C (55.0 F) 352 kPa (51.0 psi)
8 C (18.0 F) 117 kPa (17.0 psi)
13 C (56.0 F) 360 kPa (52.2 psi)
7 C (20.0 F) 127 kPa (18.4 psi)
14 C (57.0 F) 369 kPa (53.5 psi)
6 C (21.0 F) 132 kPa (19.1 psi)
14 C (58.0 F) 377 kPa (54.7 psi)
6 C (22.0 F) 137 kPa (19.8 psi)
15 C (59.0 F) 385 kPa (55.9 psi)
5 C (23.0 F) 141 kPa (20.5 psi)
16 C (60.0 F) 394 kPa (57.2 psi)
4 C (24.0 F) 147 kPa (21.3 psi)
16 C (61.0 F) 403 kPa (58.2 psi)
4 C (25.0 F) 152 kPa (22.0 psi)
17 C (62.0 F) 412 kPa (59.8 psi)
3 C (26.0 F) 157 kPa (22.8 psi)
17 C (63.0 F) 421 kPa (61.1 psi)
3 C (27.0 F) 163 kPa (23.6 psi)
18 C (64.0 F) 430 kPa (62.4 psi)
2 C (28.0 F) 168 kPa (24.4 psi)
18 C (65.0 F) 440 kPa (63.8 psi)
2 C (29.0 F) 174 kPa (25.2 psi)
19 C (66.0 F) 450 kPa (65.2 psi)
1 C (30.0 F) 179 kPa (26.0 psi)
(continued)
(continued)
SENR5664-13 147
(Table 15, contd) (Table 15, contd)

Relationship Between Temperature and Pressure Relationship Between Temperature and Pressure
(R-134a Refrigerant) (R-134a Refrigerant)
Temperature C (F) Pressure kPa (psi)(1) Temperature C (F) Pressure kPa (psi)(1)
19 C (67.0 F) 459 kPa (66.8 psi) 40 C (104.0 F) 911 kPa (132.1 psi)
(1) All pressures in this table are gauge pressures.
37 C (98.0 F) 823 kPa (119.4 psi)
37 C (99.0 F) 838 kPa (121.5 psi)
38 C (100.0 F) 852 kPa (123.5 psi)
38 C (101.0 F) 866 kPa (125.6 psi)
39 C (102.0 F) 881 kPa (127.8 psi)
39 C (103.0 F) 896 kPa (129.9 psi)
(continued)
148 SENR5664-13
Procedure for Labeling (Table 16, contd)

System Capacity Part Number for Label
Attach a label to the air conditioning system that
indicates the system charge. Attaching a label 1.6 kg (3.53 lb) 114-0074
to the system will allow easy identification of the 1.7 kg (3.75 lb) 114-0075
system. Refer to Table 16 for the part number of the
appropriate label. A 8L-8413 Cable Strap may be 1.8 kg (3.97 lb) 114-0076
used in order to secure the tag to the air conditioning 1.9 kg (4.19 lb) 114-0077
system.
2.0 kg (4.41 lb) 114-0078
Table 16
2.1 kg (4.63 lb) 114-0079
System Capacity Part Number for Label
2.2 kg (4.85 lb) 114-0080
9U-7551 Air Conditioner Oil
2.3 kg (5.07 lb) 114-0081
1.5 kg (3.31 lb) 130-4677
2.4 kg (5.29 lb) 114-0082
1.8 kg (3.97 lb) 114-0050
2.5 kg (5.51 lb) 114-0083
1.9 kg (4.19 lb) 114-0051
2.6 kg (5.73 lb) 114-0084
2.0 kg (4.41 lb) 114-0052
2.7 kg (5.95 lb) 122-3301
2.1 kg (4.63 lb) 114-0053
2.8 kg (6.17 lb) 114-0085
2.2 kg (4.85 lb) 114-0054
3.0 kg (6.61 lb) 122-3302
2.3 kg (5.07 lb) 114-0055
2.5 kg (5.51 lb) 114-0056
Charging the System
2.7 kg (5.95 lb) 114-0057
114-0058
Note: An accurate refrigerant charge may only be
3.0 kg (6.61 lb)
determined by weight or by the temperature of the
3.1 kg (6.83 lb) 140-7484 evaporator core. Pressures can not be used in order
to determine if the air conditioning system is correctly
4C-2959 Air Conditioner Oil
charged. Do not add or remove part of the refrigerant.
1.6 kg (3.54 lb) 114-0059
Note: Never charge liquid or gas through the
1.7 kg (3.75 lb) 114-0060
discharge side (high side) of the system when the
1.8 kg (3.97 lb) 114-0061 engine is in operation.
1.9 kg (4.19 lb) 114-0062
NOTICE
2.0 kg (4.41 lb) 114-0063 In an expansion valve system which uses poly alkaline
2.1 kg (4.63 lb) 114-0064 glycol (PAG), the sight glass is not a reliable way to
determine the system charge.
2.2 kg (4.85 lb) 114-0065
2.3 kg (5.07 lb) 114-0066
Note: For expansion valve systems that contain
2.4 kg (5.29 lb) 114-0067 PAG oil, the sight glass can not be used for the
purpose of charging the system. In order to achieve
2.5 kg (5.51 lb) 114-0068 a full charge for the system, the refrigerant must be
2.6 kg (5.73 lb) 114-0048 recovered from the system and the system must be
evacuated. After the system has been recovered and
2.7 kg (5.95 lb) 114-0069 the system has been evacuated, the system needs
3.0 kg (6.61 lb) 114-0070 to be charged with the correct amount of refrigerant.
This is the only procedure that is recommended.
3.8 kg (8.38 lb) 114-0071 Refer to the Specifications, System Capacities for
4C-2960 Air Conditioner Oil Refrigerant section for the proper capacity. Also,
refer to the Service Manual, SENR5664, Identifying
1.1 kg (2.42 lb) 122-3300 the Air Conditioning System section.
1.4 kg (3.09 lb) 114-0072
1.5 kg (3.31 lb) 114-0073
(continued)
SENR5664-13 149
Note: If the engine is running, charge the system with Note: After the system has been recovered and the
refrigerant gas through the low pressure side. Never system has been evacuated, the system needs to
charge liquid refrigerant through the suction side be charged with the correct amount of refrigerant.
(low pressure side) of the air conditioning system. If Measure the refrigerant by weight. Refer to the
the engine is not running, charge with liquid or gas Specifications, System Capacities for Refrigerant
through the high pressure side. section for the proper capacity. Also, refer to the
Service Manual, SENR5664, Identifying the Air
Note: Before you charge the system, these important Conditioning System section.
items should be checked.
1. Condenser and evaporator

Complete Charge of the System
from a Refrigerant Tank with a
Inspect the condenser and inspect the Scale
evaporator for foreign material that would inhibit
air flow such as dirt, insects, plastic bags, etc. The use of a refrigerant tank and a scale is necessary
in order to charge the system. Use the procedure that
With condensers that are mounted on the roof follows to charge the system.
and with remote mounted condensers, always
check that both fan motors are running. Check Note: When you charge the system with a liquid,
for restrictions. A clean condenser will lead to ensure that the engine is not running.
improved life for the compressor.
1. In order to find the refrigerant capacity for the
2. Check for a loose belt on the compressor. system that needs a refrigerant charge, refer to the
Specifications, System Capacities for Refrigerant
3. Clean the fresh air filter and clean the recirculation section. Also, refer to the Service Manual,
filter. SENR5664, Identifying the Air Conditioning
System section.
4. Check the moisture indicator on either the
receiver-dryer or the in-line dryer. If the moisture
indicator is pink or white, there is moisture in the
system. Replace the receiver-dryer or the in-line
dryer. Refer to the Service Manual, SENR5664,
Machine Preparation for Dissassembly and
Assembly section. If the moisture indicator is
blue, the system is normal.
5. Check the condensate tube on the evaporator.

Make sure that the tube is not plugged and that
the valve is properly in place.
Note: Before an accurate reading for moisture can

be attained, a new receiver-dryer requires 2 to 3
hours of operation.
Refer to the Troubleshooting, Machine

Preparation for Troubleshooting section in testing
and adjusting before service work is performed on
the air conditioning system.
Note: The preferred method for charging the air

conditioning system is listed below.
Recover the refrigerant.

Evacuate the system.
150 SENR5664-13
g00669264
Illustration 65
(1) Low pressure valve (6) Manifold gauge set (14) Scale
(2) High pressure valve (7) Service valve (discharge) (E) Vapor
(3) Charging hose (8) Service valve (suction) (F) Liquid
(4) Low pressure hose (12) Refrigerant tank
(5) High pressure hose (13) Valve on top of refrigerant tank
SENR5664-13 151
2. Hand tighten charging hose (3) from the manifold Note: If the compressor fails one of the steps, then
gauge set directly to the valve (13) on refrigerant the air conditioning system should be diagnosed
tank (12). Open the valve (13) on top of refrigerant in order to find the root cause of the failure. The
tank (12). This allows the flow of refrigerant root cause of the failure should be repaired. If
through the charging hose (3) to the manifold the compressor is considered to be good, then
gauge set (6). additional assistance with the diagnosis of the air
conditioning system can be found in Service Manual,
3. Loosen the hose (3) at the manifold gauge set SENR5664, Air Conditioning and Heating R134a
(6) for two to three seconds. Then tighten the for all Caterpillar Machines or by contacting your
connection. This procedure will purge the air from Caterpillar dealer.
the line.
4. Place the refrigerant tank (12) on the scale (14)

Procedures
so that the valve (13) is at the bottom. Check the
weight of the tank.
5. Open the high pressure valve (2) on the manifold Personal injury can result from contact with refrig-
gauge set (6). This action allows the liquid erant.
refrigerant to charge the system through the high
pressure side of the compressor. This system is under pressure at all times, even
6. Check the weight of the refrigerant tank (12) often. applied to a charged system.
The weight will decrease as the refrigerant leaves
the tank and the refrigerant enters the system. Contact with refrigerant can cause frost bite. Keep
When the required amount of refrigerant (system face and hands away to help prevent injury.
capacity) has entered the system, close the valve
(13) and close the high pressure valve (2). Closing Protective goggles must always be worn when re-
the valves stops the flow of the refrigerant. For frigerant lines are opened, even if the gauges in-
example, 1.8 kg (4 lb) of refrigerant has entered a dicate the system is empty of refrigerant.
system with 1.8 kg (4 lb) capacity.
Note: A heater blanket may be required when you Slowly loosen the fitting. If the system is still
charge an air conditioning system with a partially full under pressure, evacuate the system recovering
refrigerant tank. the refrigerant before removing the fitting.
7. In order to ensure correct system operation, Personal injury or death can result from inhaling
disconnect charging hose (3) and conduct a refrigerant through a lit cigarette.
performance check. Refer to the Service Manual,
SENR5664, Performance Checks for the Air Inhaling air conditioner refrigerant gas through a
Conditioning System section. lit cigarette or other smoking method or inhaling
i02545188 death.
Refrigerant Compressor - Test Do not smoke when servicing air conditioners or
SMCS Code: 1802-081
Identifying compressors that function is the purpose
of this instruction. Compressors that function should
be identified before the compressors are removed
from a machine. Compressors that function should
produce both high pressure and low pressure. If
the compressor fails any one of Steps 3, 5, 7, or 8,
then the compressor is considered to be a failed
compressor. Please indicate the steps which were
failed by the compressor in the Warranty Claim Story. 1. Check the air filters. If the complaint of the
customer is poor cooling of the cab, past
experience has shown that plugged air filters can
often be the cause. Most air conditioning systems
have return air filters and fresh air filters. Be sure
to check both the return air filters and fresh air
filters.
152 SENR5664-13
Air Filters Checked? Yes or No. Measured New Belt Tension: ________ (N) or (lbs)
2. Test the voltage. While the engine is running Measured Old Belt Tension: ________ (N) or (lbs)
and the air conditioning is switched ON, check
the voltage at the compressor. The voltage at the
compressor should be a minimum of 11.5VDC
for a 12VDC system or 23 volts for a 24VDC
system. The routinely used electrical loads should Accidental machine starting can cause injury or
be turned ON. For example, a lighting system death to personnel working on the machine.
which is added by the customer could cause
available voltage to decrease below the minimum To avoid accidental machine starting, turn the bat-
specification. tery disconnect switch to the OFF position and re-
move the key. If the machine is not equipped with
Voltage Checked? Yes or No. a battery disconnect switch, disconnect the bat-
tery cables from the battery and tape the battery
Measured Voltage Level: ________ (volts) clamps.
Note: When the air conditioning is switched ON, Place a do not operate tag at the battery discon-
for air conditioning systems with a Compressor nect switch location to inform personnel that the
Protection System (CPS), there is approximately a 30 machine is being worked on.
second delay before a voltage signal is detected at
the compressor. Air conditioning systems with CPS Note: The electrical power supply to the compressor
can be identified by the use of either the 169-7443 should be switched OFF in order to perform this test.
On Delay Timer As or the 212-2204 Air Conditioner
Control Gp. In most applications, the electronic 5. Test the rotation. Rotate the compressor in the
control group is located near the compressor. direction of belt travel by turning the nut on the
end of the main shaft of the compressor. Rotation
3. Test the resistance. Measure resistance of the should be smooth with no binding.
clutch coil at the compressor connector. For
12VDC models, measured resistance should be Rotation Checked? Yes or No.
within -0.3 to +1.1 ohms of the amount which
is listed in the Specifications section of Service Rotation Smooth? Yes or No.
Manual, SENR5664, Air Conditioning and Heating
R134a for all Caterpillar Machines, Refrigerant 6. Check the charge level. The air conditioning
Compressor. For 24VDC models, measured system must be correctly charged per Caterpillar
resistance should be within -1.3 to +5.5 ohms of specification or an incorrect diagnosis will occur.
the amount which is listed in Specification section Recovering, evacuating, and recharging with
of Service Manual, SENR5664, Air Conditioning clean refrigerant to the correct level is the best
and Heating R134a for all Caterpillar Machines, method of achieving the correct refrigerant charge
Refrigerant Compressor. The resistance ranges for the system. Charging the air conditioning
which are listed above compensate for the effect system must be conducted by weighing refrigerant
of temperature on the clutch coil. The values with a calibrated scale in order to ensure
which are listed in the Specifications section of accuracy. Also, be sure to replace the oil which
Service Manual, SENR5664, Air Conditioning was removed during refrigerant recovery with
and Heating R134a for all Caterpillar Machines, new oil. Reference Service Manual, SENR5664,
Refrigerant Compressor are nominal for 20 C Air Conditioning and Heating R134a for all
(68 F). Caterpillar Machines, Refrigerant Compressor
for procedures regarding refrigerant charging and
Resistance Checked? Yes or No. capacity of Caterpillar air conditioning systems.
Measured Level of Resistance: ________ (ohms) Charge Level Checked? Yes or No.
4. Check the belt tension. For new belts and old Volume of Oil that was Removed During Recovery:
belts, use the 144-0235 Belt Tension Gauge. For ________(ml) or (oz)
a new belt installation, the initial belt tension for a
compressor which drives the system without an Weight of Refrigerant Charge: ________ (Kg) or
auto tensioning device should be 534 N (120 lb). (lbs)
For used belts, the belt tension should be 400 N
(90 lb).
Belt Tension Checked? Yes or No.

SENR5664-13 153
7. Test for low pressure. The test for low pressure

should be performed with ambient temperatures
of less than 30 C (86 F). Park the machine in an
area that is not in direct sunlight. Close all cab
doors and windows. Block the flow of fresh air
into the cab. If the air conditioning system is so
equipped, bypass the low pressure switch . Start
the machine. Operate the machine at high idle.
Turn ON the air conditioning. Set the cab blower
on LOW. After 10 to 15 minutes of operation,
measure the low-side pressure at the refrigerant
compressor. If the pressure reading is less than
69 kPa (10 psi) then the suction valves of the
compressor are operating correctly.
Low Pressure Checked? Yes or No.
Low Pressure Reading: ________ (kPa) or (Psig)
Note: If the cab temperature is above 25 C (77 F),

then the cab blower may need to be set to HIGH in
order to reduce the temperature before starting the Illustration 66
g01127048
procedure. 3E-1906 Refrigerant Compressor Gp (Typical Refrigerant
Compressor)
8. Test for high pressure. Start the engine and
set the speed at approximately 1200 rpm.
Turn ON the air conditioning. Place a sheet of
cardboard over the condenser in order to block
the flow of air. Limiting the flow of air over the
condenser will cause the discharge pressure
of the compressor to increase. Check if the
discharge of the compressor is able to increase
up to 2414 kPa (350 psi). Once the specified
pressure is reached, immediately remove the
cardboard. If the compressor passes the test, the
discharge valves are operating correctly.
High Pressure Checked? Yes or No.
High Pressure Reading: ________ (kPa) or (Psig)
The functional test is now complete. If this test

procedure results in inconclusive results, your
dealerships Technical Communicator can report
the problem by using the on-line Dealer Solution
Network. The Dealer Solution Network will provide g01123619
your Technical Communicator with additional Illustration 67
troubleshooting support. Wire lead and pin location for field coil
Illustrations 66 through 69 are provided as Good Air

Conditioning System Practices and Troubleshooting
Tips.
154 SENR5664-13
g01126988
Illustration 68
The permissible mounting location and orientation of Suction Port S and Discharge Port D.
(1) Suction Port S (2) Discharge Port D
g01127111
Illustration 69
On Delay Timer Assembly (Compression Protection System)
Procedure to Test the On Delay Timer 1. Separate the four-pin connector from the wiring
Assembly harness.
The engine start switch must be in the ON position, 2. In order to check that power is getting from the
and the air conditioning switch must be activated in on delay timer to the compressor, perform the
order to diagnose a faulty on delay timer assembly following steps:
for the refrigerant compressor.
a. Set the 146-4080 Digital Multimeter Gp to
Note: The on delay timer assembly will delay the DC voltage.
power supply to the compressor clutch coil for 30
seconds after the air conditioning switch is activated.
SENR5664-13 155
b. Connect the multimeters positive probe to pin d. Connect the negative lead to a suitable ground.
4 on the wiring harness.
e. Check each of the two pins on the two-pin
c. Connect the multimeters negative probe to a connectors for continuity. One of the two pins
suitable ground. The multimeter should read should display OL.
24VDC for 24 volt machines. The multimeter
should read 12VDC for 12 volt machines. 7. If both the correct ground and voltage are
present, check the resistance of the compressor
Note: On a 24 volt system, if the voltage is below clutch coil. Refer to the Specifications section in
18VDC or if the voltage is above 32VDC, the on Service Manual, SENR5664, Air Conditioning
delay timer will not supply power to the compressor. and Heating R134a for all Caterpillar Machines,
On 12 volt systems, the range is 9VDC to 24VDC. Refrigerant Compressor.
3. Set the 146-4080 Digital Multimeter Gp to

i01693236
OHMS. Connect the multimeters positive probe to
pin location 2 on the wiring harness. Connect the
multimeters negative probe to a suitable chassis
Manifold Gauge Set
ground. The multimeter will display OL if the (Refrigerant) - Remove
ground is not present.
SMCS Code: 7465-011
4. Set the 146-4080 Digital Multimeter Gp to
OHMS. Connect the multimeters positive probe to
pin location 1 on the wiring harness. Connect the
multimeters negative probe to a suitable chassis Personal injury can result from contact with refrig-
ground. If the multimeter displays OL, one of erant.
the three switches is open. If an open condition
occurs, check each of the switches. This system is under pressure at all times, even
Note: There must be refrigerant in the air conditioning applied to a charged system.
system in order to close both of the pressure
switches. Contact with refrigerant can cause frost bite. Keep
5. In order to check that power is getting from the on
delay timer assembly to the compressor clutch Protective goggles must always be worn when re-
coil, reconnect the on delay timer assembly to the frigerant lines are opened, even if the gauges in-
wiring harness. dicate the system is empty of refrigerant.
a. Set the 146-4080 Digital Multimeter Gp to Always use caution when a fitting is removed.
DC voltage. Slowly loosen the fitting. If the system is still
b. Remove the 2-pin connector from the the refrigerant before removing the fitting.
compressor clutch coil.
c. Connect the negative probe to a suitable refrigerant through a lit cigarette.
chassis ground.
d. Check each of the two pins on the wiring lit cigarette or other smoking method or inhaling
harness for voltage. On a 24 volt system, one fumes released from a flame contacting air con-
of the pins should supply 24VDC. On a 12 volt ditioner refrigerant gas, can cause bodily harm or
system, one of the pins should supply 12VDC. death.
6. In order to check the ground path from the Do not smoke when servicing air conditioners or
compressor clutch coil to the chassis, perform the wherever refrigerant gas may be present.
following steps:
a. Turn OFF the air conditioning switch in the cab. heating system are made, move the machine to a
b. Set the 146-4080 Digital Multimeter Gp to to the ground. Make sure the transmission is
Ohms. in neutral or park and that the parking brake is
c. Remove the two-pin connector from the machine or where they can be seen.
compressor clutch coil.
156 SENR5664-13
Remove charging hoses properly. A low system S/N: AXF1-Up

charge will result from charging hoses that are not
removed correctly. In order to ensure accuracy of the S/N: CBF1-Up
refrigerant charge, the refrigerant should be removed
S/N: 9XG343-Up
from the charging hoses. Refer to the following steps
in order to remove the refrigerant from the charging S/N: AFG1-Up
hoses:
S/N: AGG1-Up
1. Allow the compressor to continue operating.
Close the valve on the high pressure side. The S/N: CCG1-Up
valve is located near the charging ports on the S/N: ALH1-Up
compressor. Disconnect the high pressure hose
from the air conditioning system. S/N: CEH1-Up
2. Open the high pressure valve and open the low S/N: CFH1-Up
pressure valve at the gauge set . The refrigerant
S/N: 7TJ1-Up
that is in the hoses will be removed by the
compressor through the low pressure hose. S/N: 8LJ884-Up
3. Close the valve on the low pressure side. This S/N: ABJ1-Up
valve is located near the charging ports on the
compressor. Disconnect the low pressure hose S/N: ACJ1-Up
from the air conditioning system. The system is S/N: BMJ1-Up
now charged.
S/N: BRJ1-Up
Note: After the manifold gauge set is removed, it is
necessary to cap the charging valves. S/N: CBJ1-Up
S/N: DFJ1-Up
i02046813
S/N: 4HK366-Up
Electronic Heat Control - Test
S/N: 4SK22-Up
(Type 1)
S/N: 6BK1-Up
SMCS Code: 7304-081-VL; 7309-081-VL
S/N: ABK1-Up
S/N: AKA1-Up
S/N: AWK1-Up
S/N: DFA1-Up
S/N: CCK1-Up
S/N: DBB1-Up
S/N: 1DL18-Up
S/N: AEC1-Up
S/N: 5ZL1-Up
S/N: BNC1-Up
S/N: 7LL1-Up
S/N: DBC1-Up
S/N: 8PL1-Up
S/N: AFD1-Up
S/N: ACL1-Up
S/N: AKD1-Up
S/N: CBL1-Up
S/N: CAD1-Up
S/N: 2HM1-Up
S/N: DBD1-Up
S/N: 4FM1-Up
S/N: ADE1-Up
S/N: 8TM1-Up
S/N: BLE1-Up
S/N: 9BM1-Up
S/N: DAE1-Up
S/N: 9HM1-Up
S/N: AAF1-Up
S/N: 9ZM1-Up
S/N: AGF1-Up
SENR5664-13 157
S/N: AEM1-Up S/N: 4BR1-Up

S/N: AFM1-Up S/N: 4FR1-Up
S/N: AGM1-Up S/N: 4JR1-Up
S/N: AKM1-Up S/N: 4SR1-Up
S/N: AXM1-Up S/N: 4TR1-Up
S/N: BPM1-Up S/N: 4WR1-Up
S/N: 2EN1-Up S/N: 5MR1-Up
S/N: 2RN1-Up S/N: 5NR1-Up
S/N: 2YN1-Up S/N: 5PR1-Up
S/N: 3DN1-Up S/N: 5RR1-Up
S/N: 3WN1-Up S/N: 6ER1-Up
S/N: 3ZN1-Up S/N: 6FR1-Up
S/N: 4HN1-Up S/N: 6HR1-Up
S/N: 4JN1-Up S/N: 7AR1-Up
S/N: 4MN1-Up S/N: 7DR1-Up
S/N: 5LN1-Up S/N: 7HR1-Up
S/N: 5TN1-Up S/N: 8ZR1-Up
S/N: 6GN1-Up S/N: 9TR1-Up
S/N: 6JN1-Up S/N: 9XR1-Up
S/N: 7FN1-Up S/N: ALR1-Up
S/N: 7KN1-Up S/N: AWR1-Up
S/N: 8LN1-Up S/N: BCR1-Up
S/N: 8XN1-Up S/N: CLR1-Up
S/N: 9MN1-Up S/N: 2YS1-Up
S/N: 9PN1-Up S/N: 4CS130-Up
S/N: AGN1-Up S/N: 4GS1-Up
S/N: BBN1-Up S/N: 4HS1-Up
S/N: CEN1-Up S/N: 4JS1-Up
S/N: AEP1-Up S/N: 4PS1-Up
S/N: ALP1-Up S/N: 5ES1-Up
S/N: AMP1-Up S/N: 5FS1-Up
S/N: DMP1-Up S/N: 5KS1-Up
S/N: 2HR1-Up S/N: 6AS1-Up
S/N: 3CR1-Up S/N: ACS1-Up
S/N: 3DR1-Up S/N: CCS1-Up
S/N: 3KR1-Up S/N: CES1-Up
S/N: 3ZR1-Up S/N: AKT1-Up
158 SENR5664-13
S/N: AXT1-Up
S/N: BLT1-Up
S/N: CKT1-Up
S/N: FDT1-Up
S/N: 1JW1-Up
S/N: 5EW1-Up
S/N: A4W1-Up
S/N: ARW1-Up
S/N: BTW1-Up
S/N: AAX1-Up
S/N: AFX1-Up
S/N: CEX1-Up
S/N: ALY1-Up
S/N: BMY1-Up
S/N: 2KZ1-Up
S/N: 4HZ1-Up
S/N: 6SZ1-Up
S/N: 6YZ1-Up
S/N: 7PZ1-Up
S/N: ADZ1-Up
S/N: AZZ1-Up
Electronic heat controls that only have an electronic

water valve are classified as a type 1 electronic heat
controls.
Table 17
Required Tools
Part Number Description Quantity
Digital Multimeter
146-4080 1
(RS-232)
SENR5664-13 159
g01069225
Illustration 70
Typical Electronic Control Circuit for the Heater Valve
(1) 24 VDC power supply from blower motor (5) Sure seal connector (3 pin) (9) Feedback potentiometer for the
breaker (6) Potentiometer assembly (temperature electronic water valve assembly
(2) Sure seal connector (7 pin) control) (10) Motor for the electronic water valve
(3) Sure seal connector (7 pin) (7) Board Control Assembly assembly
(4) Sure seal connector (6 pin) (8) Electronic water valve assembly
1. Turn off the power supply. 9. Connect the multimeter leads to pin (A) and
pin (B) on the sure seal connector that is on
2. Disconnect the sure seal connector (2). potentiometer assembly (6). Turn the knob on
the potentiometer assembly (6). The resistance
3. Hook the multimeter leads to pin (1) and pin (2). should vary smoothly.
Set the multimeter to DC voltage.
10. Reconnect sure seal connector (5).
4. Turn on the power supply. The multimeter should
read approximately 24 VDC. 11. Disconnect sure seal connector (4).
5. Turn off the power supply. 12. Connect the multimeter leads to pin (3) and pin
(5) on the sure seal connector that is on electronic
6. Reconnect the sure seal connector (2). water valve assembly (8). Set the multimeter to
read ohms. The multimeter should read 5000
7. Disconnect the sure seal connector (5). 500 ohms.
8. Connect the multimeter leads to pin (A) and pin (C) 13. Connect the multimeter leads to pin (1) and pin (2)
on the sure seal connector that is on potentiometer on the sure seal connector that is on board control
assembly (6). Set the multimeter to read ohms. assembly (7). Set the multimeter to DC voltage.
The multimeter should read 5000 500 ohms.
14. Turn on the power supply.
160 SENR5664-13
15. Turn the knob on the potentiometer assembly (6). S/N: BDP1-Up
The multimeter should read either 9 to 10 VDC or
the multimeter should read 9 to 10 VDC. S/N: 2KR1-Up
S/N: 2SR1-Up
16. Turn off the power supply.
S/N: 2JS1-Up
17. Connect two wires to a remote 12 volt DC power
supply. S/N: 3BS1-Up
Note: Do not use a power supply higher than 12 volts S/N: 3ZS1-Up
DC. If you use a power supply higher than 12 volts S/N: 4BS1-Up
DC, you may damage the water valve assembly.
S/N: 5AS1-Up
18. Connect one wire to pin (2) on the sure seal
connector that is on the electronic water valve S/N: 5RS1-Up
assembly (8).
S/N: 6NS1-Up
19. Touch the other wire to pin (1) on the sure S/N: 6PS1-Up
seal connector that is on electronic water valve
assembly (8) in order to pulse motor (10). The S/N: 7LS1-Up
motor should turn clockwise or counterclockwise.
The polarity of the power supply determines the S/N: 9RS1-Up
direction of rotation. S/N: 1EW1-Up
Note: Do not pulse motor (10) for more than a fraction S/N: 2TW1-Up
of a second. If you supply power for a longer period
of time you may damage the water valve assembly. S/N: 3JW1-Up
20. Disconnect the test equipment and reconnect S/N: 3PW1-Up

sure seal connector (4). S/N: 3SW1-Up
S/N: 4PW1-Up
i02046851
S/N: 4WW1-Up
Electronic Heat Control - Test
(Type 2) S/N: 5FW1-Up
S/N: 5MW1-Up
SMCS Code: 7304-081-VL; 7309-081-VL
S/N: 6AW1-Up
S/N: AXB1-Up
S/N: 6EW1-Up
S/N: BPC1-Up
S/N: 6HW1-Up
S/N: BXD1-Up
S/N: 7BW1-Up
S/N: AWF1-Up
S/N: 8JW1-Up
S/N: AAH1-Up
S/N: 8XW1-Up
S/N: AYH1-Up
S/N: 9GW1-Up
S/N: BNH1-Up
S/N: AAW1-Up
S/N: BRL1-Up
S/N: AWW1-Up
S/N: 9CM1-Up
S/N: AZW1-Up
S/N: 4SN1-Up
S/N: ASX1-Up
S/N: 6RN1-Up
S/N: 6GZ1-Up
S/N: 7LN1-Up
S/N: 7MZ1-Up
S/N: AKP1-Up
SENR5664-13 161
Electronic heat controls that have a blend door

actuator and an electronic water valve are classified
as a type 2 electronic heat control.
Table 18
Required Tools
Digital
146-4080 Multimeter(RS- 1
232)
g01069275
Illustration 71
Typical Electronic Control Circuit for the Heater Valve
(1) Electronic controller (6) Electronic blend door actuator (9) Potentiometer assembly (temperature
(2) Deutsch connector (2 pin) (7) Motor for the electronic blend door control)
(3) Deutsch connector (6 pin) actuator (10) 24 VDC power supply from blower
(4) Deutsch connector (3 pin) (8) Feedback potentiometer for the motor breaker
(5) Electronic water valve assembly electronic blend door actuator (11) Deutsch connector (12 pin)
1. Turn off the power supply. 5. Turn off the power supply.
2. Disconnect Deutsch connector (11). 6. Reconnect the Deutsch connector (11) at

electronic controller (1).
3. Hook the multimeter leads to pin (1) and pin (2).
Set the multimeter to DC voltage. 7. Disconnect Deutsch connector (4).
4. Turn on the power supply. The multimeter should

read approximately 24 VDC.
162 SENR5664-13
8. Connect the multimeter leads to pin (A) and pin (C) Note: The actuators must be given 60 seconds in
on the Deutsch connector that is on potentiometer order to completely stroke.
assembly (9). Set the multimeter to read ohms.
The multimeter should read 5000 500 ohms. 23. Connect the multimeter leads to pin (1) and pin (2)
on the Deutsch connector that is on the electronic
9. Connect the multimeter leads to pin (A) and water valve assembly (5). Set the multimeter to
pin (B) on the Deutsch connector that is on read DC voltage.
potentiometer assembly (9). Turn the knob on
the potentiometer assembly (9). The resistance 24. Turn on the power supply.
should vary smoothly.
25. Turn the knob on potentiometer assembly (9).
10. Reconnect Deutsch connector (4). The multimeter should read 11 to 12 VDC or
the multimeter should read 11 to 12 VDC while the
11. Disconnect Deutsch connector (3). actuator is rotating. The multimeter should read 0
VDC, after the motor has completed rotating.
12. Connect the multimeter leads to pin (3) and pin
(5) on the Deutsch connector that is on electronic 26. Turn the knob to full cooling on the potentiometer
blend door actuator (6). Set the multimeter to read assembly (9). The multimeter should read 11 to
ohms. The multimeter should read 10000 1000 12 VDC or the multimeter should read 11 to 12
ohms. VDC while the actuator is rotating. The multimeter
should read 0 VDC after the motor has completed
13. Connect the multimeter leads to pin (1) and pin rotating.
(2) on the Deutsch connector that is on electronic
blend door actuator (6). Set the multimeter to DC 27. Turn off the power supply.
voltage.
28. Connect two wires to a remote 12 volt DC power
14. Turn on the power supply. supply.
15. Turn the knob on the potentiometer assembly (9). 29. Connect one wire to pin (1) on Deutsch connector
The multimeter should read either 11 to 12 VDC (2) that is on the electronic water valve assembly.
or the multimeter should read 11 to 12 VDC while
the actuator is rotating. The multimeter should 30. Touch the other wire to pin (2) on the Deutsch
read 0 VDC after the motor has stopped rotating. connector (2) that is on electronic water valve
assembly in order to pulse motor (5). The motor
16. Turn off the power supply. should turn clockwise or counterclockwise. The
polarity of the motor determines the direction of
17. Connect two wires to a remote 12 volt DC power rotation.
supply.
Note: Do not pulse motor (5) for more than a fraction
18. Connect one wire to pin (2) on the Deutsch of a second. If you supply power for a longer period
connector that is on the electronic blend door of time you may damage the actuator.
actuator (6).
31. Disconnect the test equipment and reconnect the
19. Touch the other wire to pin (1) on the Deutsch Deutsch connector (2).
connector that is on electronic blend door actuator
(6) in order to pulse motor (7). The motor should
i02387491
turn clockwise or counterclockwise. The polarity of
the motor determines the direction of rotation. Electronic Heat Control - Test
Note: Do not pulse motor (7) for more than a fraction (Type 3)
of a second. If you supply power for a longer period
of time you may damage the actuator. SMCS Code: 7304-081-VL; 7309-081-VL
20. Disconnect the test equipment and reconnect S/N: AYA1-Up

Deutsch connector (3). S/N: BAA1-Up
21. Disconnect Deutsch connector (2). S/N: AYB1-Up
22. Rotate the potentiometer assembly (9) to full S/N: BAB1-Up

cooling.
S/N: AXC1-Up
SENR5664-13 163
S/N: BAC1-Up
S/N: AYD1-Up
S/N: BAD1-Up
S/N: AXE1-Up
S/N: AYE1-Up
S/N: AXG1-Up
S/N: AYG1-Up
S/N: AWH1-Up
S/N: AXJ1-Up
S/N: AXL1-Up
S/N: AYL1-Up
S/N: AXN1-Up
S/N: AWP1-Up
S/N: AXP1-Up
S/N: AXR1-Up
S/N: AXS1-Up
S/N: AYS1-Up
S/N: ANT1-Up
S/N: AYT1-Up
S/N: AXX1-Up
S/N: ANY1-Up
S/N: AWY1-Up
S/N: AXY1-Up
S/N: ANZ1-Up
S/N: AWZ1-Up
Electronic heat controls that have a blend air door

are classified as a Type 3 electronic heat control.
Table 19
Required Tools
Digital
146-4080 Multimeter(RS- 1
232)
164 SENR5664-13
g01191792
Illustration 72
Typical Electronic Control Circuit for the blend air door
(1) Deutsch connector (12 pin) (7) Blower motor
(2) Potentiometer assembly (temperature (8) Electronic blend door actuator
control) (9) Deutsch connector (2 pin)
(3) Resistor 6.2 k (10) Packard connector (3 pin)
(4) Resistor 3.3 k (11) Thermal fuse
(5) Freeze switch (12) 12 VDC power supply (converter)
(6) Blower resistor (13) Deutsch connector (3 pin)
1. Turn off the power supply. 8. Connect the multimeter leads to pin (A) and pin (C)
on the Deutsch connector that is on potentiometer
2. Disconnect Deutsch connector (1). assembly (2). Set the multimeter to read ohms.
The multimeter should read 5000 500 ohms.
3. Hook the multimeter leads to pin (1) and pin (8).
Set the multimeter to DC voltage. 9. Connect the multimeter leads to pin (A) and
pin (B) on the Deutsch connector that is on
4. Turn on the power supply. The multimeter should potentiometer assembly (2). Turn the knob on
read approximately 12 VDC. the potentiometer assembly (2). The resistance
should vary smoothly.
10. Reconnect Deutsch connector (13).
6. Reconnect the Deutsch connector (1).
11. Disconnect Packard connector (10) that is located
7. Disconnect Deutsch connector (13). on electronic blend door actuator (8).
12. Disconnect Deutsch connector (1) again.

SENR5664-13 165
13. Connect the multimeter leads to pin (1) and pin

(2) on the Deutsch connector. Set the multimeter
to read ohms. The multimeter should read 6200
500 ohms for the value of resistor (3).
14. Disconnect Deutsch connector (9) that is located

on blower motor (7).
15. Connect the multimeter leads to pin (4) and pin (8)
on the Deutsch connector (1). Set the multimeter
to read ohms. The multimeter should read 3300
500 ohms for the value of resistor (4).
18. Reconnect Packard connector (10) that is located

on electronic blend door actuator (8).
19. Attach the positive multimeter leads to pin (D)

and pin (C) on thePackard connector (10). Set the
multimeter to DC voltage.
20. Turn on the power supply.
21. Turn the knob on potentiometer assembly (2) to

full heat. The electronic blend door actuator (8)
should rotate counterclockwise. The multimeter
should read either 2.7 VDC or the multimeter
should read 2.7 VDC.
22. Turn the knob on potentiometer assembly (2) to

full cold. The electronic blend door actuator (8)
should rotate clockwise. The multimeter should
read either 7.0 VDC or the multimeter should
read 7.0 VDC.

166 SENR5664-13
Disassembly and Assembly The radius of bends in the flexible hose must never
be less than 10 times the outside diameter of the
Section hose.
Do not allow the flexible hoses to come within

i01707048 63.5 mm (2.50 inch) of the exhaust manifold.
General Information The hoses need to be inspected yearly for leaks
and for hardness. Conduct a leak test on all the
SMCS Code: 1808; 7309
hoses and the 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
Personal injury can result from contact with refrig- new hose that is sealed and free of contaminants.
erant.
The correct use of wrenches is very important
This system is under pressure at all times, even when connections are made. The type of wrench
if the engine is not running. Heat should never be that is used is also important. Only use wrenches
applied to a charged system. that are made for use with tube type fittings. When
a hose is connected or disconnected from the
Contact with refrigerant can cause frost bite. Keep system, use a wrench on the fitting and use a
face and hands away to help prevent injury. wrench on the nut. When a metal line is connected
or disconnected from the system, use a wrench on
Protective goggles must always be worn when re- the fitting and use a wrench on the nut.
dicate the system is empty of refrigerant. Install protective plugs or protective caps on all
components and hoses that are disconnected or
Always use caution when a fitting is removed. removed.
under pressure, evacuate the system recovering O-ring seals and O-ring seats must be in good
the refrigerant before removing the fitting. condition. Small cuts, scratches, or particles of dirt
will cause a leak in the system. Put new refrigerant
Personal injury or death can result from inhaling oil on all new O-ring seals at the time of installation.
refrigerant through a lit cigarette. Do not use any kind of sealant on connections.
Inhaling air conditioner refrigerant gas through a Dust caps on the compressor block fittings are the
lit cigarette or other smoking method or inhaling primary seals on the air conditioning system.
ditioner refrigerant gas, can cause bodily harm or All machines should have an identification tag
death. that specifies the refrigerant charge for the
machine. The tag should be located in the operator
Do not smoke when servicing air conditioners or compartment.
If water is in the vents check the nonreturn valve. If
Before any checks of the air conditioning and water leaks from the air conditioning system, check
heating system are made, move the machine to a the nonreturn valve. The nonreturn valve should
smooth horizontal surface. Lower all implements have the proper position and the proper direction.
in neutral or park and that the parking brake is If engine coolant is leaking into the operator
engaged. Keep all other personnel away from the compartment, check for loose clamps on the heater
machine or where they can be seen. hoses.
All refrigerant lines that are metal or flexible hose

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 location of
the restriction. Restrictions in the lines reduce the
performance and the efficiency of the system.
SENR5664-13 167
i01707044 Dust caps on the refrigerant compressor block

fitting are the primary seal on the air conditioning
Machine Preparation for system.
Disassembly and Assembly
All machines should have an identification tag in
SMCS Code: 7320-017 the cab that specifies the proper refrigerant charge
for the machine.
When replacement or repair of components and

hoses are required, perform the following procedure:
Personal injury can result from contact with refrig-
erant. 1. Remove the refrigerant charge. Refer to the
Service Manual, SENR5664, Refrigerant
This system is under pressure at all times, even Recovery section in Testing and Adjusting.
applied to a charged system. 2. Remove the component or remove the hose that is
being repaired or replaced. Install protective plugs
Contact with refrigerant can cause frost bite. Keep on components or hoses that are left exposed to
face and hands away to help prevent injury. the air.
Protective goggles must always be worn when re- 3. Replace any damaged component or hose.
dicate the system is empty of refrigerant. 4. Use the following table in order to determine
the amount of oil that is lost during individual
Always use caution when a fitting is removed. replacements of components. Add the correct
Slowly loosen the fitting. If the system is still amount of oil to the compressor before the system
under pressure, evacuate the system recovering is evacuated. No additional oil should be added to
the refrigerant before removing the fitting. the system if the compressor is replaced at the
same time as other components in the system.
refrigerant through a lit cigarette. Table 20
Oil Capacities for Component Replacements

lit cigarette or other smoking method or inhaling Accumulator 30 mL (1 fl oz)
Compressor Refer to the Service Manual,
SENR5664, Refrigerant Compressor
death. Oil-Check section in Testing and
Adjusting.
wherever refrigerant gas may be present. Condenser 30 mL (1 fl oz)
Evaporator 90 mL (3 fl oz)
heating system are made, move the machine to a In-Line Dryer(1) 30 mL (1 fl oz)
smooth horizontal surface. Lower all implements Receiver-Dryer 30 mL (1 fl oz)
(1) Refer to the Service Manual, SENR5664,
In-Line-Refrigerant Dryer - Remove and Install
engaged. Keep all other personnel away from the before any oil is added.
5. Refer to the Service Manual, SENR5664,
When the service work is done on the air conditioning Refrigerant System-Evacuate section in testing
system, it is important to keep the system clean and and adjusting.
free from contamination. Plugs and caps must be
used in order to close the components and hoses 6. Refer to the Service Manual, SENR5664,
when the components and hoses are open. The Refrigerant System-Charge section in Testing
plugs and caps protect the system from dirt and air and Adjusting.
(moisture). Only new refrigerant oil of the correct
viscosity and new refrigerant can be added to the
system. Refer to the Service Manual, SENR5664,
Refrigerant Compressor section in this manual
for the correct oil. Any other material or any other
substance is considered non-condensable and the
material will contaminate the system. Keep the work
area clean.
168 SENR5664-13
i01934503 3. Install the compressor (4). Do not tighten the

mounting bolts until drive belt (2) is installed and
Refrigerant Compressor - adjusted.
Remove and Install
4. Connect the discharge and the suction hoses
SMCS Code: 1802-010 (3) to the discharge and suction ports on the
compressor.
Removal 5. Connect the electrical wires to the magnetic clutch.
6. Evacuate the system. Refer to the Service Manual,

7. Charge the system. Refer to the Service Manual,

SENR5664, Refrigerant System - Charge
8. For the correct system operation, refer to the

Service Manual, SENR5664, Troubleshooting
Heating and Air Conditioning Control System
Illustration 73
g00742981 Note: Refer to the Service Manual, SENR5664,
Refrigerant Compressor in the Specifications
(1) Bolt
(2) Drive belt Section for the correct belt tension.
(3) Suction and discharge hoses
(4) Compressor 9. For the oil level in the system, refer to Service
Manual, SENR5664, Refrigerant Compressor
1. Remove the refrigerant charge. Refer to the Oil - Check.
Service Manual, SENR5664, Refrigerant
i01525664
2. Disconnect electrical wires from the magnetic

clutch.
Refrigerant Accumulator -
Remove and Install
3. Loosen all the mounting bolts and loosen the belt
tightener (if equipped). Remove drive belt (2). SMCS Code: 1808-010-ZJ; 7320-010-ZJ
4. Disconnect hoses (3) and put plugs or caps on The refrigerant must be recovered before the
the hoses. Put plugs or caps on the fittings of accumulator is removed. Refer to the Service
the compressor. Put identification marks on the Manual, SENR5664, Refrigerant Recovery section
hoses. The marks will ensure that the hoses will in Testing and Adjusting.
be connected correctly at a later time.
Refer to the Service Manual, SENR5664, Machine
5. Remove all the mounting bolts and remove the Preparation for troubleshooting section in Testing
compressor (4). The weight of the compressor is and Adjusting before service work is performed.
approximately 18 kg (40 lb).
Installation
1. Check the amount and condition of the oil in the
compressor (4). Refer to the Service Manual,
SENR5664, Refrigerant Compressor Oil-Test
2. Inspect the drive belt (2). If the drive belt (2) is

damaged or worn replace the belt.
SENR5664-13 169
Remove the accumulator. The accumulator has an 7. Use a 8P-6355 Clip to hold the sensing bulb
internal oil drain hole which could become plugged. onto the evaporator outlet pipe. The sensing bulb
The oil could be trapped inside the accumulator. It should be as close to the coil as possible. The
is necessary to check for excessive oil when the bulb should be upstream of the pressure sensing
accumulator is changed. Add the same amount of connection on the evaporator outlet pipe. The
oil that was drained from the old accumulator. Add 5P-7070 Insulation should be wrapped tightly
an additional 30 mL (1 fl oz) to the new accumulator around the clip, the sensing bulb and the outlet
before the new accumulator is installed. Do not add pipe. There should be no insulation between the
oil if the compressor was changed also. Evacuate bulb and the outlet pipe.
the system and recharge the system. Refer to the
Service Manual, SENR5664, Refrigerant System - 8. Tighten all the connections correctly.
Evacuate section in Testing and Adjusting. Refer to
the Service Manual, SENR5664, Refrigerant System 9. Evacuate the system. Refer to the Service Manual,
- Charge section in Testing and Adjusting. SENR5664, Refrigerant System - Evacuate
section in testing and adjusting.
Note: If the accumulator has frost on the outside, the
air conditioning system still contains refrigerant. 10. Charge the system with the correct amount of
refrigerant by weight. Refer to the Service Manual,
SENR5664, Refrigerant System - Charge
i00945988
section in testing and adjusting.
Refrigerant Expansion Valve -
Remove and Install i02547429
SMCS Code: 7320-010-EV

Receiver-Dryer - Remove and
Install
To replace the expansion valve, use the procedure
that follows. Refer to Service Manual, SENR5664, SMCS Code: 7322-010
Troubleshooting Heating and Air Conditioning
Control System before service work is performed on
the air conditioning system.
1. Recover the refrigerant.
Note: Cap all disconnected lines and hoses.
2. Remove the insulation and the clip. The insulation

and the clip hold the sensing bulb to the evaporator
outlet pipe.
3. Disconnect the sensing line for pressure from the

g01257459
4. Loosen and remove the two connections at the Illustration 74
expansion valve. Remove the expansion valve. Top View of Receiver-Dryer
(1) Inlet
Note: Check the O-ring seals. The seals must be (2) Quick Disconnect Fittings
in good condition and the seals must be properly (3) Moisture Indicator
(4) Outlet
lubricated with the correct refrigerant oil before
assembly.
NOTICE
5. Install the expansion valve for replacement and If the receiver-dryer does not have air conditioner
tighten the two connections. quick disconnects, the system must be completely
recovered, evacuated, and recharged after the re-
6. Tighten the pressure sensing connection on the ceiver-dryer has been replaced.
170 SENR5664-13
The refrigerant that is in the system must be i02547188

recovered if the receiver-dryer does not have air
conditioner quick disconnects (2). Refer to the In-Line Refrigerant Dryer -
Service Manual, SENR5664, Refrigerant Recovery Remove and Install
section in Testing and Adjusting before you remove
the receiver-dryer. If the receiver-dryer has air SMCS Code: 7322-010-QT
conditioner quick disconnects (2) use the procedure
that follows.
Refer to Safety Requirements before service is

performed on the air conditioning system.
1. Stop the engine for five minutes. This allows the

air conditioning system to equalize the pressure.
2. Disconnect the inlet hose (1) from the old

receiver-dryer at the air conditioner quick
disconnects.
3. Connect the hose that was disconnected in Step 2

to the inlet on the new receiver-dryer.
4. Disconnect the electrical connections on the old

receiver-dryer. Connect the electrical connections
to the new receiver-dryer.
Note: If the receiver-dryer has quick disconnects, do

not add additional oil or refrigerant to the system.
5. Start the engine. Operate the air conditioning

system for one minute.
6. With the air conditioning system in operation,

disconnect the outlet hose (4) from the old
receiver-dryer. Disconnect the old receiver-dryer Illustration 75
g01257417
at the air conditioner quick disconnects. Typical In-Line Dryer with quick disconnects
(1) Inlet hose with air conditioner quick disconnect
7. Stop the engine for five minutes. This allows the (2) Dryer
air conditioning system to equalize pressure. (3) Outlet hose with air conditioner quick disconnect
8. Connect the outlet hose (4) that was disconnected Note: Replace dryer (2) annually. Dryer (2) should
in step 6 to the new receiver-dryer. also be replaced whenever the system is opened.
Note: The receiver-dryer must be replaced annually.
The receiver-dryer must also be replaced whenever
the system is opened. The receiver-dryer should
be replaced if moisture indicator (3) is filled with
moisture. Moisture indicator (3) will display a pink
color or white color if the receiver-dryer is full of
moisture.
SENR5664-13 171
Note: If the dryer has air conditioner quick

disconnects, do not add additional oil or refrigerant
to the system.
4. Start the engine. Operate the air conditioning

system for one minute.
5. With the air conditioning system in operation,

disconnect the outlet hose from the old dryer.
Disconnect the old dryer.

air conditioning system to equalize pressure.
7. Connect the outlet hose that was disconnected in

step 6 to the new dryer.
i00946003
Refrigerant Orifice Tube -

Remove and Install
SMCS Code: 7320-010-QT
The orifice tube may be located in the refrigerant line

near the evaporator inlet, or in the in-line dryer.
g01263982
Illustration 76 If the orifice tube is located in the refrigerant line near
In-line dryer without quick disconnects the evaporator inlet use the procedure that follows. If
(4) Inlet hose without air conditioner quick disconnect the orifice tube is located in the in-line dryer, refer to
(5) Dryer Dryer Replacement.
(6) Outlet hose without air conditioner quick disconnects
Removing the Orifice Tube
Note: Every two years replace dryer (5). Dryer (5)
should also be replaced whenever the system is Refer to Safety Requirements before service work is
opened. performed on the air conditioning system.
Before any service work is performed on the The refrigerant must be recovered before removing
air conditioning system, refer to the Service the accumulator. Refer to the Service Manual,
Manual, SENR5664, Machine Preparation for SENR5664, Refrigerant Recovery section in testing
Troubleshooting section in Testing and Adjusting. and adjusting.
The refrigerant that is in the system must be
recovered if the dryer does not have air conditioner NOTICE
quick disconnects. Refer to the Service Manual, Do not attempt to remove the orifice tube with pliers.
SENR5664, Refrigerant Recovery section in Testing Do not twist or rotate the orifice tube in the tube as-
and Adjusting before you remove the dryer. If the sembly.
dryer has air conditioner quick disconnects use the
procedure that follows.
Refer to Safety Requirements before service is

performed on the air conditioning system.

air conditioning system to equalize the pressure.
2. Disconnect the inlet hose from the old dryer.
3. Connect the hose that was disconnected in Step

2 to the inlet on the new dryer.
172 SENR5664-13
g00379603 g00381412
Illustration 77 Illustration 78
Orifice tube Removing the broken orifice tube
(1) O-Ring seals (3) Body
(2) Lugs (4) Drive screw
(3) Body (6) Extractor tip
(4) Drive screw
(5) Finger lock
6. For the removal of the orifice tube assembly, use
the extractor tip (6) on 1U-9890 Orifice Removal
1. Disconnect the high side line at the enlarged Tool. Insert the tool into the evaporator inlet tube
section of the evaporator inlet port. This will and thread the tool into the brass center of the
expose the orifice tube for removal. orifice tube.
2. Align the short fingers of the 1U-9890 Orifice 7. Repeat steps 3 and 4.
Removal Tool with the ribs of the orifice tube.
Insert the tool onto the tube until the tool bottoms 8. If only the brass center of the orifice tube is
out. removed, thread the tool into the plastic body and
repeat step 3 and 4.
3. Turn drive screw (4) clockwise. Turn far enough
to engage the lugs (2) on the orifice tube in the
finger lock (5). The finger lock (5) is part of the Orifice Tube Installation
removal tool.
1. Lubricate the O-Ring on the orifice tube with the
4. Hold the drive screw (4) stationary. Thread the proper clean refrigerant oil.
body (3) forward until the body makes contact
with the inlet port. 2. Place the orifice tube into the 1U-9890 Orifice
Removal Tool. Insert the orifice tube straight into
5. Continue holding the drive screw stationary, and the evaporator inlet tube without twisting until the
thread the body forward until the orifice tube tube is seated.
becomes free.
3. Disengage the removal tool from the orifice tube.
4. Use a new O-Ring that is lubricated with clean

refrigerant oil. Reconnect the high side line at the
enlarged section of the evaporator inlet port.
5. Do a leak test. Evacuate the system and recharge

the system. Refer to the Service Manual,
SENR5664, Refrigerant Systems-Evacuate
section in testing and adjusting. Also, refer to
the Service Manual, SENR5664, Refrigerant
Systems-Charge section in testing and adjusting.
SENR5664-13 173
Index Section
Index
C P
Cab Air Filters...................................................... 105 Preparation of Air Conditioner Units for Seasonal
Use .................................................................... 104
D
R
Disassembly and Assembly Section.................... 166
Receiver-Dryer - Remove and Install .................. 169
Refrigerant Accumulator - Remove and Install.... 168
E Refrigerant Compressor ....................................... 20,
24, 26, 2836, 3840, 4245, 4850, 5254, 99
Electronic Heat Control - Test (Type 1)................ 158 Compressor ......................... 30, 34, 36, 4041, 43
Electronic Heat Control - Test (Type 2)................ 160 Specifications for the Clutch .............................. 53
Electronic Heat Control - Test (Type 3)................ 163 Specifications for the Compressor ..................... 53
Evaporator Coil.................................................... 100 V-belt.................................................................. 37
Refrigerant Compressor - Remove and Install .... 168
Refrigerant Compressor - Test ............................ 151
G Procedures....................................................... 151
Refrigerant Compressor Oil - Check ................... 143
General Information....................................... 92, 166 Complete Check of Compressor Oil ................ 144
General Troubleshooting Information ................... 111 Refrigerant Compressor Protection System ........ 103
Glossary of Terms................................................ 107 Refrigerant Condenser ........................................ 100
Refrigerant Expansion Valve - Remove and
Install ................................................................. 169
H Refrigerant Expansion Valve System .................... 94
Moisture Indicator .............................................. 97
Heating and Air Conditioning Control System ..... 101 Receiver-Dryer................................................... 96
Adjustable Thermostat ..................................... 101 Refrigerant Expansion Valve.............................. 95
Nonadjustable Thermostat (Freeze Control Refrigerant Leakage - Test .................................. 142
System) .......................................................... 101 Dye................................................................... 142
Heating and Air Conditioning System Leak Detector................................................... 142
Troubleshooting .................................................. 113 Refrigerant Orifice Tube - Remove and Install .... 171
Additional Refrigerant Circuit Problems for Orifice Refrigerant Orifice Tube System ........................... 97
Tube System .................................................. 125 Orifice Tube ....................................................... 98
False Seizure of the Compressor .................... 126 Refrigerant Accumulator .................................... 99
Performance Checks for the Air Conditioning Refrigerant Recovery........................................... 135
System ............................................................ 116 System Contamination..................................... 137
Problem Solving................................................ 116 Refrigerant System - Charge............................... 145
Refrigerant Circuit Problems............................. 117 Charging the System ....................................... 148
Refrigerant Quick-Check Procedure for R-134a Complete Charge of the System from a Refrigerant
Expansion Valve And Orifice Tube Systems ... 113 Tank with a Scale ........................................... 149
Heating System Schematic ................................. 104 Procedure for Labeling..................................... 148
Relationship Between Temperature and Pressure
(R-134a Refrigerant) ...................................... 146
I Refrigerant System - Evacuate............................ 139
Required Tools..................................................... 109
Identifying the Air Conditioning System................. 92
Important Safety Information ................................... 2
In-Line Refrigerant Dryer - Remove and Install ... 170 S
Specifications Section ............................................. 5

M
Machine Preparation for Disassembly and

Assembly ........................................................... 167
Machine Preparation for Troubleshooting ............ 110
Manifold Gauge Set (Refrigerant) - Install ........... 138
Manifold Gauge Set (Refrigerant) - Remove ....... 155
174 SENR5664-13
Index Section
System Capacities for Refrigerant (Agricultural System Capacities for Refrigerant

Tractors) .............................................................. 54 (Excavators)....................................... 6066, 6869
Challenger 35 Refrigerant Capacities ................ 54 304 CR Refrigerant Capacities .......................... 60
Challenger 45 Refrigerant Capacities ................ 55 305 CR Refrigerant Capacities .......................... 60
Challenger 55 Refrigerant Capacities ................ 55 307B Refrigerant Capacities .............................. 60
Challenger 65 Refrigerant Capacities ................ 55 307C Refrigerant Capacities.............................. 61
Challenger 70C Refrigerant Capacities ............. 55 311B Refrigerant Capacities ........................ 6162
Challenger 75 Refrigerant Capacities ................ 55 311C Refrigerant Capacities .............................. 61
Challenger 85 Refrigerant Capacities ................ 55 312B Refrigerant Capacities ........................ 6163
Challenger 95E Refrigerant Capacities.............. 55 312C Refrigerant Capacities........................ 6465
DV87 Refrigerant Capacities ............................. 54 313B Refrigerant Capacities .............................. 60
System Capacities for Refrigerant (Articulated 315B Refrigerant Capacities ........................ 6163
Trucks) ................................................................. 55 315C Refrigerant Capacities.............................. 65
725 Refrigerant Capacities ................................ 56 317B Refrigerant Capacities .............................. 63
730 Refrigerant Capacities ................................ 56 318B Refrigerant Capacities .............................. 63
735 Refrigerant Capacities ................................ 56 318C Refrigerant Capacities.............................. 65
D20 Refrigerant Capacities................................ 55 320B Refrigerant Capacities ........................ 6163
D25 Refrigerant Capacities................................ 55 320C Refrigerant Capacities........................ 61, 65
D250 Refrigerant Capacities.............................. 56 320D Refrigerant Capacities.............................. 66
D30 Refrigerant Capacities................................ 55 320D RR Refrigerant Capacities........................ 67
D300 Refrigerant Capacities.............................. 56 321B Refrigerant Capacities .............................. 60
D350 Refrigerant Capacities.............................. 56 322B Refrigerant Capacities ........................ 6163
D40 Refrigerant Capacities................................ 55 322C Refrigerant Capacities........................ 64, 66
D400 Refrigerant Capacities.............................. 56 323D Refrigerant Capacities.............................. 67
System Capacities for Refrigerant (Backhoe 324D Refrigerant Capacities.............................. 67
Loaders)............................................................... 56 325B Refrigerant Capacities ........................ 6163
416 Refrigerant Capacities ................................ 56 325C Refrigerant Capacities........................ 6566
420 Refrigerant Capacities ................................ 57 325D Refrigerant Capacities.............................. 67
424 Refrigerant Capacities ................................ 57 330B Refrigerant Capacities ........................ 6163
426 Refrigerant Capacities ................................ 57 330C Refrigerant Capacities........................ 6566
430 Refrigerant Capacities ................................ 58 345B Refrigerant Capacities ........................ 6263
432 Refrigerant Capacities ................................ 58 345B Series II Refrigerant Capacities................ 64
436 Refrigerant Capacities ................................ 58 365B Refrigerant Capacities ........................ 62, 64
438 Refrigerant Capacities ................................ 58 365B Series II Refrigerant Capacities................ 64
444 Refrigerant Capacities ................................ 59 385B Refrigerant Capacities ........................ 62, 64
System Capacities for Refrigerant (Compact Wheel 5090B Refrigerant Capacities ............................ 64
Loaders)............................................................... 59 M312 Refrigerant Capacities ............................. 68
904 Refrigerant Capacities ................................ 59 M313C Refrigerant Capacities........................... 69
906 Refrigerant Capacities ................................ 59 M315 Refrigerant Capacities ............................. 68
908 Refrigerant Capacities ................................ 59 M315C Refrigerant Capacities........................... 69
System Capacities for Refrigerant (Compactors) .. 59 M316C Refrigerant Capacities........................... 69
Landfill Compactors ........................................... 59 M318 Refrigerant Capacities ............................. 68
Soil Compactors................................................. 59 M318C Refrigerant Capacities........................... 69
M320 Refrigerant Capacities ............................. 68
M322C Refrigerant Capacities........................... 69
M325B Refrigerant Capacities ........................... 63
M325C Refrigerant Capacities........................... 69
TK1051 Refrigerant Capacities.......................... 65
W345B Series II Refrigerant Capacities ............ 64
SENR5664-13 175
Index Section
System Capacities for Refrigerant (Forest System Capacities for Refrigerant (Off-Highway
Products) ............................................................. 69 Trucks) ................................................................. 78
Forwarders......................................................... 70 69 Refrigerant Capacities .................................. 78
Knuckleboom Loaders ....................................... 70 73 Refrigerant Capacities .................................. 78
Track Feller Bunchers ........................................ 70 768 Refrigerant Capacities ................................ 78
Track Skidders ................................................... 69 769 Refrigerant Capacities ................................ 78
Wheel Feller Bunchers....................................... 70 771 Refrigerant Capacities ................................ 78
Wheel Harvesters .............................................. 70 772 Refrigerant Capacities ................................ 78
Wheel Skidders.................................................. 69 773 Refrigerant capacities ................................. 78
System Capacities for Refrigerant (Integrated 775 Refrigerant Capacities ................................ 78
Toolcarriers) ......................................................... 71 776 Refrigerant Capacities ................................ 78
Medium Integrated Toolcarriers ......................... 72 777 Refrigerant Capacities ................................ 78
Small Integrated Toolcarriers ............................. 71 784 Refrigerant Capacities ................................ 79
System Capacities for Refrigerant (Large Wheel 785 Refrigerant Capacities ................................ 79
Loaders)............................................................... 72 789 Refrigerant Capacities ................................ 79
988 Refrigerant Capacities ................................ 72 793 Refrigerant Capacities ................................ 79
992 Refrigerant Capacities ................................ 72 System Capacities for Refrigerant (Paving
994 Refrigerant Capacities ................................ 73 Products) ............................................................. 79
System Capacities for Refrigerant (Load Haul CB-434 Refrigerant Capacities .......................... 79
Dump) .................................................................. 73 CB-534 Refrigerant Capacities .......................... 79
R1300 Refrigerant Capacities............................ 73 CP-633 Refrigerant Capacities .......................... 81
R1600 Refrigerant Capacities............................ 73 CP/CS-423 Refrigerant Capacities .................... 79
System Capacities for Refrigerant (Medium Wheel CP/CS-563 Refrigerant Capacities .................... 80
Loaders)............................................................... 73 CP/CS-663 Refrigerant Capacities .................... 81
936F Refrigerant Capacities .............................. 73 CS-531 Refrigerant Capacities .......................... 80
938 Refrigerant Capacities ................................ 73 CS-573 Refrigerant Capacities .......................... 80
950 Refrigerant Capacities ................................ 74 CS-583 Refrigerant Capacities .......................... 80
960F Refrigerant Capacities .............................. 74 CS-683 Refrigerant Capacities .......................... 81
962 Refrigerant Capacities ................................ 74 RM-350 Refrigerant Capacities.......................... 79
966 Refrigerant Capacities ................................ 74 RR-250 Refrigerant Capacities .......................... 79
970F Refrigerant Capacities .............................. 75 SS-250 Refrigerant Capacities .......................... 79
972 Refrigerant Capacities ................................ 75 System Capacities for Refrigerant (Skid Steer
980 Refrigerant Capacities ................................ 75 Loaders)............................................................... 81
System Capacities for Refrigerant (Mining 216 Refrigerant Capacities ................................ 81
Excavators).......................................................... 75 226 Refrigerant Capacities ................................ 81
5110 Refrigerant Capacities............................... 75 236 Refrigerant Capacities ................................ 81
5130 Refrigerant Capacities .............................. 75 242 Refrigerant Capacities ................................ 81
5230 Refrigerant Capacities .............................. 75 246 Refrigerant Capacities ................................ 81
System Capacities for Refrigerant (Motor 248 Refrigerant Capacities ................................ 81
Graders)............................................................... 76 252 Refrigerant Capacities ................................ 81
12 Refrigerant Capacities .................................. 76 262 Refrigerant Capacities ................................ 81
130 Refrigerant Capacities ................................ 76 System Capacities for Refrigerant (Small Wheel
135 Refrigerant Capacities ................................ 76 Loaders)............................................................... 82
24 Refrigerant Capacities .................................. 77
System Capacities for Refrigerant (Multi-Terrain
Loaders)............................................................... 77
247 Refrigerant Capacities ................................ 77
System Capacities for Refrigerant (Telehandlers).. 83 System Capacities for Refrigerant (Wheel
TH210 Refrigerant Capacities............................ 83 Dozers) ................................................................ 89
TH215 Refrigerant Capacities............................ 83 814 Refrigerant Capacities ................................ 89
TH350 Refrigerant Capacities............................ 83 854G Refrigerant Capacities.............................. 90
TH355 Refrigerant Capacities............................ 83 System Capacities for Refrigerant (Wheel
TH360 Refrigerant Capacities............................ 83 Tractor-Scrapers)................................................. 90
TH460 Refrigerant Capacities............................ 83 611 Refrigerant Capacities................................. 90
System Capacities for Refrigerant (Track-Type 621 Refrigerant Capacities ................................ 90
Loaders)............................................................... 83 623 Refrigerant Capacities ................................ 90
933C Refrigerant Capacities.............................. 83 627 Refrigerant Capacities ................................ 90
939C Refrigerant Capacities.............................. 83 631 Refrigerant Capacities ................................ 90
System Capacities for Refrigerant (Track-Type 657 Refrigerant Capacities ................................ 91
Tractors) .............................................................. 84 Systems Operation Section ................................... 92
583T Pipelayer Refrigerant Capacities .............. 89
D10N Refrigerant Capacities ............................. 88
D10R Refrigerant Capacities ............................. 88 T
D10T Refrigerant Capacities.............................. 88
D11N Refrigerant Capacities ............................. 88 Table of Contents..................................................... 3
D11R Refrigerant Capacities ............................. 88 Testing and Adjusting .......................................... 135
D3C Series III Refrigerant Capacities ................ 84 Testing and Adjusting Section ............................. 109
D3G Refrigerant Capacities ............................... 84 Troubleshooting................................................... 109
D4C series III Refrigerant Capacities................. 84 Troubleshooting Heating and Air Conditioning Control
D4G Refrigerant Capacities ............................... 84 System............................................................... 127
D4H Series II Refrigerant Capacities ................. 85 Electrical System ............................................. 127
D4H TSK Series III Refrigerant Capacities ........ 85 Heating System................................................ 127
D5C Series III Refrigerant Capacities ................ 85 Test Procedure for Testing Electrical Components
D5G Refrigerant Capacities ............................... 85 in the Air Conditioning System ....................... 128
D5H Series II Refrigerant Capacities ................. 85
D5M Refrigerant Capacities............................... 85
D5N Refrigerant Capacities ............................... 85 V
D6C Refrigerant Capacities ............................... 85
D6G Refrigerant Capacities ............................... 85 Visual Inspection .................................................. 112
D6M Refrigerant Capacities............................... 86
D6N Refrigerant Capacities ............................... 86
D6R Refrigerant Capacities ............................... 86
D6R Series II Refrigerant Capacities ................. 86
D6R Series III Refrigerant Capacities ................ 87
D7R Series II Refrigerant Capacities ................. 87
D8T Refrigerant Capacities................................ 87
D9T Refrigerant Capacities................................ 88
System Capacities for Refrigerant (Underground
Articulated Truck)................................................. 89
AD30 Refrigerant Capacities ............................. 89
AD40 and AE40 Refrigerant Capacities............. 89
2006 Caterpillar
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SENR5664-13

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents System Capacities for Refrigerant (Mining

Refrigerant Compressor - Test ............................ 151

Disassembly and Assembly Section

Specifications Section Part No.: 106-5122

Refrigerant Compressor S/N: HAB1-Up

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 S/N: H2C1-Up

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 106-5122

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Cat 4C-2959 Air Conditioner Lubricant (250 mL

DuPont ........................ SUVA TRANS A/C HFC134a

ICI ........................................................... KLEA 134a

Torque for Fittings

Torque for 7/8 inch threaded fitting .. 25 Nm (18 lb ft)

Note: The 7/8 inch threaded fitting is located on

Oil capacity .................................... 300 mL (10 fl oz) Part No.: 163-0872

Part No.: 163-0872 Part No.: 218-0324

Part No.: 163-0872 Part No.: 218-0324

Part No.: 106-5122 Part No.: 218-0324

Part No.: 218-0324 Part No.: 163-0872

Maximum Current ...................................... 1.42 amp

g01010215 Part No.: 198-4564

DuPont ........................ SUVA TRANS A/C HFC134a Part No.: 198-4564

Minimum voltage for engagement ................ 16 DCV

Part No.: 198-4564

Part No.: 198-4564 (2) Final installation torque .. 25 7 Nm (18 5 lb ft)

(4) Torque for oil plug ....... 10 2 Nm (89 18 lb in)

Note: Oil plug (4) is pressurized.

(5) V-belt tension

Note: Used belt tension is for a belt that has been

Note: Use a Caterpillar 144-0235 Belt Tension

Torque for Fittings

Torque for 3/4 inch threaded fitting ................ 17 Nm

SMCS Code: 1802 Part No.: 176-1895